A data backup and automatic comparison system and method for resistance welding machines

Abstract

This invention relates to a data backup and automatic comparison system and method for resistance welding machines. The host computer monitors the welding main control circuit, data management system, and file management system of the resistance welding controller in real time. Through an MQTT service program and an FTP data access server, it performs periodic automatic and manual backups of data such as internal equipment parameters, welding programs, grinding parameters, and calibration parameters in the welding controller. It can automatically compare the backed-up data with all parameters of the current equipment and generate reports. The data backup method, automatic backup method, and parameter comparison method of this invention can periodically and intuitively understand the changes in all welding processes and equipment parameters in the workshop, and monitor the welding parameter changes of each piece of equipment at any time. When problems occur in the production process or equipment, the equipment can be quickly restored to a relatively earlier state, facilitating problem location and troubleshooting.

Description

Technical Field

[0001] This invention belongs to the field of resistance welding machine control technology, and in particular to a data backup and automatic comparison system and method for resistance welding machines. Background Technology

[0002] Resistance welding machines are welding equipment that uses the principle of resistance heating for welding. Resistance welding machines can be classified into different types according to different uses and requirements. Classified by welding method, there are spot welding machines, seam welding machines, projection welding machines, and butt welding machines; classified by electrode pressure application method, there are lever-type, electric cam-type, pneumatic type, hydraulic type, and combined pneumatic and hydraulic type, etc.; classified by welding current type, there are single-phase power frequency welding machines, secondary rectifier welding machines, three-phase low-frequency welding machines, capacitor energy storage welding machines, and inverter power supply welding machines, etc. Resistance welding machines mainly consist of a main circuit section, a pressure transmission section, and a control section.

[0003] To meet the actual needs of welding multiple car models on the same line during automotive welding, mainstream resistance welding equipment currently supports more than 256 welding programs and more than 10 grinding specifications. The number of parameters is very large and complex, making it difficult for users to intuitively observe the changes and adjustments of equipment parameters. Moreover, once the equipment fails, after replacing the main control unit, it is necessary to manually restore each specification and internal parameter, which consumes a lot of time and manpower. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and propose a data backup and automatic comparison system and method for resistance welding machines. This system can automatically and manually back up data such as internal parameters of the equipment, welding program, grinding parameters, and calibration parameters in the welding controller. It can also automatically compare the backup data with all parameters of the current equipment and generate reports.

[0005] The technical problem solved by this invention is achieved through the following technical solution:

[0006] A resistance welding machine data backup and automatic comparison system includes a resistance welding controller and a host computer, wherein the resistance welding controller is connected to the host computer via an Ethernet interface.

[0007] The resistance welding controller includes a welding main control circuit, a data management system, and a file management system. The welding main control circuit is used to execute the welding process according to the set process parameters; the data management system is used to read, write, and synchronize equipment parameters; the file management system is used to store and keep the equipment parameters of the data management system in the form of files. At the same time, the resistance welding controller also has an MQTT service program and an FTP data access server for data interaction with the host computer.

[0008] The host computer includes a parameter comparison module, a data backup module, and a parameter read / write and monitoring module. The parameter comparison module is used to compare the equipment parameters between different resistance welding equipment, the data backup module is used to back up the equipment parameters between different resistance welding equipment, and the parameter read / write and monitoring module is used to read the equipment parameters of the data management system in the resistance welding controller in real time.

[0009] Furthermore, the equipment parameters include internal equipment parameters, adaptive welding parameters, welding program parameters, grinding program parameters, welding clamp calibration parameters, equipment fault alarm list, and adaptive resistance curve.

[0010] A method for a resistance welding machine data backup and automatic comparison system includes a data backup method, an automatic backup method, and a parameter comparison method.

[0011] Furthermore, the data backup method includes the following steps:

[0012] Step 1.1: The resistance welding controller starts up. The data management system checks whether the system's backup synchronization flag is 1. If the flag is 1, proceed to step 1.6; otherwise, if the flag is 0, proceed to step 1.2.

[0013] Step 1.2: The data management system begins backup, reading each device parameter in the controller;

[0014] Step 1.3: After each set of parameters is successfully read, the corresponding data content and data type are published through the MQTT server via the corresponding topic in the MQTT. The file system subscription subscribes to the topic in advance to receive the data type and data content, and after converting the data into a line of text according to the agreed storage format, writes it into the backup data file under the specified path.

[0015] Step 1.4: Publish the message to the data management system via MQTT topic. After receiving the message, the data management system will start reading the next parameter until the last parameter is read. Then, set the backup synchronization flag to 1 and proceed to step 1.5.

[0016] Step 1.5: The resistance welding controller is ready to start working. When the equipment parameters are modified through external devices, the file management system determines whether the parameters of the resistance welding controller need to be modified successfully. If successful, proceed to step 1.6; otherwise, notify the external device and return to repeat step 1.5.

[0017] Step 1.6: Set the backup synchronization flag to 0;

[0018] Step 1.7: Notify the file management system via the MQTT protocol to generate the corresponding modified data string and write it into the corresponding line of the backup file;

[0019] Step 1.8: After successfully modifying the backup file, set the backup synchronization flag to 1, notify the external device, and return to repeat step 1.5;

[0020] Furthermore, the specific implementation method for the external device to modify the device parameters in step 1.5 is as follows: the data type and data content to be modified are sent to the MQTT server in JSON data format through the corresponding MQTT topic. After receiving the data, the data processing system converts the data into a private write command data message and sends it to the resistance welding controller. The resistance welding controller modifies the corresponding parameters and returns the modification result to the external device through MQTT communication.

[0021] Furthermore, the automatic backup method includes the following steps:

[0022] Step 2.1: Start the backup process. The data management system creates a timer thread and sets the timer period.

[0023] Step 2.2: The timer is triggered after the timer reaches its timing period;

[0024] Step 2.3: Read the parameter with key BackupDate in the program configuration file to read the date the device was last backed up;

[0025] Step 2.4: Compare the date with the current date to determine if the difference in days is equal to or greater than the backup cycle days. If it is equal to or greater than the backup cycle days, proceed to step 2.4; otherwise, return to step 2.2.

[0026] Step 2.5: Read the parameter with the key BackupPath from the configuration file to obtain the preset total backup path.

[0027] Step 2.6: Read the data backup files of all devices sequentially via FTP protocol and write them to the corresponding device folders;

[0028] Step 2.7: Determine if the total number of backup files exceeds the maximum number of backup files. If it exceeds the maximum number of backups, delete the earliest backup file and proceed to step 2.7; otherwise, proceed directly to step 2.7.

[0029] Step 2.8: Update the BackupDate parameter in the configuration file, reset the timer, and return to step 2.2.

[0030] Furthermore, the specific implementation method of step 2.6 is as follows: the device folder is named based on the device's IP address and created under the backup master path, and the device backup file name is named according to the backup date.dat format.

[0031] Furthermore, the parameter comparison method includes the following steps:

[0032] Step 3.1: Start automatic parameter comparison. The data management system creates a timer thread and sets the timer period.

[0033] Step 3.2: The timer is triggered after the timer reaches its timing period;

[0034] Step 3.3: Read the parameter with the key CompareDate in the program configuration file to obtain the date when the device last performed parameter comparison;

[0035] Step 3.4: Compare the current date with the current date and determine whether the difference in days is equal to or greater than the parameter comparison period in days. If it is equal to or greater than the backup parameter comparison period in days, proceed to step 3.4; otherwise, return to step 3.2.

[0036] Step 3.5: Read the parameter with the key ComparePath in the configuration file and obtain the pre-set total path for saving the parameter comparison file.

[0037] Step 3.6: Determine if there is a comparison sample file Sample.dat in the corresponding device folder. If not, it means that the device will not perform parameter comparison. Skip the device and return to step 3.2. If there is, proceed to step 3.7.

[0038] Step 3.7: Obtain the backup file of the current equipment parameters of the corresponding resistance welding controller via FTP protocol and store it in the cache for later retrieval;

[0039] Step 3.8: Compare the sample file with the device parameter file in the cache line by line and parameter by parameter, and generate an Excel report file and save it to the corresponding device folder;

[0040] Step 3.9: Determine whether the total number of comparison files exceeds the maximum number of comparison files. If it exceeds the maximum number of comparison files, delete the earliest comparison file and proceed to step 3.10; otherwise, proceed directly to step 3.10.

[0041] Step 3.10: Update the CompareDate parameter in the configuration file, reset the timer, and return to step 3.2.

[0042] The advantages and positive effects of this invention are:

[0043] 1. This invention uses a host computer to monitor the welding main control circuit, data management system, and file management system of the resistance welding controller in real time. It uses an MQTT service program and an FTP data access server to perform periodic automatic and manual backups of data such as equipment internal parameters, welding programs, grinding parameters, and calibration parameters in the welding controller. It can also automatically compare the backup data with all parameters of the current equipment and generate reports.

[0044] 2. The data backup method, automatic backup method, and parameter comparison method of the present invention can periodically and intuitively understand the changes in all welding processes and equipment parameters in the workshop, and keep track of the changes in welding parameters of each piece of equipment at any time. When problems occur in the production process or equipment, the equipment can be quickly restored to a relatively earlier state, which facilitates problem location and elimination. When the process quality changes, it can also quickly locate which parameter changes caused the changes, helping managers to grasp the process changes in the entire workshop and improve management efficiency. Attached Figure Description

[0045] Figure 1 This is a structural diagram of the system of the present invention;

[0046] Figure 2 This is a flowchart illustrating the data backup process of the present invention.

[0047] Figure 3 This is a screenshot showing the interface for data backup in this invention.

[0048] Figure 4 This is a flowchart illustrating the automatic backup process of the present invention;

[0049] Figure 5 This is a schematic diagram illustrating the automatic backup file storage of the present invention;

[0050] Figure 6 This is a diagram showing the automatic backup interface of the present invention;

[0051] Figure 7 The comparison sample interface is set for this invention;

[0052] Figure 8 This is a flowchart of the automatic comparison process of the present invention;

[0053] Figure 9 This is a schematic diagram illustrating the automatic file format comparison of the present invention;

[0054] Figure 10 This is an example diagram of the automatic file comparison method of the present invention. Detailed Implementation

[0055] The present invention will be further described in detail below with reference to the accompanying drawings.

[0056] A resistance welding machine data backup and automatic comparison system, such as Figure 1 As shown, it includes a resistance welding controller and a host computer, wherein the resistance welding controller is connected to the host computer via an Ethernet interface;

[0057] The resistance welding controller includes a welding main control circuit, a data management system, and a file management system. The welding main control circuit is used to execute the welding process according to the set process parameters; the data management system is used to read, write, and synchronize equipment parameters; the file management system is used to store and keep the equipment parameters of the data management system in the form of files. At the same time, the resistance welding controller also has an MQTT service program and an FTP data access server for data interaction with the host computer.

[0058] The host computer includes a parameter comparison module, a data backup module, and a parameter read / write and monitoring module. The parameter comparison module is used to compare the equipment parameters between different resistance welding equipment, the data backup module is used to back up the equipment parameters between different resistance welding equipment, and the parameter read / write and monitoring module is used to read the equipment parameters of the data management system in the resistance welding controller in real time.

[0059] The equipment parameters include internal equipment parameters, adaptive welding parameters, welding program parameters, grinding program parameters, welding clamp calibration parameters, equipment fault alarm list, and adaptive resistance curve.

[0060] A method for a resistance welding machine data backup and automatic comparison system includes a data backup method, an automatic backup method, and a parameter comparison method.

[0061] like Figure 2 As shown, the data backup method includes the following steps:

[0062] Step 1.1: The resistance welding controller starts up. The data management system checks whether the system's backup synchronization flag is 1. If the flag is 1, proceed to step 1.6. Otherwise, if the flag is 0, it means that the current controller system has not performed a file backup or the last backup was unsuccessful. Proceed to step 1.2.

[0063] Step 1.2: The data management system begins backup, reading each device parameter in the controller;

[0064] Step 1.3: After each set of parameters is successfully read, the corresponding data content and data type are published through the MQTT server via the corresponding topic: / File / Backup / Update. The file system subscription pre-subscribes to this topic to receive the data type and data content, and after converting the data into a line of text according to the agreed storage format, it is written to the backup data file ( / Backup / Setting.dat) under the specified path.

[0065] Step 1.4: Publish the backup synchronization flag to 1 via the MQTT topic: / File / Backup / Result and notify the data management system. After receiving the notification, the data management system will start reading the next parameter until the last parameter is read, and then proceed to step 1.5.

[0066] Step 1.5: The resistance welding controller is ready to start working. When the equipment parameters are modified through external devices, the file management system determines whether the parameters of the resistance welding controller need to be modified successfully. If successful, proceed to step 1.6; otherwise, notify the external device and return to repeat step 1.5.

[0067] The specific implementation method for external devices to modify device parameters in this step is as follows: The data type and content to be modified are sent to the MQTT server in JSON format via the corresponding MQTT topic. After receiving the data, the data processing system converts it into a private write command data message and sends it to the welding main control system. The main control board system modifies the corresponding parameters and returns the modification result to the external device via MQTT communication. If the modification is successful, the data acquisition system immediately notifies the file management system of the modification result via the MQTT protocol. The file management system generates the corresponding data string and writes it to the corresponding line in the backup file. This effectively ensures the consistency of device parameters between the data in the main control board and the data file.

[0068] Step 1.6: Set the backup synchronization flag to 0;

[0069] Step 1.7: Notify the file management system via the MQTT protocol to generate the corresponding modified data string and write it into the corresponding line of the backup file;

[0070] Step 1.8: After successfully modifying the backup file, set the backup synchronization flag to 1, notify the external device, and return to repeat step 1.5;

[0071] like Figure 3 As shown, this invention utilizes the WPF framework to develop a computer program that implements a backup function for all data of a resistance welding machine. By selecting the corresponding device and clicking the corresponding backup button within the program, when the device is online, the computer program will connect to the device's file management system via the FTP protocol, retrieve the corresponding backup file, and save it to the user's specified path, thus achieving a manual one-click backup function for the device. Simultaneously, the program also supports an automatic backup function, with four settings: enabling backup, backup cycle, maximum number of files, and backup path.

[0072] like Figure 4 As shown, the automatic backup method includes the following steps:

[0073] Step 2.1: Start the backup. The data management system creates a timer thread and sets the timer period to 4 hours.

[0074] Step 2.2: The timer is triggered after the timer reaches its timing period;

[0075] Step 2.3: Read the parameter with key BackupDate in the program configuration file to read the date the device was last backed up;

[0076] Step 2.4: Compare the date with the current date to determine if the difference in days is equal to or greater than the backup cycle days. If it is equal to or greater than the backup cycle days, proceed to step 2.4; otherwise, return to step 2.2.

[0077] Step 2.5: Read the parameter with the key BackupPath from the configuration file to obtain the preset total backup path.

[0078] Step 2.6: Read the data backup files of all devices sequentially via FTP protocol and write them to the corresponding device folders;

[0079] In this step, if the device's IP address is 192.168.0.232, then its corresponding backup folder name will be "192-168-0-232". The device backup files will be named in the format "AutoBackup_{backup date}.dat" to ensure the uniqueness of the device folder and device files.

[0080] Step 2.7: Determine if the total number of backup files exceeds the maximum number of backup files. If it exceeds the maximum number of backups, delete the earliest backup file and proceed to step 2.7; otherwise, proceed directly to step 2.7.

[0081] Step 2.8: Update the BackupDate parameter in the configuration file, reset the timer, and return to step 2.2.

[0082] like Figure 5 As shown, this invention successfully implements automatic file backup, with the storage format being "AutoBackup_{backup date}.dat", the device IP being 192.168.18.231, the backup cycle being 1 day, and the maximum number of backup files being 5.

[0083] like Figure 6As shown, the parameter comparison settings interface has four settings: enable parameter comparison, comparison cycle, maximum number of files, and comparison path. Unlike the automatic backup function settings, in addition to the above parameters, it is necessary to set the parameter comparison sample file for each welding controller individually to facilitate comparison with the latest equipment parameters. The program can either directly select to read the current equipment parameter backup file from the welding controller as the comparison sample or select the corresponding parameter backup file from the computer for comparison. Its operation interface is as follows... Figure 7 As shown. After selecting a suitable sample comparison file and clicking "Set," the computer program will automatically copy the file to the corresponding device folder under the comparison path (naming method is the same as backup), and the file name will be "Sample.dat". For controllers for which parameter comparison is not desired, click the "Clear" button, and the program will automatically delete the corresponding "Sample.dat" sample file.

[0084] like Figure 8 As shown, the parameter comparison method includes the following steps:

[0085] Step 3.1: Start automatic parameter comparison. The data management system creates a timer thread and sets the timer period.

[0086] Step 3.2: The timer is triggered after the timer reaches its timing period;

[0087] Step 3.3: Read the parameter with the key CompareDate in the program configuration file to obtain the date when the device last performed parameter comparison;

[0088] Step 3.4: Compare the current date with the current date and determine whether the difference in days is equal to or greater than the parameter comparison period in days. If it is equal to or greater than the backup parameter comparison period in days, proceed to step 3.4; otherwise, return to step 3.2.

[0089] Step 3.5: Read the parameter with the key ComparePath in the configuration file and obtain the pre-set total path for saving the parameter comparison file.

[0090] Step 3.6: Determine if there is a comparison sample file Sample.dat in the corresponding device folder. If not, it means that the device will not perform parameter comparison. Skip the device and return to step 3.2. If there is, proceed to step 3.7.

[0091] Step 3.7: Obtain the backup file of the current equipment parameters of the corresponding resistance welding controller via FTP protocol and store it in the cache for later retrieval;

[0092] Step 3.8: Compare the sample file with the device parameter file in the cache line by line and parameter by parameter, and generate an Excel report file and save it in the corresponding device folder. The naming method of the device folder is the same as that of the automatic backup process. The comparison file name is "AutoCheck_{comparison date}.xlsx".

[0093] Step 3.9: Determine whether the total number of comparison files exceeds the maximum number of comparison files. If it exceeds the maximum number of comparison files, delete the earliest comparison file and proceed to step 3.10; otherwise, proceed directly to step 3.10.

[0094] Step 3.10: Update the CompareDate parameter in the configuration file, reset the timer, and return to step 3.2.

[0095] like Figure 9 The image shows an example of the file format. The device folder is named in the same way as the automatic backup process, and its comparison file name is "AutoCheck_{Comparison Date}.xlsx". Figure 10 As shown, this is the format of the generated comparison file. When changes occur in process quality, managers can quickly pinpoint which parameters changed, helping them understand the overall process changes in the workshop and improve management efficiency.

[0096] It should be emphasized that the embodiments described in this invention are illustrative rather than limiting. Therefore, this invention includes, but is not limited to, the embodiments described in the specific implementation. Any other implementations derived by those skilled in the art based on the technical solutions of this invention are also within the scope of protection of this invention.

Claims

1. A method for a resistance welder data backup and automatic comparison system, characterized by: The system used includes a resistance welding controller and a host computer, and the resistance welding controller is connected with the host computer through an Ethernet interface; The resistance welding controller includes a welding main control circuit, a data management system and a file management system, the welding main control circuit is used for executing a welding process according to set process parameters; the data management system is used for reading and writing and synchronous management of equipment parameters; the file management system is used for storing the equipment parameters of the data management system in the form of files and keeping consistent, and the resistance welding controller is internally provided with an MQTT service program and an FTP data access server, which are used for data interaction with the host computer; The host computer includes a parameter comparison module, a data backup module and a parameter reading and writing and monitoring module, the parameter comparison module is used for comparing equipment parameters between different resistance welding devices, the data backup module is used for backing up the equipment parameters between different resistance welding devices, and the parameter reading and writing and monitoring module is used for reading the equipment parameters of the data management system in the resistance welding controller in real time; The equipment parameters include internal equipment parameters, adaptive welding parameters, welding programs, grinding programs, welding tong calibration parameters, equipment fault alarm lists and adaptive resistance curves; The method of the automatic comparison system includes a data backup method, an automatic backup method and a parameter comparison method; The data backup method includes the following steps: Step 1.1, the resistance welding controller is started, the data management system judges whether the backup synchronization flag of the system is 1, if the flag is 1, step 1.6 is performed, otherwise the flag is 0, and step 1.2 is performed; Step 1.2, the data management system starts backup, and reads the equipment parameters in the controller item by item; Step 1.3, after each reading is successful, the corresponding data content and data type are published through the MQTT server through the corresponding topic of MQTT, the file system subscribes to the topic in advance to receive the data type and data content, and writes the data into the backup data file under the specified path after converting the data into a line of text according to the agreed storage format; Step 1.4, the data management system is notified through the topic of MQTT, and after receiving, the data management system starts to read the next parameter until the last parameter is read, and the backup synchronization flag is set to 1; and step 1.5 is performed; Step 1.5, the resistance welding controller is ready to work, when the equipment parameters are modified through an external device, the file management system judges whether the parameters of the resistance welding controller need to be modified successfully, if yes, step 1.6 is performed, otherwise the external device is notified and step 1.5 is repeated; Step 1.6, the backup synchronization flag is set to 0; Step 1.7, the file management system is notified through the MQTT protocol to generate the corresponding modified data string and write it into the corresponding line of the backup file; Step 1.8, after the backup file is modified successfully, the backup synchronization flag is set to 1, the external device is notified and step 1.5 is repeated; The parameter comparison method includes the following steps: Step 3.1, starting the automatic parameter comparison, the data management system creates a timer thread and sets a timing period, Step 3.2, the timer triggers after the timing period arrives; Step 3.3, read the parameter with key CompareDate in the program configuration file to obtain the date when the device last performed parameter comparison; Step 3.4, compare the date with the current date to determine whether the difference in days is equal to or greater than the parameter comparison period, and if so, proceed to step 3.5, otherwise return to step 3.2; Step 3.5, read the parameter with key ComparePath in the configuration file to obtain the pre-set parameter comparison file saving path; Step 3.6, determine whether there is a comparison sample file Sample.dat under the corresponding device folder, if not, it means that the device does not perform parameter comparison, skip the device and return to step 3.2, if so, proceed to step 3.7; Step 3.7, obtain the current device parameter backup file of the corresponding resistance welding controller through the FTP protocol and store it in the cache for calling; Step 3.8, compare the sample file with the device parameter file in the cache line by line and parameter by parameter, and generate an Excel report file and store it in the corresponding device folder; Step 3.9, determine whether the total number of comparison files exceeds the maximum number of comparison files, if so, delete the earliest comparison file and proceed to step 3.10, otherwise, directly proceed to step 3.10; Step 3.10, update the CompareDate parameter in the configuration file and reset the timer, and return to step 3.

2.

2. The method of a resistance welder data backup and automatic comparison system of claim 1, wherein: The specific implementation method of the external device modifying the device parameters in step 1.5 is: publishing the data type and data content to be modified to the MQTT server in JSON data format through the corresponding MQTT topic, after the data processing system receives the data, it converts the data into a private write command data packet and sends it to the resistance welding controller, the resistance welding controller modifies the corresponding parameters, and returns the modified result to the external device through MQTT communication.

3. The method of a resistance welder data backup and automatic comparison system of claim 1, wherein: The automatic backup method includes the following steps: Step 2.1, start backup, the data management system creates a timer thread and sets a timing period; Step 2.2, the timer triggers after the timing period arrives; Step 2.3, read the parameter with key BackupDate in the program configuration file to read the date when the device last performed backup; Step 2.4, compare the date with the current date to determine whether the difference in days is equal to or greater than the backup period, if so, proceed to step 2.5, otherwise return to step 2.2; Step 2.5, read the parameter with key BackupPath in the configuration file to obtain the pre-set backup path, Step 2.6, read all device data backup files in sequence through the FTP protocol and write them into the corresponding device folder; Step 2.7, judging whether the total number of backup files exceeds the maximum number of backup files, if exceeding the maximum number of backup files, deleting the earliest backup file and proceeding to step 2.8, otherwise directly proceeding to step 2.8; Step 2.8, updating the BackupDate parameter in the configuration file and resetting the timer, and returning to step 2.

2.

4. The method of a resistance welder data backup and automatic comparison system of claim 3, wherein: The specific implementation method of step 2.6 is that the device folder is named based on the IP address of the device and created under the backup total path, and the device backup file name is named in the format of backup date.dat.

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