A multi-person symmetrical welding synchronization device and method to reduce welding deformation

Abstract

This invention discloses a multi-person symmetrical welding synchronization device and method to reduce welding deformation. It includes a controller with a first wireless communication module, multiple weld point position monitoring devices, and multiple welding masks. The weld point position monitoring device includes a long, high-temperature resistant box, an infrared temperature sensor array disposed inside the long, high-temperature resistant box, and a wireless communication box connected to the long, high-temperature resistant box. The infrared temperature sensor array includes a number of infrared temperature sensing probes evenly spaced along the length of the top surface inside the long, high-temperature resistant box. A number of detection holes are provided on the bottom surface inside the long, high-temperature resistant box, opposite to the top surface, for the detection light from the infrared temperature sensing probes to pass through. The controller is wirelessly connected to an MCU control unit for the box and an MCU control unit for the masks. This invention improves the consistency of welding speed at each welding point during multi-person welding, thereby reducing welding deformation of the workpiece.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and specifically to a multi-person symmetrical welding synchronous device and method for reducing welding deformation. Background Technology

[0002] In the welding of large structural components, welding deformation is a significant factor affecting the post-weld accuracy of the workpiece. To reduce welding deformation, for structurally regular or symmetrical workpieces, an effective welding method is symmetrical welding. For example, a two-person welding method can be used to weld simultaneously on both sides of the workpiece; for even larger workpieces, several people may be needed to weld simultaneously, in order to both reduce welding deformation and shorten the welding cycle.

[0003] However, when multiple people are welding at the same time, each welding operator usually performs welding work independently. Due to the differences in welding habits, welding skills and welding experience among the welding operators, it is actually difficult to achieve a strict consistency in the welding speed at each welding station when multiple people are welding. When the welding speed difference between each welding station is large, it will inevitably reduce the effect of symmetrical welding, thus failing to achieve the goal of reducing welding deformation. Summary of the Invention

[0004] To address the aforementioned problems, this invention proposes a multi-person symmetrical welding synchronization device and method to reduce welding deformation. The aim is to improve the consistency of welding speed at different welding points during multi-person welding, thereby reducing workpiece welding deformation. The specific technical solution is as follows:

[0005] A multi-person symmetrical synchronous welding device for reducing welding deformation includes a controller with a first wireless communication module, multiple weld point position monitoring devices, and multiple welding masks. The weld point position monitoring device includes a long, high-temperature resistant box, an infrared temperature sensor array disposed inside the long, high-temperature resistant box, and a wireless communication box connected to the infrared temperature sensor array inside the long, high-temperature resistant box via cables. The infrared temperature sensor array includes a plurality of infrared temperature sensing probes evenly spaced along the length of the long, high-temperature resistant box on the top surface inside the box. The bottom surface opposite the top surface of the part is provided with a number of detection holes for the detection light of the infrared temperature sensing probe to pass through; the wireless communication box includes a box body and a box body MCU control unit with a second wireless communication module disposed inside the box body, and each infrared temperature sensing probe is connected to the box body MCU control unit; each of the welding masks is provided with a mask MCU control unit and a microphone connected to the mask MCU control unit, and the mask MCU control unit is provided with a third wireless communication module and a voice prompt module; the controller is wirelessly connected to the box body MCU control unit and the mask MCU control unit respectively.

[0006] In use, the outer bottom surface of the elongated high-temperature resistant box is installed on the surface of the workpiece adjacent to the welding path of the workpiece to be welded, and the elongated high-temperature resistant box is equidistant from the welding path of the workpiece to be welded.

[0007] Preferably, the elongated high-temperature resistant cassette is a straight cassette or an arc-shaped cassette that is adapted to the welding path shape of the workpiece to be welded.

[0008] Among them, the straight-line condenser box is suitable for welding straight weld seams, while the arc-shaped condenser box is suitable for welding circumferential circumferential seams on cylindrical workpieces.

[0009] Preferably, the elongated high-temperature resistant dark box is provided with a number of replaceable angle steels fixed by screws for spot welding connection with the workpiece.

[0010] In this invention, the inside of the welding mask is also provided with a facial sensing sensor, which is connected to the MCU control unit of the mask.

[0011] The aforementioned facial sensor is used to monitor whether the welding mask has been put on properly.

[0012] In this invention, the elongated high-temperature resistant dark box is provided with a wiring protection box for leading out the data line of the infrared temperature sensing probe inside the elongated high-temperature resistant dark box, and the wiring protection box is provided with a wiring protection lead-out tube.

[0013] To reduce the impact of welding heat on the elongated high-temperature resistant cassette and thus reduce the accuracy of temperature detection, the preferred solution is that the outer surface of the elongated high-temperature resistant cassette is provided with a high-temperature resistant reflective heat-insulating coating.

[0014] The present invention provides a multi-person symmetrical welding synchronization device for reducing welding deformation, which further includes multiple welding torches. Each welding torch handle is equipped with a hand sensor and a wireless transmitter. The wireless transmitter includes a welding torch MCU control unit with a fourth wireless communication module and a transmitter button connected to the welding torch MCU control unit. The hand sensor is connected to the welding torch MCU control unit, and the controller is wirelessly connected to the welding torch MCU control unit.

[0015] A synchronization method for a multi-person symmetrical welding synchronous device to reduce welding deformation includes the following steps:

[0016] (1) Pre-welding preparation: Based on the welding points and the number of welders in synchronous welding, use the corresponding number of welding guns, welding masks and long strip high-temperature resistant boxes.

[0017] (2) Installation of long strip high temperature resistant boxes: Install each long strip high temperature resistant box on the adjacent part of each welding path on the workpiece, so that the long strip high temperature resistant box is close to the welding path and is set at equal distance. After it is in place, spot weld the replaceable angle steel on the long strip high temperature resistant box to the workpiece to fix the long strip high temperature resistant box.

[0018] (3) Synchronous welding: Each welding operator takes their position, puts on their welding mask, holds their welding gun, and presses the signal button on their welding gun to report to the controller that they are ready via wireless communication. After receiving the information that all welding operators are ready, the controller sends a welding start command to each mask MCU control unit via wireless communication. After receiving the welding start command, each mask MCU control unit informs the welding operator that welding will start immediately through the voice prompt module and microphone, thus realizing synchronous welding of each operator.

[0019] Preferably, the synchronization method of the multi-person symmetrical welding synchronization device for reducing welding deformation according to the present invention further includes the following steps after step (3):

[0020] (4) Synchronous monitoring: During the welding process, the MCU control unit of each long strip high-temperature resistant box dynamically monitors the temperature measured by each infrared temperature sensor probe through the infrared temperature sensor array, and obtains the position of the infrared temperature sensor probe with the highest detected temperature. The position of the infrared temperature sensor probe with the highest detected temperature corresponds to the current welding position of the welding torch, that is, the welding length completed by the welding torch from the welding start point to the current position. The MCU control unit of each box wirelessly sends the welding torch's current welding position information, i.e. the completed welding length information, to the controller. After receiving the welding length information of the welding torch sent by the MCU control unit of each box, the controller calculates the average value of the welding length completed by the welding torch and compares the completed welding length of each welding torch with the average value of the welding length to obtain the welding length deviation of the welding torch. When a welding torch with a welding length deviation exceeding the threshold is found, the controller immediately sends a correction command to the MCU control unit of the mask in the welding mask corresponding to the welding torch, and the MCU control unit of the mask issues a command to the welding operator to adjust the welding speed through the voice prompt module and microphone.

[0021] Specifically, when the welding length is less than the average welding length and the welding length deviation exceeds a preset threshold, the voice prompt module issues a command to speed up the welding; when the welding length is greater than the average welding length and the welding length deviation exceeds the threshold, the voice prompt module issues a command to slow down the welding.

[0022] The beneficial effects of this invention are:

[0023] First, the present invention provides a multi-person symmetrical welding synchronization device and method for reducing welding deformation. Utilizing the principle that the temperature around the welding position on the workpiece is higher than other positions, a weld point position monitoring device is installed next to the welding path on the workpiece. An infrared temperature sensor array on the weld point position monitoring device tracks the dynamic changes of the highest temperature position on the workpiece in real time, obtaining the dynamic information of the current welding position of the welding torch. This dynamic information is then sent to a controller via a wireless communication module, where the controller makes a comprehensive decision. Using the completed welding length as a criterion, the controller provides reminders to welding operators with slower or faster welding speeds via a prompt module on the welding mask and a microphone. This achieves uniform welding speed across all welding stations, thereby reducing welding deformation of the workpiece.

[0024] Secondly, the present invention provides a multi-person symmetrical welding synchronous device and method for reducing welding deformation. The weld point position monitoring device can be made into a straight line shape or an arc shape to adapt to the monitoring needs of welding paths of different workpiece shapes. Attached Figure Description

[0025] Figure 1This is a schematic diagram of the weld point position monitoring device in a multi-person symmetrical synchronous welding device for reducing welding deformation according to the present invention.

[0026] Figure 2 This is a schematic diagram of the welding mask in a multi-person symmetrical synchronous welding device for reducing welding deformation according to the present invention.

[0027] Figure 3 This is a schematic diagram of the welding torch (handle part) in a multi-person symmetrical welding synchronous device for reducing welding deformation according to the present invention.

[0028] Figure 4 This is a schematic diagram of the wireless communication connection between the controller, the weld point position monitoring device, and the welding mask.

[0029] In the diagram: 1. First wireless communication module; 2. Controller; 3. Welding point position monitoring device; 4. Welding mask; 5. Long strip-shaped high-temperature resistant dark box; 6. Infrared temperature sensor array; 7. Wireless communication box; 8. Infrared temperature sensor probe; 9. Detection hole; 10. Box body; 11. Second wireless communication module; 12. MCU control unit for box body; 13. MCU control unit for mask; 14. Microphone; 15. Third wireless communication module; 16. Voice prompt module; 17. Screw; 18. Replaceable angle steel; 19. Facial sensor; 20. Wiring protection box; 21. Wiring protection lead tube; 22. Welding torch handle; 23. Wireless transmitter; 24. Fourth wireless communication module; 25. MCU control unit for welding torch; 26. Transmit button; 27. Hand sensor; 28. Protective goggles. Detailed Implementation

[0030] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solutions of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0031] Example 1:

[0032] like Figures 1 to 4The illustration shows an embodiment of a multi-person symmetrical welding synchronous device for reducing welding deformation according to the present invention, comprising a controller 2 with a first wireless communication module 1, multiple weld point position monitoring devices 3, and multiple welding masks 4; the weld point position monitoring device 3 includes a long strip-shaped high-temperature resistant box 5, an infrared temperature sensor array 6 disposed inside the long strip-shaped high-temperature resistant box 5, and a wireless communication box 7 connected to the infrared temperature sensor array 6 inside the long strip-shaped high-temperature resistant box 5 via a cable; the infrared temperature sensor array 6 includes a plurality of infrared temperature sensing probes 8 evenly spaced along the length direction of the long strip-shaped high-temperature resistant box 5 on the top surface inside the long strip-shaped high-temperature resistant box 5, and the probes are located inside the long strip-shaped high-temperature resistant box 5 and on the top surface inside the long strip-shaped high-temperature resistant box 5. The bottom surfaces facing each other are provided with a number of detection holes 9 for the detection light of the infrared temperature sensing probes 8 to pass through; the wireless communication box 7 includes a box body 10 and a box body MCU control unit 12 with a second wireless communication module 11 disposed inside the box body 10, and each infrared temperature sensing probe 8 is respectively connected to the box body MCU control unit 12; each welding mask 4 is provided with a mask MCU control unit 13 and a microphone 14 connected to the mask MCU control unit 13, and the mask MCU control unit 13 is respectively provided with a third wireless communication module 15 and a voice prompt module 16; the controller 2 is wirelessly connected to the box body MCU control unit 12 and the mask MCU control unit 13 respectively.

[0033] In use, the outer bottom surface of the elongated high-temperature resistant box 5 is installed on the surface of the workpiece adjacent to the welding path of the workpiece to be welded, and the elongated high-temperature resistant box 5 is equidistant from the welding path of the workpiece to be welded.

[0034] Preferably, the elongated high-temperature resistant box 5 is a straight box or an arc-shaped box that is adapted to the welding path shape of the workpiece to be welded.

[0035] Among them, the straight-line condenser box is suitable for welding straight weld seams, while the arc-shaped condenser box is suitable for welding circumferential circumferential seams on cylindrical workpieces.

[0036] Preferably, the elongated high-temperature resistant dark box 5 is provided with a number of replaceable angle steels 18 fixed by screws 17 for spot welding connection with the workpiece.

[0037] In this embodiment, a facial sensing sensor 19 is also provided inside the welding mask 4, and the facial sensing sensor 19 is connected to the MCU control unit 13 for the mask.

[0038] The aforementioned facial sensor 19 is used to monitor whether the welding mask 4 has been put on properly.

[0039] In this embodiment, the elongated high-temperature resistant dark box 5 is provided with a wiring protection box 20 for leading out the data line of the infrared temperature sensing probe 8 inside the elongated high-temperature resistant dark box 5, and the wiring protection box 20 is provided with a wiring protection lead-out tube 21.

[0040] To reduce the impact of welding heat on the elongated high-temperature resistant cassette 5 and thus reduce the accuracy of temperature detection, the preferred solution is that the outer surface of the elongated high-temperature resistant cassette 5 is provided with a high-temperature resistant reflective heat-insulating coating.

[0041] This embodiment of a multi-person symmetrical welding synchronous device for reducing welding deformation also includes multiple welding torches. Each welding torch handle 22 is equipped with a hand sensor 27 and a wireless transmitter 23. The wireless transmitter 23 includes a welding torch MCU control unit 25 with a fourth wireless communication module 24 and a transmitter button 26 connected to the welding torch MCU control unit 25. The hand sensor 27 is connected to the welding torch MCU control unit 25, and the controller 2 is wirelessly connected to the welding torch MCU control unit 25.

[0042] A synchronization method for a multi-person symmetrical welding synchronous device to reduce welding deformation includes the following steps:

[0043] (1) Pre-welding preparation: Based on the welding points and the number of welders in synchronous welding, use the corresponding number of welding guns, the corresponding number of welding masks 4 and the corresponding number of long strip high temperature resistant boxes 5.

[0044] (2) Installation of long strip high temperature resistant boxes: Install each long strip high temperature resistant box 5 at the adjacent point of each welding path on the workpiece, so that the long strip high temperature resistant box 5 is close to the welding path and is set at equal distance. After it is in place, spot weld the replaceable angle steel on the long strip high temperature resistant box 5 to the workpiece so that the long strip high temperature resistant box 5 is fixed.

[0045] (3) Synchronous welding: Each welding operator takes their position, puts on the welding mask 4, holds the welding gun, and presses the signal button 26 on the welding gun to report to the controller 2 that they are ready via wireless communication. After receiving the information that all welding operators are ready, the controller 2 sends a welding start command to the MCU control unit 13 of each mask via wireless communication. After receiving the welding start command, the MCU control unit 13 of each mask informs the welding operator that welding will start immediately through the voice prompt module 16 and the microphone 14, thereby realizing synchronous welding of each operator.

[0046] Preferably, the synchronization method of the multi-person symmetrical welding synchronization device for reducing welding deformation in this embodiment further includes the following steps after step (3):

[0047] (4) Synchronous monitoring: During the welding process, the MCU control unit 12 dynamically monitors the temperature measured by each infrared temperature sensor probe 8 through the infrared temperature sensor array 6 of each elongated high-temperature resistant box 5, and obtains the position of the infrared temperature sensor probe 8 with the highest detected temperature. The position of the infrared temperature sensor probe 8 with the highest detected temperature corresponds to the current welding position of the welding torch, that is, the welding length completed by the welding torch from the welding start point to the current position. The MCU control unit 12 of each box wirelessly sends the current welding position information of the welding torch, that is, the welding length information completed, to the controller 2. After receiving the welding length information of each welding gun from the MCU control unit 12 of each box, the controller 2 calculates the average welding length of each welding gun and compares the welding length of each welding gun with the average welding length to obtain the welding length deviation of the welding gun. When a welding gun with a welding length deviation exceeding the threshold is found, the controller 2 immediately sends a correction command to the MCU control unit 13 of the mask in the welding mask 4 corresponding to the welding gun. The MCU control unit 13 of the mask then issues a command to the welding operator to adjust the welding speed through the voice prompt module 16 and the microphone 14.

[0048] Specifically, when the welding length is less than the average welding length and the welding length deviation exceeds a preset threshold, the voice prompt module 16 issues a command to speed up the welding speed; when the welding length is greater than the average welding length and the welding length deviation exceeds the threshold, the voice prompt module 16 issues a command to slow down the welding speed.

[0049] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A multi-person symmetrical synchronous welding device for reducing welding deformation, characterized in that, The system includes a controller with a first wireless communication module, multiple solder joint position monitoring devices, and multiple welding masks. The solder joint position monitoring device includes a long, high-temperature resistant box, an infrared temperature sensor array disposed inside the long, high-temperature resistant box, and a wireless communication box connected to the infrared temperature sensor array inside the long, high-temperature resistant box via a cable. The infrared temperature sensor array includes a plurality of infrared temperature sensing probes evenly spaced along the length of the long, high-temperature resistant box on the top surface inside the box, and a sensor located on the bottom surface inside the long, high-temperature resistant box opposite to the top surface. There are a number of detection holes for the infrared temperature sensing probe to detect the passage of light; the wireless communication box includes a box body and a box body MCU control unit with a second wireless communication module disposed inside the box body, and each infrared temperature sensing probe is connected to the box body MCU control unit; each welding mask is provided with a mask MCU control unit and a microphone connected to the mask MCU control unit, and the mask MCU control unit is provided with a third wireless communication module and a voice prompt module; the controller is wirelessly connected to the box body MCU control unit and the mask MCU control unit.

2. The multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 1, characterized in that, The outer bottom surface of the elongated high-temperature resistant box is installed on the surface of the workpiece adjacent to the welding path of the workpiece to be welded, and the elongated high-temperature resistant box is equidistant from the welding path of the workpiece to be welded.

3. A multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 2, characterized in that, The elongated high-temperature resistant cassette is a straight cassette or an arc-shaped cassette that is adapted to the welding path shape of the workpiece to be welded.

4. A multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 2, characterized in that, The elongated high-temperature resistant dark box is equipped with a number of replaceable angle steels fixed with screws for spot welding connection with the workpiece.

5. A multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 1, characterized in that, The welding mask is also equipped with a facial sensing sensor inside, which is connected to the MCU control unit of the mask.

6. A multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 1, characterized in that, The elongated high-temperature resistant dark box is equipped with a wiring protection box for leading out the data line of the infrared temperature sensing probe inside the elongated high-temperature resistant dark box, and the wiring protection box is equipped with a wiring protection lead-out tube.

7. A multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 1, characterized in that, The outer surface of the elongated high-temperature resistant dark box is provided with a high-temperature resistant reflective heat-insulating coating.

8. A multi-person symmetrical synchronous welding device for reducing welding deformation according to claim 1, characterized in that, It also includes multiple welding torches, each with a hand sensor and a wireless transmitter on its handle. The wireless transmitter includes a welding torch MCU control unit with a fourth wireless communication module and a transmitter button connected to the welding torch MCU control unit. The hand sensor is connected to the welding torch MCU control unit, and the controller is wirelessly connected to the welding torch MCU control unit.

9. A synchronization method using a multi-person symmetrical welding synchronization device for reducing welding deformation as described in any one of claims 1 to 8, characterized in that, Includes the following steps: (1) Pre-welding preparation: Based on the welding points and the number of welders for synchronous welding, use the corresponding number of welding guns, welding masks and long strip high-temperature resistant boxes. (2) Installation of long strip high temperature resistant boxes: Install each long strip high temperature resistant box on the adjacent part of each welding path on the workpiece, so that the long strip high temperature resistant box is close to the welding path and is set at equal distance. After it is in place, spot weld the replaceable angle steel on the long strip high temperature resistant box to the workpiece to fix the long strip high temperature resistant box. (3) Synchronous welding: Each welding operator takes their position, puts on their welding mask, holds their welding gun, and presses the signal button on their welding gun to report to the controller that they are ready via wireless communication. After receiving the information that all welding operators are ready, the controller sends a welding start command to each mask MCU control unit via wireless communication. After receiving the welding start command, each mask MCU control unit informs the welding operator that welding will start immediately through the voice prompt module and microphone, thus realizing synchronous welding of each operator.

10. The synchronization method of a multi-person symmetrical welding synchronization device for reducing welding deformation according to claim 9, characterized in that, It also includes the following steps set after step (3): (4) Synchronous monitoring: During the welding process, the MCU control unit of each long strip high-temperature resistant box dynamically monitors the temperature measured by each infrared temperature sensor probe through the infrared temperature sensor array, and obtains the position of the infrared temperature sensor probe with the highest detected temperature. The position of the infrared temperature sensor probe with the highest detected temperature corresponds to the current welding position of the welding torch, that is, the welding length completed by the welding torch from the welding start point to the current position. The MCU control unit of each box wirelessly sends the welding position information of the welding torch, that is, the welding length information completed, to the controller. After receiving the welding length information completed by the welding torch sent by the MCU control unit of each box, the controller calculates the average value of the welding length completed by the welding torch and compares the welding length completed by each welding torch with the average value of the welding length to obtain the welding length deviation of the welding torch. When a welding torch with a welding length deviation exceeding the threshold is found, the controller immediately sends a correction command to the MCU control unit of the mask in the welding mask corresponding to the welding torch, and the MCU control unit of the mask issues a command to the welding operator to adjust the welding speed through the voice prompt module and microphone.

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