Improved welding gun testing apparatus and method

Abstract

The present invention relates to an improved welding gun testing apparatus and method, said apparatus comprising: a control module comprising a welding controller corresponding to the same welding controller of the production line for which the welding gun to be tested is used, and a test controller having the same control operating system corresponding to the same production line for which the welding gun to be tested is used; a user interface; a test interface comprising a water interface, a gas interface, an electric interface for coupling to the respective coupling ports of the welding gun to be tested.

Description

Technical Field

[0001] This invention relates to improved welding torch testing equipment and methods. Background Technology

[0002] Welding torches, such as pneumatic welding torches, are used in the automotive manufacturing industry, for example, for spot welding. Typically, various parameters of the welding torch need to be tested, including water supply (cooling water), air supply (compressed air), power supply, motion characteristics, force characteristics, temperature characteristics, and electrical design, to determine whether it should be put into production or requires further maintenance.

[0003] The design of existing test arrangements may be flawed. For example, offline testing may not match the configuration of the work site; it may not be convenient to use; it may lack some necessary functions; and some test components may be easily damaged.

[0004] In addition, electric welding guns are also used. The existing testing arrangements only use pneumatic welding guns and cannot meet the new testing requirements. Summary of the Invention

[0005] Therefore, there is a need in this field to provide an integrated and convenient welding torch testing equipment and method that meets the required standards.

[0006] According to some aspects of the present invention, a welding torch testing equipment is provided, comprising: a control module including a welding controller and a test controller, the welding controller corresponding to the same welding controller used on the production line where the welding torch under test is used, and the test controller having the same control operating system as the production line where the welding torch under test is used; a user interface; and a test interface including a water interface, a gas interface, and an electrical interface for coupling to the corresponding connection ports of the welding torch under test. Thus, the welding controller adopts a model consistent with the one used on the production line (e.g., Bosch PRC7000), while the test controller adopts a control operating system compatible with the field (e.g., SIEMENS TIA 1518 based on PLC). Therefore, the welding torch under test will receive essentially the same instruction patterns and operating modes as on the production line, thereby better reflecting the actual parameters and characteristics of the welding torch under test, leading to better test conclusions. Furthermore, this encourages personnel to operate in a manner essentially the same as on the production line, thereby becoming more proficient and avoiding misoperation.

[0007] According to some aspects of the invention, the welding torch testing equipment further includes a welding torch flushing device configured to flush (e.g., using water flow) the cooling water circuit of the welding torch under test. When a water flow test is performed on the welding torch and the welding torch water flow rate does not reach a predetermined flow rate, the flushing can be initiated manually in some cases and automatically in others. For this purpose, the user interface includes a corresponding activation interface. Additionally or alternatively, the control module is configured to activate the welding torch flushing device in response to the welding torch water flow rate not reaching the predetermined flow rate. Preferably, the flushing is a pulse flush (e.g., pulsed water flow). This ensures sufficient unobstructed cooling water flow in the welding torch under test, which helps to avoid abnormal temperatures during continuous operation, a crucial factor for the welding torch under test.

[0008] According to some aspects of the invention, the welding torch rinsing device includes the following rinsing modes: closed-loop rinsing, wherein water flows annularly and / or reciprocally between the welding torch rinsing device and the welding torch under test; and open-loop rinsing, wherein water flows from the welding torch rinsing device through the welding torch under test and then is discharged to a wastewater discharge section. This advantageously satisfies different rinsing requirements.

[0009] According to some aspects of the present invention, the welding torch rinsing device includes an outlet water port and a return water port, the outlet water port being disengaged in fluid connection to a first upstream portion of a water supply port in the water interface, and the return water port being disengaged in fluid connection to a first downstream portion of a return water port in the water interface; the welding torch rinsing device further includes a water receiving port, the water receiving port being disengaged in fluid connection to a second upstream portion of the water supply port, the second upstream portion being located further upstream of the first upstream portion relative to the water supply port; at least one wastewater discharge port is disengaged in fluid connection to a second downstream portion of the return water port, the second downstream portion being located further downstream of the first downstream portion relative to the return water port. Thus, the integration of the welding torch rinsing device into the welding torch testing equipment ensures an efficient process.

[0010] According to some aspects of the present invention, the test interface of the welding torch testing equipment includes a temperature sensor, which is provided in the form of a clamp configured to be directly clamped onto the electrode of the welding torch to be tested. Preferably, the clamp includes a nylon block for at least partially contacting the electrode surface, and the probe portion of the temperature sensor is at least partially embedded in the nylon block. More preferably, a section of the probe portion of the temperature sensor is positioned to protrude from the outer surface of the nylon block for direct contact with the electrode of the welding torch to be tested. As mentioned above, temperature is an important consideration for the welding torch to be tested. Therefore, the electrode temperature sensor adopts a clamping method, which allows for direct clamping onto the electrode head during use, resulting in quick installation, simple structure, resistance to damage, and strong anti-interference capability.

[0011] According to some aspects of the invention, the welding torch testing equipment is suitable for testing pneumatic welding torches, and further includes an additional motor driver for controlling electric welding torches so that it is also suitable for testing electric welding torches. Preferably, at least the air inlet and the motor driver operate interchangeably. Thus, an electric torch motor driver is added to perform functional testing on newly introduced electric torches, while retaining all the testing functions of the original pneumatic welding torch.

[0012] According to some aspects of the invention, at least one of the water, gas, and electrical interfaces in the test interface employs a flexible conduit. The welding torch testing equipment further includes an automatic conduit retractor configured to receive and release the conduit. The automatic conduit retractor includes a support and a roller rotatably supported on the support for receiving and releasing the coiled portion of the conduit. The automatic conduit retractor is configured to operate as follows: when the conduit is released by pulling it out to the desired length, the automatic conduit retracts the conduit automatically; and by slightly pulling the conduit again, the automatic conduit retracts the conduit in the winding direction. This facilitates operation and saves operators time spent coiling the conduit sequentially.

[0013] According to some aspects of the invention, the automatic retractor further includes an extension arm extending from the support in the release direction, and having an opening at the end facing the release direction for the released portion of the tubing to pass through. Preferably, a guide element is provided on at least a portion of the inner circumference of the opening. This restricts undesirable lateral movement of the tubing and reduces the possibility of the tubing getting stuck.

[0014] According to some aspects of the present invention, the test controller is configured with a cylinder leakage detection module. When the welding torch under test is coupled to the welding torch testing equipment, the cylinder leakage detection module is configured to determine a stroke change after a predetermined time period in response to the cylinder stroke position reaching a set distance and the locking solenoid valve being disengaged. If the stroke change exceeds a threshold, cylinder leakage is determined. Preferably, the cylinder leakage detection module is configured to detect two cylinder stroke positions. Two stroke positions are chosen because the cylinder may not leak when in a specific position, thus taking into full account the possible leakage points of the cylinder.

[0015] According to some aspects of the invention, the test controller is configured with a multi-stage clamping force test module. When the welding torch under test is coupled to the welding torch test equipment, the multi-stage clamping force test module is configured to actuate the electrodes of the welding torch under test in response to the closing of the electrodes and with a clamping force that increases in stages, thereby identifying any abnormalities during the clamping process (e.g., failure to reach a set value within a specified time). In the event of an abnormality during clamping, a force establishment fault is identified. Preferably, clamping is actuated multiple times with each stage of clamping force. In the case of a pneumatic welding torch, the actuation can be achieved by a gas supply from a gas interface; in the case of an electric welding torch, the actuation can be achieved by the operation of a motor driver. Thus, multiple clamping forces (e.g., corresponding to multiple pressures of a cylinder) are selected because a specific clamping force (e.g., a specific pressure of a cylinder) may not trigger an alarm, but using a clamping force (e.g., other pressure values) may cause problems. Multi-stage testing is chosen for a more comprehensive test of the clamping function and / or to better reflect field usage conditions.

[0016] According to some aspects of the invention, the welding torch testing equipment includes or is associated with a database to provide storage and / or retrieval of welding torch test data, particularly reference data and / or historical data. Preferably, the welding torch test data is organized based on torch serial number.

[0017] According to some aspects of the present invention, a welding torch testing method is provided, comprising: coupling the welding torch to be tested to a welding torch testing equipment via a test interface; and performing at least one of the following tests on the welding torch: visual inspection, water tightness test, water flow test, cylinder leakage test, closing time test, multi-stage clamping force test, clamping force build-up time test, pressure compensation function test, welding test, resistance check, and temperature test.

[0018] According to some aspects of the invention, the method further includes reading the gun number to obtain welding gun test data, particularly welding gun test reference data, from a database.

[0019] According to some aspects of the invention, the method further includes, in water flow detection, activating and / or notifying the rinsing of the welding torch under test if the welding torch water flow does not reach a predetermined flow rate.

[0020] According to some aspects of the invention, the method further includes detecting the stroke positions of two cylinders in cylinder leakage detection.

[0021] According to some aspects of the invention, the method further includes, in a multi-stage clamping force test, actuating the electrodes of the welding torch under test with successively applied, progressively increasing clamping forces.

[0022] According to some aspects of the invention, cylinder leakage detection and / or multi-stage clamping force testing are implemented by functional modules added to a test controller (e.g., a PLC). For example, the welding torch can execute a pre-set program, wherein the welding torch may notify of errors or other messages or read and / or view parameters from the welding torch to determine the welding torch status.

[0023] According to some aspects of the invention, the method further includes visualizing and / or persisting the test results. For example, visualization is achieved through a user interface, and / or persistence is achieved by storing the data as historical data in a database or as a document file.

[0024] It should be noted that although some aspects of the present invention have been described above with respect to equipment and methods, the features described with respect to one of the equipment and methods can be applied individually or in combination to the other of the equipment and methods. Attached Figure Description

[0025] Figure 1 A schematic diagram of at least a portion of an exemplary welding torch is shown.

[0026] Figure 2 A block diagram of a welding torch testing apparatus according to various embodiments is shown.

[0027] Figure 3 A schematic diagram of a welding torch testing apparatus according to various embodiments is shown.

[0028] Figures 4A-4B A schematic diagram of a welding torch rinsing apparatus according to various embodiments is shown.

[0029] Figure 5 A schematic diagram of the connection of some test interfaces according to various embodiments is shown.

[0030] Figure 6 A schematic diagram of a temperature sensor according to various embodiments is shown.

[0031] Figure 7 A schematic diagram of an automatic tube take-up device according to various embodiments is shown. Detailed Implementation

[0032] The invention is described with reference to the accompanying drawings, in which certain embodiments of the invention are illustrated. However, the invention can be embodied in many different forms and should not be construed as limited to the embodiments depicted and described herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. It will also be understood that the embodiments disclosed herein can be combined in any manner and / or in any combination to provide many other embodiments.

[0033] Unless otherwise defined, all technical and scientific terms used in this disclosure have the same meaning as advantageously understood by one of ordinary skill in the art to which this invention pertains. The terminology used in the foregoing description is for the purpose of describing particular embodiments only and is not intended to limit the invention.

[0034] For ease of explanation, the same reference numerals refer to the same or similar structures, units and / or parts in the figures, and the parts in the figures are not necessarily drawn to scale.

[0035] Now for reference Figure 1 , Figure 1 A schematic diagram of at least a portion of an exemplary welding torch 1 is shown. In the illustrated example, the welding torch 1 includes a first electrode 11 and a second electrode 12. The first electrode 11 and the second electrode 12 are integrated into a movable arm 15 and a stationary arm 16, respectively. Of course, both arms 15 and 16 may also be movable arms. In the context of this application, the terms "electrode" and "arm" are generally used interchangeably. Additionally, the welding torch 1 includes several connection ports (not shown), such as water connection ports, gas connection ports, and / or electrical connection ports. The electrical connection ports may include power connection portions and signal connection portions. Therefore, the welding torch 1 may be a pneumatic welding torch, including a cylinder. Alternatively, the welding torch 1 may also be an electric welding torch, including a motor; for this purpose, the welding torch 1 may not include a gas connection port, but instead be coupled to a motor driver in terms of power and / or signal.

[0036] Now for reference Figure 2 , Figure 2 A block diagram of a welding torch testing apparatus 2 according to various embodiments is shown. The welding torch testing apparatus 2 includes a control module 21, a test interface 22, and a user interface 23. The control module 21 includes a welding controller 211 and a test controller 212. Specifically, the welding controller 211 corresponds to the same welding controller as the production line in which the welding torch under test is used, and the test controller 212 has the same control operating system as the production line in which the welding torch under test is used. Particularly advantageously, the welding controller includes a Bosch PRC7000 controller, and the test controller 212 has a SIEMENS TIA 1518 control operating system. Further, the test controller 212 corresponds to the same process controller (e.g., the same PLC) as the production line in which the welding torch under test is used. The test interface 22 includes a water interface, a gas interface, and an electrical interface for coupling to the corresponding connection port of the welding torch under test. The electrical interface may include a power interface section and a signal interface section. The user interface 23 may include output devices (e.g., a display screen, lights, etc.) and input devices (e.g., a touch screen, buttons, a keyboard, a mouse, etc.). For example, the display screen (touchscreen) can provide an interface that conforms to specific standards (e.g., Chinese and English interfaces), especially corresponding to the display mode and / or operation mode on the production line.

[0037] According to an advantageous embodiment, the welding torch testing apparatus 2 is suitable for testing pneumatic welding torches and also includes an additional motor driver 24 for controlling electric welding torches to further suit testing electric welding torches. For example, at least the gas interface and the motor driver 24 operate alternately (or even mutually exclusively) to each other. A control module 21 (e.g., a test controller 212) can be configured to detect at least the coupling of the gas interface to disable the motor driver 24. The control module 21 (e.g., the test controller 212) can communicate with the motor driver 24.

[0038] Now for reference Figure 3 , Figure 3 A schematic diagram of a welding torch testing apparatus 2 according to various embodiments is shown, with particular emphasis on its exemplary configuration and some other equipment. The welding torch testing apparatus 2 includes a cabinet 20, a test platform, and tooling 25. In the illustrated example, the cabinet 20 includes three compartments 201, 202, and 203; the test platform and tooling 25 include a test bench 251 and a tooling 252 fixedly mounted on the test bench 251; the tooling 252 is configured to hold the welding torch to be tested. Specifically, the tooling 252 in the figure holds the welding torch, and the circled detail shows a temperature sensor 6, which will be described in detail below. The welding torch testing apparatus 2 includes various pumps, pipes, and valves. In the illustrated example, some pumps 26, 26', pipes 27, and / or valves 28 are located in the first compartment 201 of the cabinet 20. The welding torch testing apparatus 2 includes a welding torch flushing device 4 and an automatic pipe retractor 7, which will be described in detail below. In the illustrated example, the welding torch rinsing device 4 and the automatic pipe retractor 7 are located in the third compartment 203 of the cabinet 20. The pipe discharged from the automatic pipe retractor 7 can exit through the side wall of the compartment and, for example, toward the tooling 25. The automatic pipe retractor 7 is located above the welding torch rinsing device 4, specifically directly mounted on its upper housing surface. The second compartment 202, located between the first compartment 201 and the third compartment 203, can be a substantially enclosed compartment. The control module 21 (e.g., welding controller 211 and test controller 212) and other possible electrical components (e.g., motor driver 24) can be located in the second compartment 202. Furthermore, the user interface 23 can be positioned relative to the cabinet 20. For example, a display screen 29 (e.g., a touchscreen) can be mounted on the front panel of the second compartment 202. For example, a keyboard and / or mouse can be placed on the workbench below the display screen 29 (e.g., the touchscreen). Therefore, the design structure of welding torch testing equipment 2 allows the water circuit, control section, and flushing section to be installed separately in a cabinet (compartment), fully considering the convenience of spare parts replacement, and the structure is more concise and clear.

[0039] Now for reference Figures 4A-4B , Figures 4A-4B A schematic diagram of a welding torch rinsing device 4 according to various embodiments is shown. Figure 4A This is a 3D view of welding torch cleaning equipment 4. Figure 4BThis is a cross-sectional view of the welding torch rinsing device 4. The welding torch rinsing device 4 is configured to rinse the cooling water circuit (i.e., the circuit for coupling the water interface) of the welding torch to be tested, which is required, for example, when a water flow test is performed on the welding torch and the welding torch water flow does not reach a predetermined flow rate (e.g., 4 L / min), as will be described in detail below. For example, the rinsing pressure can be up to 12 bar.

[0040] According to some embodiments, rinsing can be manually initiated; for this purpose, user interface 23 includes a corresponding activation interface. The activation interface includes, for example, a welding torch rinsing button. Furthermore, user interface 23 may also include an indication interface notifying that the welding torch water flow rate has not reached a predetermined flow rate. The indication interface includes, for example, an alarm light or an indicator on the user interface.

[0041] According to other embodiments, rinsing can be initiated automatically, for which control module 21 (e.g., test controller 212) is configured to activate welding torch rinsing equipment 4 in response to welding torch water flow not reaching a predetermined flow rate.

[0042] According to an advantageous embodiment, rinsing is performed using pulsed rinsing. Therefore, the welding torch rinsing device 4 can supply pulsed water flow.

[0043] In the illustrated example, the welding torch rinsing device 4 includes its own control module 40, which is, for example, housed within its own housing. The control module 40 of the welding torch rinsing device 4 can communicate with control module 21 (e.g., test controller 212). The welding torch rinsing device 4 includes its own user interface, such as a display screen 411 (e.g., touchscreen), a buzzer 412, an emergency stop button 413, and / or a power switch 414, which are, for example, housed on the front panel of its own housing. The aforementioned activation and indication interfaces may also be additionally or alternatively included in the user interface of the welding torch rinsing device 4. The welding torch rinsing device 4 includes a water tank 42 and a pump 43, which are, for example, housed within its own housing.

[0044] As can be seen from the above, welding torch rinsing and welding torch water supply involve the same circuit of the welding torch with respect to the water connection port. Therefore, the welding torch rinsing device 4 can have a specific configuration relative to the welding torch water supply. Note that the water interface typically includes a water supply interface and a water return interface; correspondingly, the water connection port typically includes a water inlet and a water outlet. Here, the welding torch rinsing device 4 also includes a water outlet 44 and a water return interface 45. In addition, the welding torch rinsing device 4 also includes a water receiving interface 46 and a drain interface 47. In particular, these interfaces 44, 45, 46, and 47 of the welding torch rinsing device 4 are, for example, provided on the side panel of the welding torch rinsing device 4's own housing.

[0045] Now for reference Figure 5 , Figure 5A schematic diagram of the connection of some test interfaces according to various embodiments is shown, particularly illustrating an exemplary configuration of the upstream lines of the interfaces and the connection of the welding torch rinsing device 4. For clarity, the schematic diagram is depicted in conjunction with the welding torch, particularly the pneumatic welding torch 1', i.e., water interfaces 221, 221' and air interface 222 are shown as connected to the corresponding connection ports. As described above, water interfaces 221, 221' are the water supply interface 221 and the water return interface 221'. In the illustrated example, the welding torch rinsing device 4 is disconnectably fluidly connected to a first upstream portion of the water supply interface 221 and a first downstream portion of the water return interface 221' via the water outlet interface 44 and the water return interface 45, respectively, for example via valves Y11-14. The welding torch rinsing device 4 is disconnectably fluidly connected to a second upstream portion of the water supply interface 221 via the water receiving interface 46, for example via valve Y9. As shown in the figure, the second upstream section is located further upstream of the first upstream section relative to the water supply interface 221. Specifically, the upstream line of the water supply interface 221 includes a main valve Y2 (e.g., a pilot valve), which can be located between the second upstream section and the first upstream section. The welding torch rinsing device 4 is disconnectably fluidly connected to the first wastewater discharge section via a drain interface 47, for example, via pump P2. The first wastewater discharge section and / or another wastewater discharge section are disconnectably fluidly connected to the second downstream section of the return water interface 221', for example, via valves Y6 and Y8. Valve Y6 manages the connection to any wastewater discharge section, and valve Y8 further manages the connection to the first wastewater discharge section. As shown in the figure, the second downstream section is located further downstream of the first downstream section relative to the return water interface 221', and valve Y15 can be located between the second downstream section and the first downstream section. Specifically, the downstream line of the return water interface 221' includes a main valve Y3 (e.g., a backflow valve), which can be located further downstream of the second downstream section. Note that although upstream and downstream sections are used, they do not necessarily refer to a single connection point. For example, the first upstream section shown in the figure includes two connection points located upstream of the water supply interface 221.

[0046] When the welding torch rinsing device 4 receives water, for example, to fill the water storage tank 42, valve Y9 is activated. When the welding torch rinsing device 4 discharges wastewater, for example, to empty or refresh the water storage tank 42, this can be operated by pump P2. When the welding torch receives water for circulation without rinsing, valves Y11-14 are all deactivated, and valve Y6 is also deactivated; while valves Y2 and Y3 (and, if any, valve Y15) are activated. When the welding torch is being rinsed, at least the following modes are possible, which can be used individually or in combination:

[0047] Closed-loop rinsing, wherein water flows in a ring and / or reciprocates between the welding torch rinsing device 4 and the welding torch 1', and can be carried out via valve Y11-14, the first upstream part of the water supply interface 221 and the first downstream part of the return water interface 221';

[0048] Open-loop rinsing, wherein water flows from the welding torch rinsing device 4 through the welding torch 1' and is then discharged to the wastewater discharge section, which can be done via some of the valves Y11-14 (e.g., those located between the outlet port 44 and the first upstream portion), the first upstream portion of the water supply port 221, and the second downstream portion of the return port 221'.

[0049] When the welding torch is being rinsed, the path for receiving water circulation for the welding torch without rinsing can be disconnected, for example by disconnecting valves Y2, Y3 (and / or, where appropriate, valve Y15).

[0050] According to some embodiments, the upstream line of the gas interface 222 is also disconnectably connected to the upstream line of the water supply interface 221, for example, via valve Y4. Specifically, the upstream line of the gas interface 222 has a branch that is connected to a third upstream portion of the water supply interface 221 via valve Y4. For example, the third upstream portion is located between the first and second upstream portions, particularly downstream of the main valve Y2. Valve Y5 may be located between the branch and the gas interface 222. Thus, the welding torch testing equipment 1 also provides gas-based rinsing. This rinsing includes open-loop rinsing (where gas flows from the branch through the welding torch under test and then is discharged to the wastewater discharge section) and may also be pulse rinsing. For example, the rinsing pressure can be up to 12 bar. Furthermore, the aforementioned water-based rinsing and gas-based rinsing can be used alternately.

[0051] The illustrated example also shows other pumps (e.g., P1), other valves (e.g., Y7, which may be a check valve), and various sensors (e.g., B3, B4, B6, B7) that can be used to measure flow rate or pressure and thus provide the corresponding signals.

[0052] Now for reference Figure 6 , Figure 6 A schematic diagram of a temperature sensor 6 according to various embodiments is shown. The test interface of the welding torch test equipment 1 includes the temperature sensor 6. The temperature sensor 6 is provided in the form of a clamp 60. The clamp 60 is configured to clamp directly onto the electrode of the welding torch to be tested. For example, the clamp 60 is configured to clamp at a distance from the end of the electrode of the welding torch. In particular, the clamp 60 in the figure clamps the electrode E of the welding torch to be tested.

[0053] According to an advantageous embodiment, the holder includes nylon blocks 61, 61' for at least partially contacting the electrode surface, with the probe portion of the temperature sensor 6 at least partially embedded in the nylon block 61. Specifically, a segment S of the probe portion of the temperature sensor 6 (e.g., including a node of a thermocouple or resistance temperature detector) can be positioned to protrude from the outer surface of the nylon block 61 for direct contact with the electrode of the welding torch under test. In the illustrated example, protruding means that segment S is positioned within a recess formed in the nylon block 61. Here, the recess is formed approximately centrally in the nylon block 61, on the side facing the electrode E.

[0054] Now for reference Figure 7 , Figure 7 A schematic diagram of an automatic tube retractor 7 according to various embodiments is shown. One or more of the water, gas, and electrical interfaces in the test interface 22 can be provided in the form of a flexible conduit H. Of course, the end of the conduit H for coupling with the welding torch under test can be provided with suitable connecting fittings (not shown). The automatic tube retractor 7 is configured to receive and release coiled conduit H. Specifically, the automatic tube retractor 7 in the figure receives coiled conduit H, and a section of conduit H has been released from the automatic tube retractor 7. In the illustrated example, the automatic tube retractor 7 includes a support 70 and a roller 71 rotatably supported on the support 70. The roller 71 can receive the coiled portion of the conduit H. The automatic tube retractor 7 also includes an extension arm 72. The extension arm 72 extends upward from the support 70, for example, obliquely, toward the release direction. The extension arm 72 has an opening 720 at its end toward the release direction. The opening 720 allows the released portion of the conduit H to pass through it. Specifically, guide elements, such as (cylindrical) rollers 721, are provided on at least a portion of the inner periphery of the opening 720. In the illustrated example, four rollers 721 are provided on the inner periphery of the opening 720, respectively, on each side of the generally rectangular opening.

[0055] According to an advantageous embodiment, the automatic tube retractor 7 is configured to operate as follows: when the tube H is released by pulling it out to the desired length, the roller 71 will automatically lock (lock the tube H); and by gently pulling the tube H out again, the roller 71 will automatically rotate in the winding direction (retract the tube H).

[0056] According to some embodiments, the welding torch testing equipment 2 includes or is associated with a database to provide storage and / or retrieval of welding torch test data. The welding torch test data includes reference data and / or historical data. Reference data can be used in welding torch testing, while historical data can be used for retrieval, querying, and retrospective comparison.

[0057] According to some embodiments, welding torch testing typically includes one or more of the following test steps or procedures.

[0058] The welding torch test includes reading the torch serial number to obtain data. Control module 21 (e.g., test controller 212) acquires data, for example, via UDP communication by sending and receiving messages. The actual torch serial number of the welding torch under test is read and searched in the database to find its corresponding location and related data (including torch model and / or type, flow rate, closing time, force build-up time, transformer resistance, etc.). The data can be saved and applied in subsequent test steps. Therefore, the welding torch testing equipment 2 may also include a torch serial number reading device, such as a barcode, QR code, and / or RFID reader, communicatively coupled to control module 21 (e.g., test controller 212). The data retrieved from the database may include reference data for the welding torch under test, alternatively or additionally, and may also include historical measurement data for the welding torch under test. Therefore, the database includes field information stored in association with the torch serial number, such as torch model and / or type, flow rate, closing time, force build-up time, transformer resistance, etc.

[0059] Welding torch testing includes visual inspection. For example, the results of the visual inspection can be judged by the tester. This test checks whether the welding torch is in good working order. Therefore, it should be ensured that the welding torch is free of defects when leaving the test station. For example, the tester can interact with the welding torch testing equipment 2 through user interface 23 to obtain the results of the visual inspection. The visual inspection can be performed by the tester with the naked eye. Of course, the welding torch testing equipment 2 may also include auxiliary devices, such as imaging devices, to provide clear and / or magnified images of the parts of interest on the welding torch to facilitate the tester's judgment.

[0060] Welding torch testing can usually be performed in an automated program, such as at least some, and in particular all, of the following.

[0061] The welding torch test includes a watertightness test. Accordingly, control module 21 (e.g., test controller 212) includes a watertightness detection module. During the watertightness test, the maximum percentage drop in water pressure over a predetermined time period is determined (e.g., the water pressure must not drop by a maximum of 3% within 10 seconds). At the start of the test, the welding torch is closed with a predetermined force (e.g., 80% of the maximum force). Water is supplied to the welding torch under test through water interfaces (e.g., 221, 221') in test interface 22 (e.g., until a predetermined initial water pressure is reached), and then the water is shut off (e.g., valves Y2, Y3 are closed). The decrease in water pressure is calculated after reading corresponding values ​​at different time periods. Accordingly, a water pressure sensor (e.g., B6) is configured to provide a signal corresponding to the corresponding value of the water pressure, and a force sensor provides a signal corresponding to the force of the welding torch (or, additionally or alternatively, a signal corresponding to the cylinder pressure from a pressure sensor). Accordingly, control module 21 (e.g., test controller 212) provides a timer.

[0062] The welding torch test includes water flow detection. Accordingly, control module 21 (e.g., test controller 212) includes a water flow detection module. This process involves PID control, controlling the regulating valve to control the inlet and outlet water pressures (differential pressure), reading the flow rate when the differential pressure stabilizes (e.g., 2 bar (+ / - 0, 1 bar)), and comparing it with reference data to obtain a result. Accordingly, a water pressure sensor is configured to provide a signal corresponding to the inlet and outlet water pressures; a flow meter provides a signal corresponding to the flow rate. For example, water flow detection and the aforementioned welding torch flushing can be used in conjunction, especially when the welding torch water flow rate does not reach the predetermined flow rate.

[0063] The welding torch test includes cylinder leak detection. Accordingly, control module 21 (e.g., test controller 212) includes a cylinder leak detection module. During cylinder leak testing, the cylinder stroke position (particularly for pneumatic welding torches) is brought to a set distance (e.g., 10mm for the first cylinder stroke position, 100mm for the second cylinder stroke position), and the locking solenoid valve is disengaged. The stroke change is then determined after a predetermined time period (e.g., 5 minutes). The stroke change is considered acceptable if it is within a threshold (e.g., 2mm). This tests for cylinder drift; if the cylinder leaks, the cylinder displacement will change. Specifically, during cylinder leak testing, the electrodes of the welding torch under test do not make contact; in other words, the cylinder is in displacement mode. Accordingly, a distance / stroke sensor is configured to provide a signal corresponding to a value corresponding to the stroke distance.

[0064] The welding torch test includes a closing time detection. Accordingly, control module 21 (e.g., test controller 212) includes a closing time detection module. During the closing time test, the closing time is the time it takes for the welding torch under test to close from a defined position (e.g., 125 mm to 200 mm; specifically, 125 mm for C-type torches and 200 mm for X-type torches) to a predetermined plate thickness (e.g., 6 mm plate). This time must be within a specified time range to be considered acceptable. In some embodiments, the closing time detection includes taking multiple measurements (e.g., 3 times) and averaging them, with the average time deemed acceptable being within the tolerance range of a reference value (e.g., 10% for electric torches and 5% for gas torches).

[0065] The welding torch test includes a multi-stage clamping force test. Accordingly, control module 21 (e.g., test controller 212) includes a multi-stage clamping force test module. When testing each clamping force (e.g., 1KN, 2KN, 3KN, 4KN), the electrodes of the welding torch under test are closed, establishing a staged increasing clamping force. For example, the staged increasing clamping force can be applied sequentially, eliminating the need to repeat the release and initial closing actions of the welding torch; or the clamping-release process can be completed each time. In some embodiments, multiple tests (e.g., 10 times) are performed with each stage of clamping force. When the welding torch uses a cylinder, the cylinder is in force mode, and when it receives a command for a different pressure (e.g., corresponding to the clamping force), it clamps the two electrodes of the welding torch (e.g., to ground). If the set pressure is reached within a specified time (e.g., 2 seconds) without an error report, it is determined that there is no problem.

[0066] The welding torch test includes clamping force build-up time detection. Accordingly, control module 21 (e.g., test controller 212) includes a clamping force build-up time detection module. The time consumed by the welding torch from reaching a predetermined plate thickness (e.g., 6 mm plate) to establishing a predetermined force (e.g., for at least one of the aforementioned multi-stage clamping forces, such as 80% of the maximum force) is measured. In some embodiments, clamping force build-up time detection includes taking multiple measurements (e.g., 3 times) and averaging them, determining that the acceptable average time is within the tolerance range of a reference value (e.g., 10% for electric torches, 5% for gas torches).

[0067] The welding torch test includes a pressure compensation function test. Accordingly, control module 21 (e.g., test controller 212) includes a pressure compensation function module. The principle of pressure compensation is that, based on different welding torch postures, the MPYD (pneumatic proportional valve) adjusts the weight of the balancing torch through input data (automatically calculated) sent by the controller, thereby ensuring the welding pressure is the actual output pressure while preventing deformation of the welded material and guaranteeing the quality of offline welding torch maintenance. The test needs to be performed multiple times (e.g., 11 times), and the test range becomes adjustable (±3 bar to ±5 bar), with a default of ±3 bar. It is necessary to verify whether the direction of motion (the direction of balancing movement) is correct, especially ensuring that the welding torch does not alarm during the balancing cylinder's operation.

[0068] The welding torch test includes a welding test. Accordingly, control module 21 (e.g., test controller 212) includes a welding test module. Here, the welding operation is performed by the welding controller 211 controlling the welding torch. In other words, the welding controller 211 stores and executes welding programs. Specifically, the welding controller 211 and control module 212 communicate. During the welding test, current values ​​(e.g., equivalent and / or normalized) for multiple (e.g., seven) welding programs are recorded. Accordingly, current sensors provide signals corresponding to the current values. The measured values ​​should be proportional to the scale division values ​​used in the welding program (e.g., SKT values ​​well known in the art). The transformer used can be selected depending on the welding torch being tested. This selection affects the welding program used by the welding controller 211. At the start of the test, the welding torch is closed and a predetermined force (e.g., 80% of the maximum force) is established. After waiting for a predetermined time (e.g., 1 second), the welding controller 211 initiates the welding program. After waiting for a predetermined time (e.g., 2 seconds), the welding torch is opened, and the current value is read. In addition, the current value is saved. This process is repeated for each welding procedure. In a further step, this process will be repeated multiple times under each welding procedure to obtain an average value. For example, these values ​​are read and / or saved from welding controller 211 and calculated. After the measurement is completed, the values ​​are checked. As mentioned above, the test is considered successful if the following conditions are met: these values ​​must be proportional to the SKT value used. For example, a fit is established based on the first and last measurements (e.g., measurements of the first and seventh welding procedures), thus establishing reference values ​​for other results. The deviation of the measured value from the reference value must not exceed a predetermined percentage (e.g., 5%). Of course, the last measured value must be greater than the first measured value, otherwise the test cannot be performed. Note that the welding test needs to be performed after the previous test has passed and the functions of the previous test are activated, especially the welding torch needs to be filled with water at a flow rate not less than a predetermined flow rate (e.g., more than 2 liters / minute). Accordingly, the valves (e.g., main valves Y2, Y3) must be opened and activated. According to some embodiments, for transformers PSG3075.10 and PSG3100.00, the SKT value can be selected as 30, 35, 40, 45, 50, 55 and 60; for transformer PSG6130.00, 15, 18, 21, 24, 27, 30 and 33 SKT can be used.

[0069] The welding torch test includes a resistance check. Accordingly, control module 21 (e.g., test controller 212) includes a resistance check module. Here, the resistance check is based on a welding operation performed by the welding controller 211 through the manipulation of the welding torch. In other words, the welding controller 211 stores and executes the welding program. In this test, the resistance of the secondary circuit (i.e., the secondary circuit from the transformer) is tested. This resistance should be within a specified range, meaning the reference value of the welding torch and the nominal value of the secondary circuit resistance will be within a predetermined percentage tolerance. For example, the average maximum value should not exceed 200 μΩ, and / or the resistance should be within 20% of the reference value. In the test, the welding torch is first closed, and a predetermined force (e.g., 80% of the maximum force) is applied. After a predetermined time (e.g., 1 second), the welding controller 211 initiates the welding program. After a predetermined time (e.g., 2 seconds), the welding torch is opened, and the actual value is read. Furthermore, the actual values ​​are saved. For example, these values ​​are read from and / or saved from the welding controller 211, and calculations are performed on them.

[0070] The welding torch test includes a temperature test. Accordingly, control module 21 (e.g., test controller 212) includes a temperature test module. In this test, multiple (particularly a large number, e.g., 30) welds are performed to check the cooling function of the welding torch. For this test, two temperature sensors (e.g., temperature sensor 6 according to an advantageous embodiment) must be mounted on the electrode tip of the welding torch. At the start of the test, a predetermined number of welds are performed. The measured temperature is recorded. The initial and final temperature difference, the maximum temperature rise, and the highest temperature are determined and compared with corresponding predetermined values. If the highest temperature of the electrode exceeds the predetermined value (e.g., 60°C), the test is stopped for safety reasons. The predetermined value for the initial and final temperature difference is, for example, a temperature difference of no more than 7°C between the first weld and the end of the test. The maximum temperature rise is, for example, 10°C.

[0071] The test results described above can be visualized to the user in an appropriate form through user interface 23, including but not limited to generated text, logs, reports, charts, etc. The test results can also be persisted, for example, stored as historical data in a database, particularly associated with a timestamp corresponding to the test time. Alternatively or additionally, the test results can be stored as document files, which, when opened, provide the user with a test report through user interface 23. Thus, all historical data can be quickly retrieved and queried using the test number, allowing for traceable comparison of results. Furthermore, analytical support is provided, enabling data integration and processing analysis (e.g., developed using VB language) to achieve a user-friendly display (e.g., aesthetically pleasing displays such as color-coded indicators).

[0072] The above description is for illustrative purposes only and should not be construed as limiting the invention. While exemplary embodiments of the invention have been described, those skilled in the art will readily understand that many modifications may be made to the exemplary embodiments without substantially departing from the novel teachings and advantages of the invention. Therefore, all such modifications are intended to be included within the scope of the invention as defined in the claims. The invention is defined by the appended claims, wherein equivalents of the claims are included.

Claims

1. A welding torch testing device, comprising: The control module includes a welding controller and a test controller. The welding controller corresponds to the same welding controller used in the production line where the welding torch under test is used, and the test controller has the same control operating system as the production line where the welding torch under test is used. User interface; The test interface includes a water interface, a gas interface, and an electrical interface for coupling to the corresponding connection ports of the welding torch to be tested, and in the case of a pneumatic welding torch, its actuation is achieved by the gas supply from the gas interface. A welding torch rinsing device, the welding torch rinsing device being configured to rinse the cooling water circuit of the welding torch to be tested; The welding torch flushing device includes a water outlet and a water return interface. The water outlet is disengaged and fluidly connected to the first upstream part of the water supply interface in the water interface, and the water return interface is disengaged and fluidly connected to the first downstream part of the water return interface in the water interface. The welding torch rinsing device also includes a water receiving interface, which is disconnectably fluidly connected to a second upstream portion of the water supply interface, the second upstream portion being located further upstream of the first upstream portion relative to the water supply interface; At least one wastewater discharge point is disengaged in fluid connection to a second downstream portion of the return water interface, the second downstream portion being located further downstream of the first downstream portion relative to the return water interface; The upstream line of the gas interface has a branch that is connected to a third upstream section of the water supply interface via a valve, wherein the third upstream section is located between the first upstream section and the second upstream section, thereby providing gas-based flushing for the welding torch testing equipment.

2. The welding torch testing equipment according to claim 1, wherein, The user interface includes a corresponding activation interface for activating the welding torch flushing equipment; and / or The control module is configured to activate the welding torch rinsing equipment or notify the welding torch to be tested to be rinsed in response to the welding torch water flow rate not reaching the predetermined flow rate.

3. The welding torch testing equipment according to claim 1 or 2, wherein, The rinsing is a pulse rinsing.

4. The welding torch testing equipment according to claim 1 or 2, wherein, The welding torch rinsing equipment includes the following rinsing modes: Closed-loop rinsing, wherein water flows in a circular and / or reciprocating manner between the welding torch rinsing equipment and the welding torch to be tested; Open-loop rinsing, in which water flows from the welding torch rinsing equipment through the welding torch to be tested and then is discharged to the wastewater discharge section; Another open-loop flushing process involves gas flowing from a branch section through the welding torch under test and then exiting to the wastewater discharge section.

5. The welding torch testing equipment according to claim 1, wherein, The testing interface of the welding torch testing equipment includes a temperature sensor, which is set in the form of a clamp configured to be directly clamped onto the electrode of the welding torch to be tested.

6. The welding torch testing equipment according to claim 5, wherein, The clamp includes a nylon block for at least partially contacting the electrode surface, and the probe portion of the temperature sensor is at least partially embedded in the nylon block.

7. The welding torch testing equipment according to claim 6, wherein, A section of the probe portion of the temperature sensor is positioned to float above the outer surface of the nylon block for direct contact with the electrodes of the welding torch to be tested.

8. The welding torch testing equipment according to claim 1, wherein, The welding torch testing equipment is suitable for testing pneumatic welding torches, and also includes an additional motor driver for controlling electric welding torches so that it is also suitable for testing electric welding torches.

9. The welding torch testing equipment according to claim 1, wherein, At least one of the water, gas, and electrical interfaces in the test interface uses a flexible conduit. The welding torch test equipment also includes an automatic retractor configured to receive and release the conduit. The automatic retractor includes a support and a roller rotatably supported on the support for receiving and releasing coiled portions of the conduit, so as to automatically lock and retract the conduit.

10. The welding torch testing equipment according to claim 9, wherein, The automatic pipe retractor also includes an extension arm that extends from the support in the release direction and has an opening at the end in the release direction for the release portion of the pipe to pass through. A guide element is provided on at least a portion of the inner circumference of the opening.

11. The welding torch testing equipment according to claim 10, wherein, The guiding element includes rollers.

12. The welding torch testing equipment according to claim 1, wherein, The test controller is equipped with a cylinder leakage detection module. When the welding torch to be tested is coupled to the welding torch test equipment, the cylinder leakage detection module is configured to determine the stroke change after a predetermined time period in response to the cylinder stroke position reaching a set distance and the locking solenoid valve being disconnected. If the stroke change exceeds a threshold, the cylinder is determined to be leaking.

13. The welding torch testing equipment according to claim 12, wherein, The cylinder leakage detection module is configured to detect the stroke positions of two cylinders.

14. The welding torch testing equipment according to claim 1, wherein, The test controller is equipped with a multi-stage clamping force test module. When the welding torch under test is coupled to the welding torch test equipment, the multi-stage clamping force test module is configured to respond to the closing of the electrode of the welding torch under test and actuate the electrode of the welding torch under test with a step-increasing clamping force to determine the abnormality in the clamping process. If an abnormality occurs in the clamping process, a force establishment fault is determined.

15. The welding torch testing equipment according to claim 14, wherein, The increasing clamping force in each stage is applied repeatedly and / or sequentially.

16. A welding torch testing method using the welding torch testing equipment according to any one of claims 1 to 15, comprising: The welding torch to be tested is coupled to the welding torch testing equipment through the test interface; Perform at least one of the following tests on the welding torch: visual inspection, water tightness test, water flow test, cylinder leakage test, closing time test, multi-stage clamping force test, clamping force build-up time test, pressure compensation function test, welding test, resistance test, and temperature test.

17. The welding torch testing method according to claim 16, wherein, The welding torch testing equipment includes or is associated with a database, and the method further includes reading the torch number to obtain welding torch test data from the database.

18. The welding torch testing method according to claim 16, wherein, The method further includes: In water flow detection, if the welding torch water flow does not reach the predetermined flow rate, the process activates and / or notifies the welding torch under test to be rinsed; and / or In cylinder leak detection, the stroke positions of two cylinders are checked; and / or In a multi-stage clamping force test, the electrodes of the welding torch under test are clamped by repeatedly and / or successively applied stage-increasing clamping forces.

Images