A real-time acquisition system for plasma welding process parameters

Abstract

The application relates to a real-time acquisition system for plasma welding process parameters, and belongs to the field of non-automatic plasma welding. The system comprises a protective gas flow sensor, an ion gas flow sensor, a plasma welding machine, a current sensor, a voltage sensor, a power module, a processor, a display module, a keyboard, a communication module, a grounding clamp and a welding gun. The welding current is acquired through the current sensor, the welding voltage is acquired through the voltage sensor, the protective gas flow is acquired through the protective gas flow sensor, the ion gas flow is acquired through the ion gas flow sensor, the acquired signals are converted through the processor, the signals are displayed on the display module, and the acquired data can be transmitted through the communication module. The application provides a kind of acquisition device with low power consumption, small size, light weight and convenient installation, which can simultaneously and real-time acquire four parameters of current, voltage, protective gas flow and ion gas flow in the plasma welding process.

Description

Technical Field

[0001] This invention belongs to the field of non-automated plasma welding and relates to a real-time acquisition system for plasma welding process parameters. Background Technology

[0002] Non-automated plasma welding power supplies are non-automated equipment. They lack the ability to collect and display four key parameters during the welding process: welding current, arc voltage, shielding gas flow rate, and ionizing gas flow rate. This makes it impossible to control the quality of the welding process. While X-ray inspection can be used to assess weld quality afterward, it is costly and inefficient, unsuitable for large-scale inspection of simple welds. Previous inventions, such as "Welding Data Acquisition Device and Welding System," addressed data acquisition by connecting welding machines with data communication ports. Other inventions, such as "A DC Welding Machine Welding Process Data Acquisition System" and "A DC Welding Machine Welding Process Data Acquisition System," addressed the acquisition of welding process parameters for DC welding machines. However, existing non-automated plasma welding power supplies lack a data acquisition module. Therefore, they cannot display key process parameters during welding, cannot acquire multiple key process parameters simultaneously and in real-time, cannot be networked for centralized control, and cannot simultaneously achieve integrated measurement and display of multiple parameters including current, voltage, shielding gas flow rate, and ionizing gas flow rate. Summary of the Invention

[0003] The technical problem solved by this invention is to overcome the shortcomings of the prior art and propose a real-time acquisition system for plasma welding process parameters. This system provides an acquisition device that is low in power consumption, small in size, light in weight, and easy to install. It can simultaneously and in real time acquire four parameters of the plasma welding process: current, voltage, shielding gas flow rate, and ion gas flow rate.

[0004] The solution of the present invention is:

[0005] A real-time acquisition system for plasma welding process parameters includes a shielding gas flow sensor, an ion gas flow sensor, a plasma welding machine, a current sensor, a voltage sensor, a power supply module, a processor, a display module, a grounding clamp, and a welding torch; wherein, the grounding clamp is connected to the negative terminal of the plasma welding machine; the welding torch is connected to the positive terminal of the plasma welding machine; and the grounding clamp is clamped onto the workpiece to be welded.

[0006] Protective gas flow sensor: Receives protective gas from the outside, generates a protective gas flow voltage signal, and sends the protective gas flow voltage signal to the processor; outputs protective gas to the plasma welding machine;

[0007] Ion gas flow sensor: Receives ion gas from the outside, generates an ion gas flow voltage signal, and sends the ion gas flow voltage signal to the processor; outputs the ion gas to the plasma welding machine;

[0008] Plasma welding machine: Connects to an external three-phase power supply and outputs power to the power module; receives shielding gas from the shielding gas flow sensor and transmits the shielding gas to the welding torch; receives ion gas from the ion flow sensor, converts the ion gas into an ion stream, and transmits the ion stream to the welding torch; generates a plasma welding voltage signal and sends the plasma welding voltage signal to the processor; generates a plasma welding current voltage signal and sends the plasma welding current voltage signal to the processor.

[0009] Power module: Receives power from the plasma welding machine to power the processor;

[0010] Welding torch: It receives the ion stream from the plasma welding machine and sprays the particle stream onto the surface of the workpiece to be welded; it also receives the shielding gas from the plasma welding machine and sprays the shielding gas onto the surface of the workpiece to be welded.

[0011] Voltage sensor: Receives the voltage signal of the plasma welding voltage from the plasma welding machine and sends the plasma welding voltage signal to the processor;

[0012] Current sensor: Receives the voltage signal of the plasma welding current from the plasma welding machine and sends the voltage signal of the plasma welding current to the processor;

[0013] Processor: Receives the protective gas flow voltage signal from the protective gas flow sensor; receives the ion gas flow voltage signal from the protective gas flow sensor; receives the plasma welding voltage signal from the voltage sensor; receives the plasma welding current voltage signal from the current sensor; performs analog-to-digital conversion on the protective gas flow voltage signal, ion gas flow voltage signal, plasma welding voltage signal, and plasma welding current voltage signal to generate digital signals of protective gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current, and sends them to the display module for display; simultaneously, it sends the digital signals of protective gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current to external devices.

[0014] In the aforementioned real-time acquisition system for plasma welding process parameters, the shielding gas is argon or other inert gas. The shielding gas is used to protect the surface of the workpiece to be welded and prevent oxidation.

[0015] In the aforementioned real-time acquisition system for plasma welding process parameters, the plasma welding machine converts the ion gas into an ion stream by exciting the ion gas.

[0016] In the aforementioned real-time acquisition system for plasma welding process parameters, the welding torch heats the surface of the workpiece by spraying an ion stream onto it, thus completing the welding process.

[0017] In the aforementioned real-time acquisition system for plasma welding process parameters, the negative electrode of the plasma welding machine is connected to a voltage sensor, the positive electrode of the plasma welding machine is connected to a voltage sensor, and the positive electrode of the plasma welding machine is connected to a current sensor.

[0018] The aforementioned real-time acquisition system for plasma welding process parameters also includes a communication module.

[0019] Communication module: Receives digital signals of shielding gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current from the processor, and sends these digital signals to external devices.

[0020] The aforementioned real-time acquisition system for plasma welding process parameters also includes a keyboard; the keyboard enables control input to the communication module.

[0021] In the aforementioned real-time acquisition system for plasma welding process parameters, the IP address of external devices can be entered via keyboard to input digital signals of shielding gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current to different external devices.

[0022] In the aforementioned real-time acquisition system for plasma welding process parameters, the communication module is connected to the processor via an RJ45 network port to realize the real-time transmission of digital signals of shielding gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current.

[0023] In the aforementioned real-time acquisition system for plasma welding process parameters, when the system is in operation, it is connected to the negative electrode of the plasma welding machine via a grounding clamp, and the welding torch is connected to the positive electrode of the plasma welding machine to form a welding circuit.

[0024] The advantages of this invention compared to the prior art are:

[0025] (1) When the plasma welding process parameter real-time acquisition system of the present invention is working, it is connected to the negative electrode of the plasma welding machine through the grounding clamp, and the welding gun is connected to the positive electrode of the plasma welding machine to form a welding circuit.

[0026] (2) The present invention uses a protective gas flow sensor, an ion gas flow sensor, a plasma welding machine, a current sensor, and a voltage sensor, which can simultaneously collect four signals: welding current, arc voltage, protective gas flow rate, and ion gas flow rate.

[0027] (3) The real-time acquisition system for plasma welding process parameters of the present invention has low power consumption and can be directly powered from the welding machine, which will not affect the power output of the welding machine itself.

[0028] (4) This invention enables the input of the IP address of an external device via a keyboard, and enables the input of digital signals of protective gas flow rate, ion gas flow rate, plasma welding voltage and plasma welding current to different external devices via a communication module. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the real-time acquisition system for plasma welding process parameters of the present invention;

[0030] Figure 2 This is a schematic diagram of the physical object and specific interface of the real-time acquisition system for plasma welding process parameters of the present invention;

[0031] Figure 3 This is a schematic diagram illustrating the principle of current sensor acquisition of current signals in this invention.

[0032] Figure 4 This is a schematic diagram illustrating the principle of voltage sensor acquisition of voltage signals according to the present invention;

[0033] Figure 5 This is a schematic diagram of the interface display of the display module of the present invention. Detailed Implementation

[0034] The present invention will be further described below with reference to the embodiments.

[0035] This invention provides a real-time acquisition system for plasma welding process parameters, overcoming the limitations of existing non-automated plasma welding power supplies, which lack a data acquisition module, making it impossible to display key process parameters during welding, acquire multiple key process parameters simultaneously and in real time, and connect the welding power supply for centralized control. This invention provides a low-power, small-sized, lightweight, and easy-to-install acquisition device that can simultaneously and in real-time acquire four parameters during the plasma welding process: current, voltage, shielding gas flow rate, and ion gas flow rate.

[0036] Real-time acquisition system for plasma welding process parameters, such as Figure 1 As shown, the system specifically includes a protective gas flow sensor, an ion flow sensor, a plasma welding machine, a current sensor, a voltage sensor, a power supply module, a processor, a display module, a grounding clamp, and a welding torch. The grounding clamp is connected to the negative terminal of the plasma welding machine, and the welding torch is connected to the positive terminal of the plasma welding machine. The grounding clamp is clamped onto the workpiece to be welded. When the real-time acquisition system for plasma welding process parameters is working, the grounding clamp is connected to the negative terminal of the plasma welding machine, and the welding torch is connected to the positive terminal of the plasma welding machine to form a welding circuit.

[0037] Protective gas flow sensor: Receives protective gas from the outside, generates a protective gas flow voltage signal, and sends the protective gas flow voltage signal to the processor; outputs protective gas to the plasma welding machine.

[0038] Ion gas flow sensor: Receives ion gas from the outside, generates ion gas flow voltage signal, and sends the ion gas flow voltage signal to the processor; outputs ion gas to the plasma welding machine.

[0039] Plasma welding machine: Connects to an external three-phase power supply and outputs power to the power module; receives shielding gas from the shielding gas flow sensor and transmits the shielding gas to the welding torch; receives ion gas from the ion flow sensor, converts the ion gas into an ion stream, and transmits the ion stream to the welding torch; generates a voltage signal for plasma welding voltage and sends the plasma welding voltage signal to the processor; generates a voltage signal for plasma welding current and sends the plasma welding current voltage signal to the processor.

[0040] Power module: Receives power from the plasma welding machine and supplies power to the processor.

[0041] Welding torch: It receives the ion stream from the plasma welding machine and sprays the particle stream onto the surface of the workpiece to be welded; it also receives the shielding gas from the plasma welding machine and sprays the shielding gas onto the surface of the workpiece to be welded.

[0042] Voltage sensor: Receives the voltage signal of the plasma welding voltage from the plasma welding machine and sends the plasma welding voltage signal to the processor.

[0043] Current sensor: Receives the voltage signal of the plasma welding current from the plasma welding machine and sends the voltage signal of the plasma welding current to the processor.

[0044] The processor receives the shielding gas voltage signal from the shielding gas flow sensor; the ion gas voltage signal from the shielding gas flow sensor; the plasma welding voltage signal from the voltage sensor; and the plasma welding current voltage signal from the current sensor. It performs analog-to-digital conversion on all the shielding gas voltage, ion gas voltage, plasma welding voltage, and plasma welding current signals to generate digital signals for shielding gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current, and sends these signals to the display module for display, such as... Figure 5 As shown in the figure. Simultaneously, digital signals for shielding gas flow rate, ionizing gas flow rate, plasma welding voltage, and plasma welding current are sent to external devices.

[0045] The real-time acquisition system for plasma welding process parameters also includes a keyboard and a communication module.

[0046] Communication module: Receives digital signals of shielding gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current from the processor, and sends these digital signals to external devices.

[0047] The communication module is controlled via a keyboard. By inputting the IP address of external devices via the keyboard, digital signals for shielding gas flow rate, ionizing gas flow rate, plasma welding voltage, and plasma welding current can be sent to different external devices.

[0048] The shielding gas is argon or other inert gas, which protects the surface of the workpiece to be welded and prevents oxidation.

[0049] Plasma welding machines convert ion gas into an ion stream by stimulating and treating the ion gas.

[0050] The welding torch heats the surface of the workpiece by spraying an ion beam onto it, thus completing the welding process. The negative terminal of the plasma welding machine is connected to a voltage sensor, and the positive terminal is also connected to a current sensor.

[0051] The communication module is connected to the processor via an RJ45 network port to enable real-time transmission of digital signals for protective gas flow, ion gas flow, plasma welding voltage, and plasma welding current.

[0052] The technical solution of the present invention is as follows: The present invention is based on a single circuit board, on which electronic components such as current sensor, voltage sensor, gas flow sensor, ion gas flow sensor, power module, controller, LED display, and network output port are deployed. The circuit board is mounted on a single metal plate, and a metal shell and external interface are installed on the outer casing. A keyboard is installed on the outer box. Data acquisition is achieved by connecting a soldering power supply.

[0053] The principle of the above scheme is as follows: the electrical signals collected by the current sensor, voltage sensor, gas flow sensor, and ion gas flow sensor are processed and transmitted to the processor. The processor processes the signals and displays them on the screen, and then transmits them out through the network port.

[0054] like Figure 2 The diagram shows the physical object and specific interfaces of the real-time acquisition system for plasma welding process parameters. The names of each interface are shown in Table 1.

[0055] Table 1

[0056]

[0057] like Figure 3The diagram shows the principle of a current sensor acquiring current signals. During welding, the welding torch is connected to the positive terminal of the welding power supply, and the ground wire is connected to the negative terminal, forming a welding circuit. To acquire the current output by the welding machine, an ammeter needs to be added to the welding circuit. However, since welding currents range from tens to hundreds of amperes, they are too large to be directly acquired. The current sensor uses a current transformer to convert the large current into a smaller current through an inductor coil for acquisition. The electrical signal output by the sensor is processed and transmitted to the microprocessor in the acquisition box, where it is displayed on the screen.

[0058] like Figure 4 The diagram shows the principle of voltage sensor acquisition of voltage signal. Arc voltage needs to be acquired in parallel with the positive and negative terminals of the welding machine. Since manual welding torches are generally water-cooled, it is not possible to directly acquire the signal in parallel with the welding torch and the power supply. A signal line needs to be led out from the positive terminal of the power supply, and the negative terminal is connected in the same way as the welding current to form a parallel circuit. A voltage sensor is added to the parallel circuit. The signal output by the voltage sensor is then transmitted to the microprocessor of the acquisition box through signal processing and displayed on the display screen of the acquisition box.

[0059] like Figure 5 The image shows an example of how data transmitted via the network port is displayed in the software interface.

[0060] When the plasma welding process parameter real-time acquisition system of the present invention is working, it is connected to the negative electrode of the plasma welding machine through a grounding clamp, and the welding torch is connected to the positive electrode of the plasma welding machine to form a welding circuit. It adopts a protective gas flow sensor, an ion gas flow sensor, a plasma welding machine, a current sensor, and a voltage sensor, and can simultaneously acquire four signals: welding current, arc voltage, protective gas flow rate, and ion gas flow rate.

[0061] The plasma welding process parameter real-time acquisition system of this invention has low power consumption and can draw power directly from the welding machine, without affecting the power output of the welding machine itself.

[0062] Furthermore, this invention enables the input of the IP address of an external device via a keyboard, allowing digital signals of protective gas flow rate, ion gas flow rate, plasma welding voltage, and plasma welding current to be input to different external devices through a communication module.

[0063] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A real-time acquisition system for plasma welding process parameters, characterized in that: The system comprises a shielding gas flow sensor, an ion gas flow sensor, a plasma welder, a current sensor, a voltage sensor, a power module, a processor, a display module, a grounding clamp and a welding gun, wherein the grounding clamp is connected with the negative electrode of the plasma welder, the welding gun is connected with the positive electrode of the plasma welder, and the grounding clamp is clamped on the workpiece to be welded. The shielding gas flow sensor receives the shielding gas from outside, generates a shielding gas flow voltage signal, and sends the shielding gas flow voltage signal to the processor, and outputs the shielding gas to the plasma welder. The ion gas flow sensor receives the ion gas from outside, generates an ion gas flow voltage signal, and sends the ion gas flow voltage signal to the processor, and outputs the ion gas to the plasma welder. The plasma welder is in communication with the external three-phase power supply, outputs power to the power module, receives the shielding gas from the shielding gas flow sensor, transmits the shielding gas to the welding gun, receives the ion gas from the ion gas flow sensor, converts the ion gas into ion flow, transmits the ion flow to the welding gun, generates a voltage signal of the plasma welding voltage, and sends the voltage signal of the plasma welding voltage to the processor, and generates a voltage signal of the plasma welding current, and sends the voltage signal of the plasma welding current to the processor. The power module receives the power supply from the plasma welder, and supplies power to the processor. The welding gun receives the ion flow from the plasma welder, sprays the particle flow on the surface of the workpiece to be welded, and receives the shielding gas from the plasma welder, sprays the shielding gas on the surface of the workpiece to be welded. The voltage sensor receives the voltage signal of the plasma welding voltage from the plasma welder, and sends the voltage signal of the plasma welding voltage to the processor. The current sensor receives the voltage signal of the plasma welding current from the plasma welder, and sends the voltage signal of the plasma welding current to the processor. The processor receives the shielding gas flow voltage signal from the shielding gas flow sensor, receives the ion gas flow voltage signal from the shielding gas flow sensor, receives the voltage signal of the plasma welding voltage from the voltage sensor, receives the voltage signal of the plasma welding current from the current sensor, performs analog-to-digital conversion on the shielding gas flow voltage signal, the ion gas flow voltage signal, the voltage signal of the plasma welding voltage and the voltage signal of the plasma welding current, generates digital signals of the shielding gas flow, the ion gas flow, the plasma welding voltage and the plasma welding current, and sends the digital signals to the display module for display, and simultaneously sends the digital signals of the shielding gas flow, the ion gas flow, the plasma welding voltage and the plasma welding current to the external device. The plasma welder converts the ion gas into ion flow through excitation of the ion gas. The real-time acquisition system of the plasma welding process parameters further comprises a communication module. The communication module receives the digital signals of the shielding gas flow, the ion gas flow, the plasma welding voltage and the plasma welding current from the processor, and sends the digital signals of the shielding gas flow, the ion gas flow, the plasma welding voltage and the plasma welding current to the external device.

2. The real-time acquisition system for plasma welding process parameters according to claim 1, characterized in that: The shielding gas is argon or other inert gas, and the shielding gas is used to protect the surface of the workpiece to be welded and prevent oxidation.

3. The real-time plasma welding process parameter acquisition system of claim 2, wherein: The welding gun realizes the heating treatment of the surface of the workpiece to be welded by spraying ion flow on the surface of the workpiece to be welded, and completes the welding.

4. The real-time plasma welding process parameter acquisition system of claim 1, wherein: The negative electrode of the plasma welder is connected with the voltage sensor, the positive electrode of the plasma welder is connected with the voltage sensor, and the positive electrode of the plasma welder is connected with the current sensor.

5. The real-time plasma welding process parameter acquisition system of claim 4, wherein: The real-time acquisition system of plasma welding process parameters also comprises a keyboard; the communication module is controlled and inputted through the keyboard.

6. The real-time plasma welding process parameter acquisition system of claim 5, wherein: The IP address of the external device is inputted through the keyboard, and the digital signals of the shielding gas flow, the ion gas flow, the plasma welding voltage and the plasma welding current are inputted to different external devices.

7. The real-time plasma welding process parameter acquisition system of claim 6, wherein: The communication module is connected with the processor through an RJ45 network port, and the real-time transmission of the digital signals of the shielding gas flow, the ion gas flow, the plasma welding voltage and the plasma welding current is realized.

8. The real-time plasma welding process parameter acquisition system of claim 1, wherein: When the real-time acquisition system of plasma welding process parameters works, the grounding clamp is connected with the negative electrode of the plasma welder, the welding gun is connected with the positive electrode of the plasma welder, and a welding circuit is formed.

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