Exothermic welding electronic starter wiring fault identification method and exothermic welding process

Abstract

The invention discloses a method for identifying wiring faults of an exothermic welding electronic starter and an exothermic welding process, and relates to the field of exothermic welding. The method comprises: connecting a fault detection circuit in an exothermic welding electronic starter, collecting a discharge current of the exothermic welding electronic starter by using the fault detection circuit, and judging whether there is a fault in the wiring of the exothermic welding electronic starter based on the size of the discharge current; the invention can identify wiring faults of an exothermic welding electronic starter and improve the safety of exothermic welding.

Description

Technical Field

[0001] The invention relates to the field of exothermic welding, and in particular to a method for identifying wiring faults of an exothermic welding electronic starter and an exothermic welding process. Background Art

[0002] Exothermic welding is a simple, efficient and high-quality metal joining process. It uses the heat of chemical reaction of metal compounds as a heat source, and directly or indirectly heats the superheated (reduced) molten metal to form a fusion welded joint of a certain shape and size in the cavity of a special graphite mold that meets engineering requirements. At present, exothermic welding has generally replaced the previous mechanical joining method between metals.

[0003] Exothermic welding technology is widely used in metal joint connection. Exothermic welding requires ignition of exothermic flux for reaction. After ignition, the exothermic welding reaction will produce flames and smoke. Since this welding method will produce high-temperature flames, the use of an electronic starter for remote ignition is a safe and convenient method. Therefore, for safety reasons, the existing technology uses an exothermic welding electronic starter to connect with the ignition wire. The ignition wire and the starter are physically connected through a connector. The exothermic welding electronic starter generates a discharge current. The discharge current ignites the ignition powder through the ignition wire, and then the ignition powder ignites the exothermic flux for reaction. Since the exothermic welding electronic starter and the ignition wire are connected by plugging, problems such as poor contact and short circuit may occur during manual operation, causing personal and property losses.

[0004] For example, when the connection is not good, the discharge current generated by the exothermic welding electronic starter will not be able to reach the ignition wire, or the discharge current will be too weak to ignite the ignition powder. At this time, the worker may try to ignite many times because he does not know that there is a fault in the wiring of the exothermic welding electronic starter, and he is worried every time he ignites because he does not know whether the ignition will be successful this time. Since there will be large flames and smoke during ignition, multiple attempts at ignition and the uncertainty of whether each ignition will be successful cause great psychological pressure on the ignition personnel. Summary of the invention

[0005] The invention aims to identify wiring faults of an exothermic welding electronic starter, thereby improving the safety of exothermic welding.

[0006] To achieve the above object, the present invention provides a method for identifying wiring faults of an exothermic welding electronic starter, the method comprising:

[0007] A fault detection circuit is connected to the exothermic welding electronic starter, and the discharge current of the exothermic welding electronic starter is collected by the fault detection circuit. Based on the discharge current, it is determined whether there is a fault in the wiring of the exothermic welding electronic starter.

[0008] Among them, this method connects a fault detection circuit in the exothermic welding electronic starter, uses the fault detection circuit to collect the discharge current of the exothermic welding electronic starter, and judges whether there is a fault in the wiring of the exothermic welding electronic starter according to the size of the discharge current, thereby realizing the identification of the wiring fault of the exothermic welding electronic starter. If the discharge current is small, it means that there is a fault in the wiring of the exothermic welding electronic starter. If the discharge current is normal, it means that there is no fault in the wiring of the exothermic welding electronic starter.

[0009] In some embodiments, the exothermic welding electronic starter includes a discharge circuit for ignition, and the fault detection circuit is used to collect a discharge current corresponding to the discharge circuit. By collecting the discharge current corresponding to the discharge circuit, the discharge current size can be obtained to determine whether the wiring of the exothermic welding electronic starter is faulty.

[0010] In some embodiments, the discharge circuit includes: a MOS tube Q1, a transistor Q2, a first resistor R1, a second resistor R2 and a third resistor R3; one end of R1 is connected to the input end of the discharge circuit, the other end of R1 is connected to one end of R2 and the base of Q2, the other end of R2 and the emitter of Q2 are grounded, the collector of Q2 is connected to one end of R3 and the gate of Q1, the other end of R3 and the drain of Q1 are connected to the power input pin, and the source of Q1 is connected to the connection end of the ignition wire.

[0011] In some embodiments, the fault detection circuit comprises:

[0012] The fourth resistor R4 and the fifth resistor R5, one end of R4 and R5 are both connected to the connection end of the ignition wire, the other end of R4 is grounded, and the other end of R5 is connected to the controller. The controller is used to calculate whether the discharge current is within a preset range, and determine whether there is a fault in the wiring of the exothermic welding electronic starter based on the calculation result.

[0013] In some embodiments, the method further comprises displaying, notifying or sending the fault judgment result of the exothermic welding electronic starter wiring. By displaying, notifying or sending the fault judgment result of the exothermic welding electronic starter wiring, the ignition personnel or corresponding staff can know whether there is a fault in the exothermic welding electronic starter wiring, so as to perform ignition or maintenance.

[0014] In order to achieve safe welding, the present invention also provides an exothermic welding process, which comprises:

[0015] Step 1: Clean the mold, mold clamp and conductor;

[0016] Step 2: Dry and dehumidify the mold and mold clamp;

[0017] Step 3: Place the conductor into the mold and fix it with a mold clamp;

[0018] Step 4: Load the exothermic flux into the mold, place ignition powder from the surface of the exothermic flux to the mold opening, and close the mold top cover;

[0019] Step 5: Connect the exothermic welding electronic starter to the ignition wire;

[0020] Step 6: Use the exothermic welding electronic starter wiring fault identification method to identify whether there is a wiring fault in the exothermic welding electronic starter;

[0021] Step 7: If there is a wiring fault, repair it. If there is no wiring fault, turn on the exothermic welding electronic starter, the ignition wire ignites the ignition powder at the mold mouth, and the exothermic flux undergoes a hot melt reaction in the mold;

[0022] Step 8: After the reaction is complete, open the mold and take out the conductor.

[0023] The process of the present invention has step 6 on the basis of the traditional process, i.e., using the wiring fault identification method of the exothermic welding electronic starter to identify whether there is a wiring fault in the exothermic welding electronic starter. By judging whether there is a wiring fault in the exothermic welding electronic starter, multiple ignition attempts can be avoided, thereby improving safety.

[0024] Among them, the applicant found that:

[0025] When welding, the amount of welding powder placed needs to be controlled according to actual needs. Too much welding powder is easy to cause waste, and it is easy to cause the reaction to overflow and cause safety accidents. If the mold is opened and closed, it is easy to overflow, causing the mold cavity and the mold top cover to be welded together and unable to be opened; if the welding powder is too little, it is easy to cause insufficient reaction and affect the welding quality. Therefore, the amount of welding powder added is strictly controlled. This leads to that in some welding situations, after the welding powder is added, the upper surface of the welding powder is still a distance away from the mold mouth. If the traditional method is used, the ignition powder is directly spread on the upper surface of the welding powder, the inner wall of the mold, and the mold mouth to form an ignition path. Since the inner wall of the mold is vertical, the ignition powder cannot be laid on it evenly and with a certain thickness. At this time, the pre-planned ignition route laid with ignition powder is easily interrupted at the inner wall of the mold, resulting in unsmooth ignition. In specific situations, direct ignition may fail or the ignition time may be prolonged. The ignition failure is due to the large area without ignition powder on the inner wall of the mold. The prolonged ignition time is due to the ignition powder on the inner wall of the mold. Uneven laying leads to the absence of ignition powder in some areas, which reduces the burning rate of the ignition powder and increases the ignition path, or incomplete combustion of some fire points, etc. When direct ignition fails, re-ignition is required to reduce welding efficiency. At this time, opening the mold for re-ignition will not pose a safety hazard; however, when the ignition time is extended, since the mold is in a closed state, the welder cannot determine whether the ignition time is extended, and therefore may think that direct ignition failed. The staff will then open the mold to check. If the mold is opened at this time, it is easy to cause the mold to shake, which may cause the ignition powder that has not been fully burned on the ignition powder to fall directly into the welding powder and ignite the welding powder, thus causing a safety accident.

[0026] In order to improve the safety of ignition, in some embodiments, step 4 specifically includes: loading the exothermic flux into the mold, pouring the ignition powder into the igniter, using the igniter to arrange the ignition powder from the surface of the exothermic flux to the mold mouth, and closing the mold top cover. The ignition powder is ignited and the exothermic flux is ignited by the ignition powder to react. The igniter avoids the ignition powder from being directly laid on the inner wall of the mold, and the ignition powder is used to lay the ignition powder on the igniter to form an ignition path, thereby ensuring the success rate of ignition and improving the safety of ignition.

[0027] In some embodiments, the igniter is a semicircular tube, the upper end of the semicircular tube is the feeding end, when in use, the feeding end is connected to the reserved opening at the mold mouth, the lower end of the semicircular tube is in contact with the exothermic flux, and the semicircular tube is spiral from the upper end to the lower end.

[0028] Among them, the design of the semicircular tube is convenient for adding ignition powder. The semicircular tube has space for laying the ignition powder, and has good air circulation in contact with the outside world, and has good ignition conditions. A reserved opening is set at the mold mouth so as not to affect the normal opening and closing of the mold cover after using the igniter. The semicircular tube is designed to be spiral in shape to avoid the ignition powder sliding due to gravity like the traditional method, resulting in uneven or blank areas of ignition powder on the ignition path. On the one hand, the use of the spiral reduces the influence of the gravity component, making it difficult for the ignition powder to slide. On the other hand, the spiral extends the ignition path, allowing the ignition personnel to have more time to evacuate to a safe area, which is safer.

[0029] In some embodiments, since the mold, mold clamp and igniter surfaces all have impurities and residual substances after exothermic welding, the process also includes step 9: cleaning the mold, mold clamp and igniter, wherein the igniter is cleaned using a cleaner, the cleaner includes a cleaning rod and a blade, one end of the cleaning rod is connected to the back of the blade, the blade is semicircular, and the outer diameter of the blade matches the inner diameter of the semicircular tube. Due to the special shape of the igniter in the present invention, in order to clean the igniter well, the present invention uses a semicircular blade to clean the semicircular tube to ensure the cleaning effect.

[0030] In some embodiments, the applicant discovered the following problem during the process of using the above-mentioned ignition device to ignite: since the semicircular tube is spiral-shaped from the upper end to the lower end, some areas cannot be well laid during the manual laying of the ignition powder. Since the overlapping upper and lower spirals block the laying space, the laying tools such as spoons or shovels cannot be well used. In order to solve this problem, the present invention has designed a sliding laying tool and a slider. The slider is filled with ignition powder and has an ignition powder outlet on the lower surface. It slides from the upper end of the semicircular tube to the lower end, and automatic laying is achieved during the sliding process. No manual work or tools are required, and the ignition powder is not affected by the reduction of the spiral operation space, so that the ignition powder can be laid evenly.

[0031] Therefore, the ignition device also includes a slider, which has a cavity for loading ignition powder, an ignition powder inlet connected to the cavity on the upper surface of the slider, and an ignition powder outlet connected to the cavity on the lower surface of the slider. Pullies for slidingly connecting to the inner walls of the semicircular tube on both sides are provided on both sides of the slider. The slider is used to lay ignition powder on the inner wall of the semicircular tube when sliding from the upper end of the semicircular tube to the lower end. When the slider slides from the upper end of the semicircular tube to the lower end, there is a gap between the lower surface of the slider and the lower end of the inner wall of the semicircular tube for laying ignition powder.

[0032] One or more technical solutions provided by the present invention have at least the following technical effects or advantages:

[0033] The present invention identifies wiring faults of an exothermic welding electronic starter.

[0034] The invention can improve the safety of exothermic welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The drawings described herein are used to provide a further understanding of the embodiments of the present invention, constitute a part of the present invention, and do not constitute a limitation on the embodiments of the present invention;

[0036] Figure 1 is a circuit diagram of the discharge circuit and the fault detection circuit;

[0037] Figure 2 It is a schematic diagram of the process of exothermic welding;

[0038] Figure 3 is a schematic cross-sectional view of a semicircular tube;

[0039] Figure 4 is a schematic diagram of the structure of the blade;

[0040] Figure 5 It is a structural schematic diagram of the slider;

[0041] Among them, 1-slider, 2-cavity, 3-ignition powder inlet, 4-ignition powder outlet, 5-pulley, 6-semicircular tube. DETAILED DESCRIPTION

[0042] In order to more clearly understand the above-mentioned purpose, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present invention and the features in the embodiments can be combined with each other without conflict.

[0043] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those within the scope of this description. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0044] Embodiment 1

[0045] The present invention provides a method for identifying wiring faults of an exothermic welding electronic starter, the method comprising:

[0046] A fault detection circuit is connected to the exothermic welding electronic starter, and the discharge current of the exothermic welding electronic starter is collected by the fault detection circuit. Based on the discharge current, it is determined whether there is a fault in the wiring of the exothermic welding electronic starter.

[0047] Wherein, in the embodiment of the present invention, the exothermic welding electronic starter includes a discharge circuit for ignition, and the fault detection circuit is used to collect the discharge current corresponding to the discharge circuit.

[0048] In the embodiments of the present invention, please refer to Figure 1 , Figure 1 The present invention is a circuit diagram of the discharge circuit and the fault detection circuit, wherein the discharge circuit comprises: a MOS tube Q1, a transistor Q2, a first resistor R1, a second resistor R2 and a third resistor R3; one end of R1 is connected to the input end of the discharge circuit, the other end of R1 is connected to one end of R2 and the base of Q2, the other end of R2 and the emitter of Q2 are grounded, the collector of Q2 is connected to one end of R3 and the gate of Q1, the other end of R3 and the drain of Q1 are connected to the power input pin, and the source of Q1 is connected to the connection end of the ignition line. Figure 1 The power input pin is VBAT.

[0049] Wherein, in an embodiment of the present invention, the fault detection circuit includes:

[0050] The fourth resistor R4 and the fifth resistor R5, one end of R4 and R5 are both connected to the connection end of the ignition wire, the other end of R4 is grounded, and the other end of R5 is connected to the controller, such as the ADC analog-to-digital conversion sampling channel of the controller. The controller is used to calculate whether the discharge current is within a preset range, and determine whether there is a fault in the wiring of the exothermic welding electronic starter based on the calculation result.

[0051] Wherein, in the embodiment of the present invention, the method further comprises displaying, notifying or sending the fault judgment result of the wiring of the exothermic welding electronic starter.

[0052] Among them, the switch circuit may include a triode and a mos tube, the model of the triode may be s8050, and the model of the mos tube may be NCE60P50K. In practical applications, the triode and the mos tube may use other models according to actual needs, and the embodiment of the present invention does not make specific limitations. For example, the mos tube may be replaced with a P-MOS, such as using FDD6637-VB, which is characterized by high power, ultra-low on-resistance, low self-heating, and high current discharge exceeding 20A. A 0.01 ohm high-precision sampling resistor is connected in series in the discharge circuit, and the normal discharge current is between 10A and 25A. Since the current is the same at each place in the series circuit, and the 0.01 ohm resistor accounts for less than 1% of the impedance of the entire discharge circuit, it will not affect the high current discharge, so the voltage across the 0.01 ohm resistor is 100mv to 250mv. The 12-bit high-precision analog-to-digital conversion function of the STM32L431RCT6 microcontroller is adopted, and there is no need to add an additional analog-to-digital conversion chip, making this solution low-cost. The voltage across the 0.01 ohm resistor is sampled. If the voltage value falls within the range of 100mV to 250mV, the wiring is normal. Otherwise, there is a wiring fault and a prompt is given on the screen.

[0053] Embodiment 2

[0054] Based on Example 1, please refer to Figure 2 , Figure 2 The figure is a schematic diagram of the process of exothermic welding. Embodiment 2 of the present invention provides an exothermic welding process, and the process includes:

[0055] Step 1: Clean the mold, mold clamp and conductor;

[0056] Step 2: Dry and dehumidify the mold and mold clamp;

[0057] Step 3: Place the conductor into the mold and fix it with a mold clamp;

[0058] Step 4: Load the exothermic flux into the mold, place ignition powder from the surface of the exothermic flux to the mold opening, and close the mold top cover;

[0059] Step 5: Connect the exothermic welding electronic starter to the ignition wire;

[0060] Step 6: using the exothermic welding electronic starter wiring fault identification method in the first embodiment to identify whether there is a wiring fault in the exothermic welding electronic starter;

[0061] Step 7: If there is a wiring fault, repair it. If there is no wiring fault, turn on the exothermic welding electronic starter, the ignition wire ignites the ignition powder at the mold mouth, and the exothermic flux undergoes a hot melt reaction in the mold;

[0062] Step 8: After the reaction is complete, open the mold and take out the conductor.

[0063] Among them, in the embodiment of the present invention, the step 4 specifically includes: loading the exothermic flux into the mold, pouring the ignition powder into the igniter, using the ignition device to arrange the ignition powder from the surface of the exothermic flux to the mold mouth, and closing the mold top cover.

[0064] Among them, in the embodiment of the present invention, the igniter is a semicircular tube, please refer to Figure 3 , Figure 3 It is a schematic diagram of the cross section of a semicircular tube. The upper end of the semicircular tube is the feeding end. When in use, the feeding end is connected to the reserved opening at the mold mouth, and the lower end of the semicircular tube is in contact with the exothermic flux. The semicircular tube is spiral from the upper end to the lower end.

[0065] In the embodiment of the present invention, the process further comprises step 9: cleaning the mold, the mold clamp and the igniter, wherein the igniter is cleaned by a cleaner, the cleaner comprising a cleaning rod and a blade, please refer to Figure 4 , Figure 4 It is a schematic diagram of the structure of the blade. One end of the cleaning rod is connected to the back of the blade. The blade is semicircular, and the outer diameter of the blade matches the inner diameter of the semicircular tube.

[0066] In the embodiments of the present invention, please refer to Figure 5 , Figure 5 This is a structural schematic diagram of a slider, the ignition device also includes a slider 1, a cavity 2 for loading ignition powder is provided in the slider, an ignition powder inlet 3 connected to the cavity is provided on the upper surface of the slider, an ignition powder outlet 4 connected to the cavity is provided on the lower surface of the slider, pulleys 5 for sliding connection with the inner walls of the semicircular tube on both sides are provided on both sides of the slider, the slider is used to lay ignition powder on the inner wall of the semicircular tube 6 when sliding from the upper end to the lower end of the semicircular tube, and a gap for laying ignition powder is provided between the lower surface of the slider and the lower end of the inner wall of the semicircular tube when the slider slides from the upper end to the lower end of the semicircular tube.

[0067] Wherein, multiple ignition powder outlets can be evenly arranged to avoid a blockage therein leading to unsuccessful laying of ignition powder. The pulley and the inner wall of the semicircular tube can be used to achieve sliding connection, so that the slide block can slide from the upper end of the semicircular tube to the lower end.

[0068] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0069] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. Exothermic welding process, characterized in that: The process comprises: Step 1: Clean the mold, mold clamp and conductor; Step 2: Dry and dehumidify the mold and mold clamp; Step 3: Place the conductor into the mold and fix it with a mold clamp; Step 4: Load the exothermic flux into the mold, place ignition powder from the surface of the exothermic flux to the mold opening, and close the mold top cover; Step 5: Connect the exothermic welding electronic starter to the ignition wire; Step 6: Use the exothermic welding electronic starter wiring fault identification method to identify whether there is a wiring fault in the exothermic welding electronic starter; the exothermic welding electronic starter wiring fault identification method includes: connecting a fault detection circuit in the exothermic welding electronic starter, using the fault detection circuit to collect the discharge current of the exothermic welding electronic starter, and judging whether there is a fault in the wiring of the exothermic welding electronic starter based on the size of the discharge current; Step 7: If there is a wiring fault, repair it. If there is no wiring fault, turn on the exothermic welding electronic starter, the ignition wire ignites the ignition powder at the mold mouth, and the exothermic flux undergoes a hot melt reaction in the mold; Step 8: After the reaction is completed, open the mold and take out the conductor; The step 4 specifically comprises: loading the exothermic flux into the mold, pouring the ignition powder into the igniter, using the igniter to arrange the ignition powder from the surface of the exothermic flux to the mold opening, and closing the mold top cover; The igniter is a semicircular tube, the upper end of which is a feeding end. When in use, the feeding end is butted against a reserved opening at a mold opening, the lower end of the semicircular tube is in contact with the exothermic flux, and the semicircular tube is spiral from the upper end to the lower end; The ignition device also includes a slider, which has a cavity for loading ignition powder, an ignition powder inlet connected to the cavity on the upper surface of the slider, and an ignition powder outlet connected to the cavity on the lower surface of the slider. Pulleys for slidingly connecting to the inner walls of the semicircular tube on both sides are provided on both sides of the slider. The slider is used to lay ignition powder on the inner wall of the semicircular tube when sliding from the upper end to the lower end of the semicircular tube, and a gap for laying ignition powder is provided between the lower surface of the slider and the lower end of the inner wall of the semicircular tube when the slider slides from the upper end to the lower end of the semicircular tube.

2. The exothermic welding process according to claim 1, characterized in that: The process also includes step 9: cleaning the mold, mold clamp and igniter, wherein the igniter is cleaned using a cleaner, the cleaner includes a cleaning rod and a blade, one end of the cleaning rod is connected to the back of the blade, the blade is semicircular, and the outer diameter of the blade matches the inner diameter of the semicircular tube.

3. The exothermic welding process according to claim 1, characterized in that: The exothermic welding electronic starter comprises a discharge circuit for ignition, and the fault detection circuit is used to collect a discharge current corresponding to the discharge circuit.

4. The exothermic welding process according to claim 3, characterized in that: The discharge circuit includes: a MOS tube Q1, a transistor Q2, a first resistor R1, a second resistor R2 and a third resistor R3; one end of R1 is connected to the input end of the discharge circuit, the other end of R1 is connected to one end of R2 and the base of Q2, the other end of R2 and the emitter of Q2 are grounded, the collector of Q2 is connected to one end of R3 and the gate of Q1, the other end of R3 and the drain of Q1 are connected to the power input pin, and the source of Q1 is connected to the connection end of the ignition line.

5. The exothermic welding process according to claim 1, characterized in that: The fault detection circuit comprises: The fourth resistor R4 and the fifth resistor R5, one end of R4 and R5 are both connected to the connection end of the ignition wire, the other end of R4 is grounded, and the other end of R5 is connected to the controller. The controller is used to calculate whether the discharge current is within a preset range, and determine whether there is a fault in the wiring of the exothermic welding electronic starter based on the calculation result.

6. The exothermic welding process according to claim 5, characterized in that: The method further includes displaying, notifying or sending a fault judgment result of the wiring of the exothermic welding electronic starter.

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