Welding wire remaining amount detection and early warning system

Abstract

The invention relates to the field of welding. The invention aims to solve the problem that the remaining amount of welding wire in a laser composite welding platemaking device cannot be detected. In the process of detecting the remaining amount of welding wire, based on the principle of electromagnetic induction, the equivalent inductance of the coil decreases as the amount of welding wire decreases. The change of the equivalent inductance of the coil is converted into a frequency change signal that is directly collected through an LC oscillation circuit. The remaining amount of the current welding wire can be determined by detecting the value of the current frequency.

Description

Technical Field

[0001] The invention belongs to the field of welding, and in particular relates to a welding wire excess detection technology. Background Art

[0002] The laser composite welding plate-making device is an efficient and high-quality processing technology. Compared with the traditional welding processing method, it has the technical advantages of fast processing speed, reduced process flow, high product consistency, and can greatly reduce the work intensity of production personnel. Under the requirement of improving processing production efficiency, it is necessary to replace the welding wire reel in advance when the welding wire is insufficient, so as to shorten the plate-making processing time and significantly improve the processing efficiency. However, in actual production, because the weld is relatively long and the welding wire reel is in the wire feeding box, the production personnel cannot check the approximate remaining amount of welding wire at any time, and because the manual labor cannot accurately judge whether the remaining amount of the coiled welding wire is enough for this welding, the embarrassing situation of wire shortage and broken welding often occurs at the end during the laser composite welding process. Furthermore, because the manual labor cannot accurately judge the remaining amount of welding wire, in order to avoid the lack of wire during the welding process, the welding wire is often replaced in advance when there is still a large amount of welding wire in the welding wire reel. However, the replaced welding wire has no place to be used, which ultimately causes a lot of unnecessary waste. Therefore, whether the remaining amount of welding wire is sufficient is particularly important for the laser composite welding platemaking device, but the simple use of wire feeding speed software algorithm cannot accurately calculate the remaining amount of welding wire; the contact detection device has the defects of short service life and inconvenient wire changing; the design and installation of the coiled welding wire using a weighing device is too complicated. Summary of the invention

[0003] The present invention aims to solve the problem that the remaining amount of welding wire in a laser composite welding plate-making device cannot be detected, and now provides a welding wire remaining amount detection and early warning system.

[0004] A welding wire remaining amount detection system, comprising: a detection coil, a detection circuit and a controller;

[0005] The detection coil is located inside the magnetic field generated by the welding wire being tested;

[0006] The detection circuit is used to convert the equivalent inductance of the detection coil into a frequency signal in real time;

[0007] The controller is used to obtain the mapping relationship between the remaining amount of welding wire and the frequency signal by using an adaptive algorithm, and then calculate the remaining amount of welding wire in real time by real-time acquisition of the frequency signal.

[0008] Furthermore, the detection coil is in the shape of a circular spiral.

[0009] Furthermore, the detection circuit includes: resistors R1 to R6, capacitors C1 to C5, transistors Q1 and Q2;

[0010] One end of the capacitor C1 is connected to one end of the resistor R1, one end of the resistor R2 and the base of the transistor Q1, and the other end of the capacitor C1 is connected to one end of the capacitor C5 and one end of the detection coil.

[0011] The collector of transistor Q1 is connected to one end of capacitor C2 and one end of resistor R3 at the same time, and the emitter of transistor Q1 is connected to one end of resistor R4 and one end of capacitor C3 at the same time.

[0012] The other end of the capacitor C2 is simultaneously connected to one end of the capacitor C4, one end of the resistor R5 and the other end of the detection coil.

[0013] The other end of resistor R5 is connected to the base of transistor Q2.

[0014] The collector of transistor Q2 is connected to one end of resistor R6 and serves as the frequency signal output end of the detection circuit.

[0015] The other end of the resistor R1, the other end of the resistor R3 and the other end of the resistor R6 are connected to the positive electrode of the power supply.

[0016] The other end of the resistor R2, the other end of the resistor R4, the other end of the capacitor C3, the other end of the capacitor C4, the other end of the capacitor C5 and the emitter of the transistor Q2 are commonly connected to the power ground.

[0017] Furthermore, the detection circuit is used to convert the equivalent inductance of the detection coil into a frequency signal, and the frequency signal is obtained by the following formula:

[0018]

[0019] Among them, F is the value of the frequency signal, L is the equivalent inductance of the detection coil, and C is the equivalent capacitance of the capacitor C4 and the capacitor C5 connected in series.

[0020] A welding wire remaining amount warning system is implemented based on the above welding wire remaining amount detection system, and the welding wire remaining amount warning system also includes a host computer;

[0021] The controller is also used to send the calculated remaining amount of welding wire, wire feeding speed, welding speed and weld length to the host computer in real time;

[0022] The host computer is used to calculate the welding wire requirement in real time according to the wire feeding speed, welding speed and weld length, and compare the welding wire requirement with the remaining welding wire in real time. When the remaining welding wire is less than the welding wire requirement, an early warning signal is sent to the controller.

[0023] Furthermore, the above-mentioned real-time calculation of welding wire demand according to wire feeding speed, welding speed and weld length includes:

[0024] Calculate the welding wire requirement according to the following formula:

[0025]

[0026] Furthermore, the above-mentioned welding wire remaining amount warning system also includes an LED display board, and the LED display board includes three green indicator lights and one red indicator light.

[0027] 3 green indicator lights are used to display the remaining amount of welding wire, and the number of green indicator lights that light up is proportional to the remaining amount of welding wire;

[0028] When the controller receives the warning signal, the three green indicator lights go out and the red indicator light turns on.

[0029] Furthermore, the host computer and the controller exchange data via an RS485 communication interface.

[0030] The welding wire remaining amount detection and early warning system of the present invention has the following beneficial effects:

[0031] (1) Non-contact detection, no wear and tear, long service life.

[0032] (2) The structure is simple and easy to install.

[0033] (3) Low cost.

[0034] (4) Through conventional physical phenomenon detection, it is less affected by the outside world and has high reliability.

[0035] (5) As the amount of welding wire in the wire reel decreases, the detection sensitivity increases, making the detection warning more accurate.

[0036] (6) The communication function can read the wire usage of the current weld sent by the host computer, and make quick judgments and early warning feedback.

[0037] (7) The display is intuitive and obvious.

[0038] In summary, the present invention can quickly and accurately detect whether the current amount of welding wire is sufficient, and is suitable for detecting the remaining amount of welding wire in the welding field. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a schematic diagram of the structure of the detection coil;

[0040] Figure 2 It is a structural schematic diagram of the detection circuit;

[0041] Figure 3 Schematic diagram of the composition of the welding wire remaining amount detection system. DETAILED DESCRIPTION

[0042] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention. 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] Specific implementation method 1: refer to Figure 1 , Figure 2 and Figure 3 The present embodiment is described in detail. The welding wire remaining amount detection system described in the present embodiment includes: a detection coil, a detection circuit and a controller.

[0044] The detection coil is a key part of the welding wire remaining detection system. It is required to have a large enough detection area, sufficient inductance and sensitivity, be stable and strong, easy to install, dustproof, waterproof, leakage-proof and safe to use. Based on the above requirements, this implementation method, such as Figure 1 As shown, a board-mounted coil is designed on a printed circuit board (PCB). To improve the sensitivity, the size of the printed circuit board is comparable to that of the wire feeding reel. For easy installation, a circular spiral paving method is adopted so that it is convenient to stick to the side wall of the wire feeding box, so that the detection coil is located inside the magnetic field generated by the welding wire being tested.

[0045] Since the remaining amount of welding wire will affect the amount of magnetic conductive medium and thus change the inductance of the detection coil, this embodiment uses the principle of changing the detection oscillation frequency by inductance to convert the equivalent inductance of the detection coil into a collectible frequency signal. Figure 2 As shown, this embodiment adopts a three-point oscillation circuit, L is the equivalent symbol of the detection coil, and A is the output end of the detection circuit. The equivalent inductance of the detection coil is converted into a frequency signal, and the frequency signal is obtained by the following formula:

[0046]

[0047] Among them, F is the value of the frequency signal, L is the equivalent inductance of the detection coil, and C is the equivalent capacitance of the capacitor C4 and the capacitor C5 connected in series.

[0048] The detection circuit uses the electromagnetic induction detection principle to convert the equivalent inductance of the detection coil into a frequency signal. The detection circuit includes: resistors R1 to R6, capacitors C1 to C5, transistors Q1 and Q2;

[0049] One end of the capacitor C1 is connected to one end of the resistor R1, one end of the resistor R2 and the base of the transistor Q1, and the other end of the capacitor C1 is connected to one end of the capacitor C5 and one end of the detection coil.

[0050] The collector of transistor Q1 is connected to one end of capacitor C2 and one end of resistor R3 at the same time, and the emitter of transistor Q1 is connected to one end of resistor R4 and one end of capacitor C3 at the same time.

[0051] The other end of the capacitor C2 is simultaneously connected to one end of the capacitor C4, one end of the resistor R5 and the other end of the detection coil.

[0052] The other end of resistor R5 is connected to the base of transistor Q2.

[0053] The collector of transistor Q2 is connected to one end of resistor R6 and serves as the frequency signal output end of the detection circuit.

[0054] The other end of the resistor R1, the other end of the resistor R3 and the other end of the resistor R6 are connected to the positive electrode of the power supply.

[0055] The other end of the resistor R2, the other end of the resistor R4, the other end of the capacitor C3, the other end of the capacitor C4, the other end of the capacitor C5 and the emitter of the transistor Q2 are commonly connected to the power ground.

[0056] In order to reduce costs, the controller of this embodiment adopts an adaptive algorithm to obtain the mapping relationship between the remaining amount of welding wire and the real-time frequency value of port A in the acquisition circuit to calculate the current remaining amount of welding wire. Specifically, this embodiment first automatically records the highest upper limit value when the plate is full of welding wire and the lowest lower limit value when the plate is empty, and performs adaptive correction according to the upper and lower limits and the current measured value. The more it is used, the more accurate the judgment value of the current remaining amount of welding wire is. In order to meet the accuracy of the acquisition, external interference is eliminated. The detection and calculation process is carried out in a non-welding state. In actual application, each time the welding wire is replaced, a self-learning correction algorithm is used to learn the state of the new welding wire, and then the new welding wire state is compared with the previously recorded state to calculate the new limit value, and the remaining amount algorithm is calibrated once by the new limit value.

[0057] Specific implementation method 2: refer to Figure 3 Specifically describe this embodiment, the welding wire remaining amount warning system described in this embodiment is implemented based on the welding wire remaining amount detection system described in the specific embodiment 1, and the welding wire remaining amount warning system also includes a host computer and an LED display board. The LED display board includes 3 green indicator lights and a red indicator light. The 3 green indicator lights are used to display the remaining amount of welding wire, and the number of green indicator lights is proportional to the remaining amount of welding wire; when the controller receives the warning signal, the 3 green indicator lights are all off and the red indicator light is on.

[0058] In order to adapt to the on-site environment, this implementation adopts the RS485 protocol to realize data interaction between the controller and the host computer. When the host computer sends the next welding demand, when it detects that the remaining amount of welding wire is lower than the next welding demand, it will feedback the alarm information to the host computer. If the welding wire usage is met, the remaining amount information will be fed back to the host computer. At the same time, the display status is changed to prompt the production personnel whether the welding wire needs to be replaced. The remaining warning display part of the welding wire adopts a simple and intuitive LED indicator display solution. It is specifically composed of 4 indicator lights vertically installed on the wall of the wire feeding box. 3 green lights display the remaining status of the welding wire. As the amount of welding wire decreases, the green indicator light gradually goes out until the bottom red indicator light is lit to indicate insufficient welding wire warning. When the welding wire is insufficient, the three green lights go out and the red indicator light is lit alone.

[0059] The controller is also used to send the calculated remaining amount of welding wire, wire feeding speed, welding speed and weld length to the host computer in real time.

[0060] The host computer is used to calculate the welding wire requirement in real time according to the wire feeding speed, welding speed and weld length, and compare the welding wire requirement with the remaining welding wire in real time. When the remaining welding wire is less than the welding wire requirement, an early warning signal is sent to the controller.

[0061] Real-time calculation of wire requirements based on wire feed speed, welding speed and weld length, including:

[0062] Calculate the welding wire requirement according to the following formula:

[0063] Specific implementation method three:

[0065] Large-format laser hybrid welding automatic layout equipment During laser arc hybrid welding, because the workpiece size is relatively large and the weld is relatively long, welding interruption is not allowed. Therefore, the demand for the remaining amount of welding wire during the welding process is more important to ensure that the weld will not affect the quality of the entire welding due to lack of welding wire.

[0066] The detection coil of the residual welding wire detection and early warning device is mounted on the side wall of the wire feeding box of the large-format laser composite welding automatic platemaking equipment, the detection coil is connected to the detection circuit and the controller, the RS485 communication interface for communication with the host computer is connected, the LED display is mounted in a conspicuous position of the wire feeding box, and the controller is powered on. The system will automatically record the current detection value and display the current remaining amount of welding wire through the LED indicator. Each time a new welding wire reel is replaced, the system will automatically learn and verify the detection data.

[0067] Before welding begins, the host computer will send the wire feeding speed, welding speed and weld length of this welding through the RS485 interface. The wire consumption will be calculated by this set of welding wire remaining warning controller and compared with the detected welding wire remaining amount. When the welding consumption is not met, the wire shortage warning information will be fed back to the host computer. The large-format laser composite welding automatic platemaking equipment of the host computer will suspend the preparation work before welding and wait for the remaining amount of welding wire to meet the requirements to continue production. At the same time, this set of devices will change the display status of the LED display board, turn off the three green LED indicators, and light up the red LED indicator. Prompt the producer to replace the welding wire. When the welding consumption is met, the information of the remaining amount of welding wire will be fed back to the host computer, and the large-format laser composite welding automatic platemaking equipment of the host computer will continue the next welding production. At the same time, this set of devices will change the display status of the LED display board, and use the green LED indicator to display the corresponding remaining amount.

[0068] By using the above method, the operator can predict whether the welding wire meets the current workpiece processing before welding and determine whether the welding wire needs to be replaced. This greatly improves the stability and reliability of the welding process, avoids major losses caused by manual misjudgment, and avoids unnecessary waste of coiled welding wire, greatly saving production costs.

[0069] In summary, the present invention discloses a welding wire remaining amount detection and early warning system. During the welding wire remaining amount detection process, based on the principle of electromagnetic induction, when the welding wire reel is installed in a wire feeding box with a detection coil attached. The coil medium condition changes, and the coil equivalent inductance decreases as the metal welding wire in the wire feeding reel decreases. Since the wire feeding reel body and the wire feeding box shell are both made of non-metallic materials, the detection result cannot be affected according to the principle of electromagnetic induction. At the same time, since the installation position of the detection coil and the wire feeding reel is relatively fixed, the change of the equivalent inductance of the coil can be converted into a frequency change signal that is directly collected through an LC oscillation circuit. The current remaining amount of welding wire can be determined by detecting the current frequency value. The present invention can achieve contactless detection, convenient wire replacement, simple installation, low cost, high reliability and high precision.

[0070] Although the present invention is described herein with reference to specific embodiments, it should be understood that these embodiments are merely examples of the principles and applications of the present invention. It should therefore be understood that many modifications may be made to the exemplary embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. It should be understood that the various dependent claims and features described herein may be combined in a manner different from that described in the original claims. It should also be understood that the features described in conjunction with a single embodiment may be used in other described embodiments.

Claims

1. A welding wire remaining amount detection system, characterized in that: include: Detection coil, detection circuit and controller; The detection coil is located inside the magnetic field generated by the welding wire being tested; The detection circuit is used to convert the equivalent inductance of the detection coil into a frequency signal in real time; The controller is used to obtain the mapping relationship between the remaining amount of welding wire and the frequency signal by using an adaptive algorithm, and then calculate the remaining amount of welding wire in real time by real-time acquisition of the frequency signal; The detection circuit includes: resistors R1-R6, capacitors C1-C5, transistors Q1 and Q2; One end of the capacitor C1 is connected to one end of the resistor R1, one end of the resistor R2 and the base of the transistor Q1, and the other end of the capacitor C1 is connected to one end of the capacitor C5 and one end of the detection coil. The collector of transistor Q1 is connected to one end of capacitor C2 and one end of resistor R3 at the same time, and the emitter of transistor Q1 is connected to one end of resistor R4 and one end of capacitor C3 at the same time. The other end of the capacitor C2 is simultaneously connected to one end of the capacitor C4, one end of the resistor R5 and the other end of the detection coil. The other end of resistor R5 is connected to the base of transistor Q2. The collector of transistor Q2 is connected to one end of resistor R6 and serves as the frequency signal output end of the detection circuit. The other end of the resistor R1, the other end of the resistor R3 and the other end of the resistor R6 are connected to the positive electrode of the power supply. The other end of the resistor R2, the other end of the resistor R4, the other end of the capacitor C3, the other end of the capacitor C4, the other end of the capacitor C5 and the emitter of the transistor Q2 are commonly connected to the power ground.

2. The welding wire remaining amount detection system according to claim 1, characterized in that: The detection coil is in a circular spiral shape.

3. The welding wire remaining amount detection system according to claim 1, characterized in that: The detection circuit is used to convert the equivalent inductance of the detection coil into a frequency signal, and the frequency signal is obtained by the following formula: Among them, F is the value of the frequency signal, L is the equivalent inductance of the detection coil, and C is the equivalent capacitance of the capacitor C4 and the capacitor C5 connected in series.

4. The welding wire remaining amount warning system is characterized by: The welding wire remaining amount warning system is implemented based on the welding wire remaining amount detection system according to any one of claims 1 to 3, and the welding wire remaining amount warning system also includes a host computer; The controller is also used to send the calculated remaining amount of welding wire, wire feeding speed, welding speed and weld length to the host computer in real time; The host computer is used to calculate the welding wire requirement in real time according to the wire feeding speed, welding speed and weld length, and compare the welding wire requirement with the remaining welding wire in real time. When the remaining welding wire is less than the welding wire requirement, an early warning signal is sent to the controller.

5. The welding wire remaining amount warning system according to claim 4, characterized in that: The real-time calculation of welding wire demand according to wire feeding speed, welding speed and weld length includes: Calculate the welding wire requirement according to the following formula:

6. The welding wire remaining amount warning system according to claim 4 or 5, characterized in that: It also includes an LED display board, which includes three green indicator lights and one red indicator light. 3 green indicator lights are used to display the remaining amount of welding wire, and the number of green indicator lights that light up is proportional to the remaining amount of welding wire; When the controller receives the warning signal, the three green indicator lights are turned off and the red indicator light is turned on.

7. The welding wire remaining amount warning system according to claim 6, characterized in that: The host computer and the controller exchange data via the RS485 communication interface.

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