A method for controlling the quality of welding and casting of spiral case seat ring

Abstract

The present invention relates to the field of quality management, and discloses a method for controlling the quality of welding and pouring of a volute seat ring. The method comprises the following steps: firstly selecting a corresponding theoretical welding parameter value according to the material of a target object and a preset welding process, then collecting in real time the actual welding parameter value, environmental parameter value and operating parameters of a welding gun in the process of welding the target object, then performing cumulative analysis based on the difference between each actual welding parameter value and the theoretical welding parameter value and obtaining a welding deviation value, comparing the welding deviation value with a preset welding deviation threshold value, and if the welding deviation value exceeds the welding deviation threshold value, judging that there is a potential risk in welding quality of the target object, performing a quality risk analysis on the welding deviation value, environmental parameter value and operating parameters of the welding gun, judging whether to issue a quality risk warning according to the result of the risk analysis, and finally controlling whether to continue the pouring process of the target object according to the quality risk warning.

Description

Technical Field

[0001] The invention relates to the field of quality management, and in particular to a method for controlling the quality of assembly welding and casting of a volute seat ring. Background Art

[0002] When assembling the volute and the seat ring, a welding process is required. First, the joints are welded using a welding gun. After welding, the welds of the assembled volute seat ring are cast to improve the strength and corrosion resistance of the welds.

[0003] The welding quality of the volute seat ring directly determines the quality of the finished product of the volute seat ring. However, the current quality control method is to conduct quality inspection on the weld after welding is completed. Once there is a welding quality problem, the welded volute seat ring often needs to be repaired at the problematic weld. In serious cases, the weld needs to be cut and polished before re-welding. The above process will obviously make the rework process complicated and affect efficiency, and it is also easy to affect the overall performance of the volute seat ring. Summary of the invention

[0004] The purpose of the present invention is to provide a method for controlling the quality of the welding and casting of the volute seat ring, so as to solve the technical problem that once there is a welding quality problem, the rework is complex and difficult and affects the efficiency.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A method for controlling the quality of volute seat ring welding and casting, comprising the following steps:

[0007] S10, selecting corresponding theoretical welding parameter values ​​according to the material of the target object and the preset welding process;

[0008] S20, collecting in real time actual welding parameter values, environmental parameter values ​​and operating parameters of the welding gun during the welding process of the target object;

[0009] S30, performing cumulative analysis based on the difference between each actual welding parameter value and the theoretical welding parameter value to obtain a welding deviation value, and comparing the welding deviation value with a preset welding deviation threshold value. If the welding deviation value exceeds the welding deviation threshold value, it is determined that there is a potential risk to the welding quality of the target object;

[0010] S40, performing a quality risk analysis on the welding deviation value, the environmental parameter value and the operating parameters of the welding gun, and determining whether to issue a quality risk warning according to the result of the risk analysis;

[0011] S50. Control whether the casting process of the target object continues according to the quality risk warning.

[0012] In a further solution, the working process of S30 is as follows:

[0013] Based on the detection sensor, the Actual welding parameter values ;

[0014] By formula Calculate the welding deviation value ; In the formula For the The weight coefficient of each welding parameter, For the Theoretical welding parameter values, is the total number of welding parameters, For the The comparison difference between the actual welding parameter value and the theoretical welding parameter value;

[0015] The welding deviation value The welding deviation threshold is set For comparison:

[0016] like , it is judged that the target object has potential risk in welding quality;

[0017] Otherwise, it is determined that the target object does not have a potential risk to welding quality.

[0018] In a further embodiment, the working process of S30 further includes:

[0019] like , then the current time Go back a preset period , get the starting time point , fitting Data on the change of welding deviation value over time during the detection period ;

[0020] Obtain reference data on welding deviation values ​​over time based on historical data ;

[0021] By formula Calculate the welding risk factor ; In the formula, for Above and The total area of ​​the area enclosed below, for Below and The total area of ​​the area enclosed above, , is the area warning value; For one Divide the quantity into multiple time periods. For the The impact coefficient corresponding to each time period is: , is the preset proportional coefficient;

[0022] According to the welding risk factor Determine the potential risk of welding quality of the target object.

[0023] Further solutions, based on the welding risk factor The process of determining the potential risk of welding quality of the target object is as follows:

[0024] Welding risk factor Welding risk factor interval Compare;

[0025] like , then the potential risk level of welding quality of the target object is judged to be level one;

[0026] like , then the potential risk level of welding quality of the target object is judged to be level 2;

[0027] like , then the potential risk level of welding quality of the target object is judged to be level three;

[0028] The potential risk levels of welding quality are ranked as follows: Level 3 > Level 2 > Level 1.

[0029] In a further solution, the working process of S40 is as follows:

[0030] S41, obtain the environmental parameter values ​​of the welding target object, including ambient temperature, ambient humidity and ambient wind speed, and then use the formula Calculate the environmental risk factor , where is the dimensionless coefficient, For the The ambient temperature detected at each monitoring point is , are the lower and upper limits of the ambient temperature, respectively. For the The ambient humidity detected at each monitoring point is For the The ambient wind speed detected at each monitoring point;

[0031] S42, obtaining the operating parameters of the welding gun during the welding process of the target object, and obtaining the welding gun risk coefficient after processing according to the preset rules ;

[0032] S43, according to the welding risk factor , Environmental risk factor And welding gun risk factor Get the quality risk index function of the target object welding ;

[0033] S44, through the quality risk indicator function Obtain the quality risk index at the tth moment ;

[0034] S45, and preset quality risk indicator thresholds For comparison, if , a quality risk warning is issued. , no quality risk warning will be issued.

[0035] In a further embodiment, the quality risk indicator function

[0036] ;

[0037] Quality risk index at the tth moment ;

[0038] In the formula, is the welding risk coefficient at the tth moment, is the environmental risk coefficient at the tth moment, is the welding gun risk coefficient at the tth moment, , , is the weight factor.

[0039] A further solution is to obtain the welding gun risk factor The process is:

[0040] By formula Calculate the risk factor of welding gun ;

[0041] In the formula, For the Welding gun operating parameters, is the total number of welding gun operating parameters, For the Preset fixed coefficients for various welding gun operating parameters.

[0042] In a further embodiment, the weight factor , , The acquisition process is:

[0043] By formula Calculate the weight factor , , ;

[0044] In the formula, is the reference value of the environmental risk factor, Reference value of welding gun risk factor, is the level of potential risk to welding quality, It is the reference value of welding risk factor.

[0045] Beneficial effects of the present invention:

[0046] The present invention can detect the welding quality in real time during the welding of the volute seat ring, so as to predict the subsequent welding quality in advance according to the quality of the already welded part. Obviously, if the welding deviation value exceeds the welding deviation threshold, it means that the potential quality risk of welding is relatively large. Therefore, it is necessary to analyze the cause to save time for adjusting the subsequent welding process. Finally, the welding deviation value, environmental parameter value and welding gun operating parameters are subjected to quality risk analysis. According to the results of the risk analysis, the overall quality risk size and the probability of problems in related projects can be seen, so as to determine whether to issue a quality risk warning. According to the quality risk warning, whether the casting process of the target object is continued is controlled, so as to reduce unnecessary casting when the welding quality is questionable, resulting in waste of casting materials, thereby playing a role in saving costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The present invention will be further described below in conjunction with the accompanying drawings.

[0048] Figure 1 It is a diagram of the method steps of the present invention. DETAILED DESCRIPTION

[0049] The following will be combined with the 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, not 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 are within the scope of protection of the present invention.

[0050] See also Figure 1 As shown, the present invention is a method for controlling the quality of volute seat ring welding and casting, comprising the following steps:

[0051] S10, selecting corresponding theoretical welding parameter values ​​according to the material of the target object and the preset welding process;

[0052] S20, real-time collection of actual welding parameter values, environmental parameter values ​​and operating parameters of the welding gun during the welding process of the target object; it should be noted that: the welding parameters include but are not limited to voltage, current, welding speed, welding temperature, and weld shape, wherein the actual welding parameter values ​​are detected and obtained according to professional detection sensors and monitoring instruments, and the weld shape is obtained through a monitoring camera, and the theoretical welding parameter values ​​are obtained by looking up the table after the comparison table is determined based on historical data and experimental data simulation, which will not be repeated here;

[0053] S30, performing cumulative analysis based on the difference between each actual welding parameter value and the theoretical welding parameter value to obtain a welding deviation value, and comparing the welding deviation value with a preset welding deviation threshold value. If the welding deviation value exceeds the welding deviation threshold value, it is determined that there is a potential risk to the welding quality of the target object;

[0054] S40, performing a quality risk analysis on the welding deviation value, the environmental parameter value and the operating parameters of the welding gun, and determining whether to issue a quality risk warning according to the result of the risk analysis;

[0055] S50. Control whether the casting process of the target object continues according to the quality risk warning.

[0056] The working process of S30 is as follows:

[0057] Based on the detection sensor, the Actual welding parameter values ;

[0058] By formula Calculate the welding deviation value ; In the formula For the The weight coefficient of each welding parameter, For the Theoretical welding parameter values, is the total number of welding parameters, For the The comparison difference between the actual welding parameter value and the theoretical welding parameter value is obtained based on the analysis of experimental data and empirical data;

[0059] Welding deviation value The welding deviation threshold is set For comparison:

[0060] like , it is judged that the target object has potential risk in welding quality;

[0061] Otherwise, it is determined that the target object does not have a potential risk to welding quality.

[0062] In the present invention, the corresponding theoretical welding parameter value is first selected according to the material of the target object and the preset welding process, and then the actual welding parameter value, environmental parameter value and operating parameters of the welding gun in the process of welding the target object are collected in real time. Subsequently, the difference between the actual welding parameter value and the theoretical welding parameter value is cumulatively analyzed and a welding deviation value is obtained. The welding deviation value is compared with a preset welding deviation threshold value. If the welding deviation value exceeds the welding deviation threshold value, it is judged that there is a potential risk in the welding quality of the target object. Through the above technical scheme, the welding quality can be detected in real time during the welding of the volute seat ring, so that the next welding can be evaluated according to the quality of the already welded part. Welding quality is predicted in advance. Obviously, if the welding deviation value exceeds the welding deviation threshold, it means that the potential quality risk of welding is relatively large. Therefore, it is necessary to analyze the cause to save time for the adjustment of the next welding process. Finally, the welding deviation value, environmental parameter value and welding gun operating parameters are analyzed for quality risk. According to the results of the risk analysis, the overall quality risk and the probability of problems in related projects can be seen, so as to determine whether to issue a quality risk warning. According to the quality risk warning, the casting process of the target object is controlled to continue, so as to reduce unnecessary casting when the welding quality is questionable, resulting in waste of casting materials, thereby saving costs;

[0063] And through the formula Calculate the welding deviation value , obviously The larger the difference, the greater the deviation of the corresponding welding parameters. By accumulating the deviation of each welding parameter, the welding deviation value can be accurately reflected in real time. , and then according to the welding deviation value The welding deviation threshold is set The comparison results can be used to determine whether the target object has potential welding quality risks, providing strong support for early intervention and timely suspension of the welding process, thereby reducing losses.

[0064] The working process of S30 also includes:

[0065] like , then the current time Go back a preset period , get the starting time point , fitting Data on the change of welding deviation value over time during the detection period ;

[0066] Obtain reference data on welding deviation values ​​over time based on historical data ;

[0067] By formula Calculate the welding risk factor ; In the formula, for Above and The total area of ​​the area enclosed below, for Below and The total area of ​​the area enclosed above, , It is the area warning value, which is determined based on historical data and experimental data; For one Divide the quantity into multiple time periods. For the The impact coefficient corresponding to each time period is determined based on historical data. , is the preset proportional coefficient;

[0068] According to the welding risk factor Determine the potential risk of welding quality of the target object.

[0069] According to the welding risk factor The process of determining the potential risk of welding quality of the target object is as follows:

[0070] Welding risk factor Welding risk factor interval Compare;

[0071] like , then the potential risk level of welding quality of the target object is judged to be level one;

[0072] like , then the potential risk level of welding quality of the target object is judged to be level 2;

[0073] like , then the potential risk level of welding quality of the target object is judged to be level three;

[0074] The potential risk levels of welding quality are ranked as follows: Level 3 > Level 2 > Level 1.

[0075] In the present invention, first fitting Data on the change of welding deviation value over time during the detection period , and then through the formula Calculate the welding risk factor Obviously, if The greater the deviation, the greater the welding risk factor The larger the welding quality, the higher the risk. , comprehensive consideration and The ratio of the enclosed area to the area warning value is obviously The closer , it means that the higher the overall welding risk, the higher the potential risk level after welding. Welding risk factor interval By comparison, the potential risk level of the welding quality of the target object is judged as level one, level two or level three. Obviously, the higher the level, the higher the probability that there is a problem with the welding quality.

[0076] The working process of S40 is as follows:

[0077] S41, obtain the environmental parameter values ​​of the welding target object, including ambient temperature, ambient humidity and ambient wind speed, and then use the formula Calculate the environmental risk factor , where is the dimensionless coefficient, For the The ambient temperature detected at each monitoring point is , are the lower and upper limits of the ambient temperature, respectively. For the The ambient humidity detected at each monitoring point is For the The ambient wind speed detected at each monitoring point;

[0078] S42, obtaining the operating parameters of the welding gun during the welding process of the target object, and obtaining the welding gun risk coefficient after processing according to the preset rules ;

[0079] S43, according to the welding risk factor , Environmental risk factor And welding gun risk factor Get the quality risk index function of the target object welding ;

[0080] S44, through the quality risk indicator function Obtain the quality risk index at the tth moment ;

[0081] S45, and preset quality risk indicator thresholds For comparison, if , a quality risk warning is issued. , no quality risk warning will be issued.

[0082] The quality risk indicator function ;

[0083] Quality risk index at the tth moment ;

[0084] In the formula, is the welding risk coefficient at the tth moment, is the environmental risk coefficient at the tth moment, is the welding gun risk coefficient at the tth moment, , , is the weight factor.

[0085] In the present invention, the welding risk factor , Environmental risk factor And welding gun risk factor Get the quality risk index function of the target object welding , , so that the comprehensive welding risk factor of the target object during the welding process can be calculated , Environmental risk factor And welding gun risk factor Establish a prediction model to improve the accuracy of quality risk warning, and also obtain the quality risk index at the tth moment ,according to and preset quality risk indicator thresholds The comparison results can be used to determine the quality risk of the welding of the current target object, and to issue quality warnings in a timely and accurate manner, providing a basis for judging whether to carry out the subsequent casting process.

[0086] Get the welding gun risk factor The process is:

[0087] By formula Calculate the risk factor of welding gun ;

[0088] In the formula, For the Welding gun operating parameters, is the total number of welding gun operating parameters, For the Preset fixed coefficients for various welding gun operating parameters.

[0089] The present invention adopts the formula Calculate the risk factor of welding gun Obviously, the greater the change of each welding gun operating parameter, the higher the final welding gun risk factor. The smaller it is, the more accurately the operating risk of the welding gun can be reflected through the above technical solution; it should be noted that the operating parameters of the welding gun include but are not limited to the welding gun angle, the welding gun movement speed and the welding gun swing amplitude. The above operating parameters are obtained through various detection sensors and monitoring cameras, and will not be elaborated here.

[0090] The weight factor , , The acquisition process is:

[0091] By formula Calculate the weight factor , , ;

[0092] In the formula, is the reference value of the environmental risk factor, Reference value of welding gun risk factor, is the level of potential risk to welding quality, It is the reference value of welding risk factor.

[0093] In the present invention, by formula Calculate the weight factor , , , so that the corresponding weight factor value can be dynamically updated and iterated, thereby avoiding the situation where the quality risk index cannot be accurately calculated due to the fixed weight factor value, and ultimately leads to the omission of quality risk warning.

[0094] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. A method for controlling the quality of welding and casting of a volute seat ring, characterized in that: The steps include: S10, selecting corresponding theoretical welding parameter values ​​according to the material of the target object and the preset welding process; S20, collecting in real time actual welding parameter values, environmental parameter values ​​and operating parameters of the welding gun during the welding process of the target object; S30, performing cumulative analysis based on the difference between each actual welding parameter value and the theoretical welding parameter value to obtain a welding deviation value, and comparing the welding deviation value with a preset welding deviation threshold value. If the welding deviation value exceeds the welding deviation threshold value, it is determined that there is a potential risk to the welding quality of the target object; S40, performing a quality risk analysis on the welding deviation value, the environmental parameter value and the operating parameters of the welding gun, and determining whether to issue a quality risk warning according to the result of the risk analysis; S50, controlling whether the casting process of the target object continues according to the quality risk warning; The working process of S30 is as follows: Based on the detection sensor, the Actual welding parameter values ; By formula Calculate the welding deviation value ; In the formula For the The weight coefficient of each welding parameter, For the Theoretical welding parameter values, is the total number of welding parameters, For the The comparison difference between the actual welding parameter value and the theoretical welding parameter value; Welding deviation value The welding deviation threshold is set For comparison: like , it is judged that the target object has potential risk in welding quality; Otherwise, it is judged that the target object does not have a potential risk to welding quality; The working process of S30 also includes: like , then the current time Go back a preset period , get the starting time point , fitting Data on the change of welding deviation value over time during the detection period ; Obtain reference data on welding deviation values ​​over time based on historical data ; By formula Calculate the welding risk factor ; In the formula, for Above and The total area of ​​the area enclosed below, for Below and The total area of ​​the area enclosed above, , is the area warning value; For one Divide the quantity into multiple time periods. For the The impact coefficient corresponding to each time period is: , is the preset proportional coefficient; According to the welding risk factor Determine the potential risk of welding quality of target objects; According to the welding risk factor The process of determining the potential risk of welding quality of the target object is as follows: Welding risk factor Welding risk factor interval Compare; like , then the potential risk level of welding quality of the target object is judged to be level one; like , then the potential risk level of welding quality of the target object is judged to be level 2; like , then the potential risk level of welding quality of the target object is judged to be level three; The potential risk levels of welding quality are ranked as follows: Level 3 > Level 2 > Level 1; The working process of S40 is as follows: S41, obtain the environmental parameter values ​​of the welding target object, including ambient temperature, ambient humidity and ambient wind speed, and then use the formula Calculate the environmental risk factor , where is the dimensionless coefficient, For the The ambient temperature detected at each monitoring point is , are the lower and upper limits of the ambient temperature, respectively. For the The ambient humidity detected at each monitoring point is For the The ambient wind speed detected at each monitoring point; S42, obtaining the operating parameters of the welding gun during the welding process of the target object, and obtaining the welding gun risk coefficient after processing according to the preset rules ; S43, according to the welding risk factor , Environmental risk factor And welding gun risk factor Get the quality risk index function of the target object welding ; S44, through the quality risk indicator function Obtain the quality risk index at the tth moment ; S45, and preset quality risk indicator thresholds For comparison, if , a quality risk warning is issued. , no quality risk warning will be issued.

2. The method for controlling the quality of the volute seat ring welding and casting according to claim 1 is characterized in that: The quality risk indicator function ; Quality risk index at the tth moment ; In the formula, is the welding risk coefficient at the tth moment, is the environmental risk coefficient at the tth moment, is the welding gun risk coefficient at the tth moment, , , is the weight factor.

3. The method for controlling the quality of the volute seat ring welding and casting according to claim 1 is characterized in that: Get the welding gun risk factor The process is: By formula Calculate the risk factor of welding gun ; In the formula, For the Welding gun operating parameters, is the total number of welding gun operating parameters, For the Preset fixed coefficients for various welding gun operating parameters.

4. The method for controlling the quality of the volute seat ring welding and casting according to claim 2 is characterized in that: The weight factor , , The acquisition process is: By formula Calculate the weight factor , , ; In the formula, is the reference value of the environmental risk factor, Reference value of welding gun risk factor, is the level of potential risk to welding quality, It is the reference value of welding risk factor.

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