Monitoring device for multiple welding devices

Abstract

A monitoring device for multiple welding devices belongs to the technical field of information, is used for solving the problems that operation is scattered, information transmission is unsmooth and process parameters cannot be recorded due to the fact that the multiple welding devices cannot be monitored in a centralized mode, and comprises a field data collecting assembly, a multi-channel serial port server, a multi-channel AI module and a monitoring terminal which are electrically connected. The transmission of data or information of the whole monitoring device is realized; the on-site data acquisition assembly is used for acquiring various on-site data needing to be monitored, the on-site data acquisition assembly is in communication connection with the multi-channel serial port server and is used for realizing data transmission, and the output end of the welding equipment is provided with the multi-channel AI module and is used for acquiring output parameters of the welding equipment and transmitting the output parameters to the multi-channel serial port server. And the monitoring terminal is used for displaying data from the field data acquisition assembly and data from the multi-channel AI module and is used for man-machine interaction. And high-cost-performance welding operation informatization transformation and one-stop monitoring requirements of welding operation are met.

Description

Technical Field

[0001] The present invention relates to the field of information technology, and in particular to a management device and method for welding equipment. Background Art

[0002] Casting welding is a repair technology that melts metal and fills it into defective areas of castings. It involves a variety of welding methods and technical requirements. Limited by industry characteristics and operating costs, the more common welding machines at casting sites are manual arc welding and gas shielded welding. Among them, manual arc welding has DC welding and AC welding, and gas shielded welding is generally DC welding.

[0003] The choice of welding process depends on the material, size, position, thickness, complexity, defect type and size of the casting, as well as cutting and technical requirements. Some preparations need to be made before welding, such as removing oil, rust and sand inclusions, beveling or preheating, electrode selection and drying, etc. During welding, attention should be paid to key process parameters such as voltage, current, welding speed, and shielding gas flow rate, as well as whether there is overheating and abnormal whistling inside the welding machine equipment; report the work after welding is completed.

[0004] In addition, the welding process mainly transmits information in paper form, the process and text management are inefficient, raw materials are seriously wasted, and there is a lack of accurate and transparent data accumulation; welding quality is mainly checked after the fact, which is time-consuming and labor-intensive, and difficult to trace; welding management lacks full-process data support and relies heavily on experience, and urgently needs end-to-end digitization and transparency. The problem was not discovered until the equipment was seriously damaged, resulting in long-term equipment downtime.

[0005] The relevant patent search results are as follows:

[0006] 1. Tangshan Matsushita Industrial Machinery Co., Ltd.'s "Welding Power Supply Control Device and Welding Power Supply" application number is CN201922302620.1, which relates to the field of welding technology, and in particular to a welding power supply control device and a welding power supply. The welding power supply control device includes a data communication unit, an over-specification judgment unit and a control unit, wherein: the data communication unit can be connected to the welding management server and receive the standard welding parameters of the welding power supply from the welding management server; the control unit is used to detect the actual welding parameters when the welding power supply is working; the over-specification judgment unit is connected to the data communication unit and the control unit, and can collect standard welding parameters from the data communication unit and actual welding parameters from the control unit, and compare the standard welding parameters with the actual welding parameters, and when the actual welding parameters exceed the range of the standard welding parameters, the over-specification judgment unit notifies the control unit to control the welding power supply to stop working. The welding power supply control device can remind welding operators to set welding parameters that meet process specifications, thereby avoiding welding quality problems.

[0007] 2. Wuhan Zhuoyu Innovation Technology Co., Ltd.'s "Industrial-grade welding equipment welding wire consumption and wire feeding speed data acquisition device", application number CN202221876796.3, relates to an industrial-grade welding equipment welding wire consumption and wire feeding speed data acquisition device, including a shell, the bottom of the shell is provided with an introduction nozzle, the top of the shell is provided with an outlet nozzle, the upper left side of the fixed wheel is provided with a speed measuring wheel, the upper right side of the fixed wheel is provided with a clamping wheel, the welding wire passes through the fixed wheel and then passes between the speed measuring wheel and the clamping wheel to reach the outlet nozzle, a spring regulator for adjusting pressure is provided between the clamping wheel and the speed measuring wheel, a speed measuring sensor is provided on the outside of the shell, the speed measuring sensor is externally connected to a data acquisition module, and the data acquisition module is connected to a communication conversion module. The utility model effectively solves the current lack of stable and high-precision data acquisition means for the consumption and speed of welding wires in welding equipment, and provides data support for welding process optimization, welding cost accounting, and welding production management in digital factory construction.

[0008] 3. Shanghai Xingyuan Software Co., Ltd.'s "An Intelligent Recording and Analysis System for Electroslag Welding Machine", application number CN202211270527.7, provides an intelligent recording and analysis system for electroslag welding machine, including MCU control module, signal data acquisition module, 4G communication module, power supply system, equipment connection module and human-computer interaction terminal. The power supply system is used to provide a constant voltage source and / or constant current source for each power module; the equipment connection module is used to provide an interface for connecting the electroslag welding machine with the signal data acquisition module; the signal data acquisition module is used to implement signal acquisition for monitoring voltage, current, and working time and transmit the collected signal to the MCU control module; the MCU control module is used to analyze the collected signal, and then process the signal through the protocol, generate corresponding data, and record it in sequence; 4G communication module: used to receive the data processed by the MCU control module and upload it to the server; the human-computer interaction terminal is used for user operation. The present invention realizes real-time acquisition, analysis and processing, online display and dynamic storage of electroslag welding machine parameters, and has a wide range of applications.

[0009] 4. Inspur General Software Co., Ltd.'s "A welding machine management and evaluation method, equipment and medium based on the Internet of Things", application number CN202310069891.5, discloses a welding machine management and evaluation method, equipment and medium based on the Internet of Things, belonging to the field of electrical digital data processing technology. Among them, the method includes: determining the management constraints of the welding machine and the core functions of the welding machine, and determining the management granularity corresponding to the core functions according to the management constraints; according to the management granularity, screening out multiple characteristic parameters for evaluating the performance of the welding machine from a number of candidate characteristic parameters; during the operation of the welding machine, collecting characteristic values ​​corresponding to multiple characteristic parameters at preset time intervals; determining the evaluation modes corresponding to the multiple characteristic parameters, and evaluating the characteristic values ​​corresponding to each characteristic parameter through the evaluation mode to obtain the evaluation values ​​corresponding to the multiple characteristic parameters; determining the characteristic weights corresponding to the multiple characteristic parameters, and weighted summing the evaluation values ​​according to the characteristic weights to obtain the comprehensive evaluation value of the welding machine.

[0010] 5. Lianyungang Metrology Verification and Testing Center's "AC / DC welding machine online calibration device", application number CN202320414123.4, discloses an AC / DC welding machine online calibration device, including a portable box, a fluxgate current sensor for measuring the current of the AC / DC welding machine is installed on the box, a mainboard for cooperating with the fluxgate current sensor is installed in the box, a controller and a data collector cooperating with the fluxgate current sensor are installed on the mainboard, the signal feedback end of the fluxgate current sensor is connected to the data collector through a load resistor, and the data collector is connected to the input end of the controller; a touch screen for information display and command input and an external correction terminal for introducing a standard signal are also installed on the box, the touch screen is connected to the controller, and the external correction terminal is connected to the data collector. This application is light and compact, and cheap, and its functions and performance fully meet the requirements of welding machine detection, and is particularly suitable for daily quality control of welding machines.

[0011] 6. Fuwei Benteler Automotive Parts (Tianjin) Co., Ltd.'s "A new resistance welding machine with data acquisition function" application number is CN202322234460.8, which provides a new resistance welding machine with data acquisition function, including a resistance welding machine, the resistance welding machine includes a resistance welding machine controller, and also includes a PLC controller, a switch, an HMI human-machine interface touch screen, a data collector and a power supply; the PLC controller is connected to the resistance welding machine and the switch respectively, and the switch is connected to the HMI human-machine interface touch screen and the data collector; the HMI human-machine interface touch screen is provided with a monitoring page for displaying the current status of the signal input pin and / or signal output pin; the HMI human-machine interface touch screen is provided with a data display area for displaying the number of production points; the utility model aims to propose a new resistance welding machine with data acquisition function, which is suitable for resistance welding machines, realizes welding data acquisition, provides underlying data support for information-based production, and provides basic data for the factory's intelligent scheduling and production.

[0012] 7. Dezhou Diget Electronic Technology Co., Ltd.'s "A Welding Data Collector" application number is CN202322564490.5, which discloses a welding data collector, including a first mounting frame and a second mounting frame located behind the first mounting frame, a circuit board is fixedly installed inside the second mounting frame, and a transformer is fixedly installed at the rear of the inner cavity of the second mounting frame and on one side of the circuit board. The utility model relates to the technical field of data collectors. The welding data collector scans the worker's IC card through the card reader in the mounting port of the first mounting frame, so that it can be known which welder is performing the welding operation. The data collector adopts an industrial-grade embedded chip design, and the input end anti-interference measures are perfect. It can be applied to pulse welding machines, argon arc welding and other high-frequency arc ignition welding machines with strong external interference. Any networking mode of wired Ethernet, WIFI, and 4G can be selected, and it has an RS485 bus to expand a variety of external devices. It has a built-in 12-bit D / A converter to ensure data sampling accuracy, and a built-in large-capacity offline memory to ensure data integrity.

[0013] 8. Guangdong Light Industry Vocational and Technical College's "A method and system for managing the operation of a variable frequency welding machine" has an application number of CN202311338547.8, which discloses a method and system for managing the operation of a variable frequency welding machine. The system includes a local controller, a wireless transmission network, a memory, a data sampler, a cloud management system, and a receiving terminal; the data sampler is used to collect working current, working voltage, and wire feeding speed data; the local controller is used for local calculation and analysis; the memory is used to save the measured data; the wireless transmission network is used to send the measured data to the cloud management system; the cloud management system is used to analyze the cause of the failure of the variable frequency welding machine based on the received data; the receiving terminal wirelessly receives the cause of the failure of the variable frequency welding machine sent by the cloud management system. The present invention adopts a variable data acquisition frequency according to the specific situation to avoid the waste of computing resources. Ordinary operations are only performed in the local controller, and the measured data is only transmitted to the cloud management system for analysis under the set conditions, so that the cloud management system is responsible for the management of multiple variable frequency welding machines as much as possible.

[0014] 9. Nanjing Aote Wisdom Digital Technology Co., Ltd.'s "An Intelligent Integrated Networked Online Collection System and Method for Manual Welding Machine" application number is CN202410095447.5, which discloses an intelligent integrated networked online collection system for manual welding machine, which relates to the technical field of welding equipment, including an electric welder, an electric welding clamp assembly, and an integrated collection terminal connected between the electric welder and the electric welding clamp assembly, wherein the integrated collection terminal includes: a data acquisition module for real-time collection of welding parameters of the electric welder; a data analysis module for analyzing the collected welding parameters and determining whether the welding parameters are abnormal; a wireless communication module for transmitting the collected welding parameters to the host computer; and a power supply module for powering other functional modules. The present invention realizes intelligent control, data collection and analysis of manual welding machines, improves welding efficiency and welding quality, and reduces production costs and safety risks. At the same time, the system is simple to operate, easy to implement and maintain, and has broad application prospects.

[0015] 10. Shenzhen Megmeet Welding Technology Co., Ltd.'s application number for "A welding management method, server and user terminal" is CN202010208053.8, which relates to the field of welding technology and discloses a welding management method, server and user terminal. The method includes: receiving the workpiece code, the welder's identity and the equipment identification code of the welding machine sent by the user terminal; determining the preset welder qualification corresponding to the workpiece code according to the workpiece code; determining the welder qualification corresponding to the welder according to the welder's identity; when the welder qualification meets the preset welder qualification, the process parameters corresponding to the workpiece code are sent to the welder according to the equipment identification code of the welder, so that the welder performs the corresponding welding operation. In this way, intelligent management of welding production is realized, the labor cost of welding production management is reduced, and the quality of welding production is improved.

[0016] The above patent or similar patents may have a built-in digital control docking module in the welding machine itself, or use a similar encoder method to measure the wire feeding speed and consumption; or collect data based on a stand-alone MCU circuit board or PLC, and after wired wireless communication transmission and edge computing, cooperate with the background or cloud to evaluate the characteristic parameters of the welding machine; or develop a welding machine calibration device to perform welding machine inspection and quality control; or adopt a combination of server and client to perform operation management based on the workpiece binding welder qualification method.

[0017] However, for welding processing in the traditional casting industry, especially the multi-variety and small-batch process, in order to cope with complex and changeable workpieces and simplify the management process, it is often necessary to form a group of welding tables with multiple welding machines to facilitate multiple operators to perform welding operations in parallel.

[0018] Limited by cost control and input-output ratio considerations, the main demands of welding control in the current foundry industry are to carry out welding rod and wire drying process and material collection management based on the current existing welding machines, welding plan review and quality inspection reporting, welding process issuance and execution monitoring, welding machine abnormality alarm, as well as statistical analysis of energy consumption, defects, costs, etc.

[0019] The above or similar patents do not involve how to achieve real-time monitoring of the welding process, do not cover the core demands of management and control, and are only applicable to batch specialized single welding machine operations. For multi-variety small-batch production lines, there are problems such as high cost investment, scattered on-site modules or large occupied space, relatively high pre-setting requirements, and poor on-site operability. They cannot fully adapt to their one-stop monitoring and high cost-effectiveness requirements. Summary of the invention

[0020] In view of the above problems in the foundry industry, such as the inability to centrally monitor multiple welding equipment operating simultaneously, scattered operations, poor information transmission between each other, and inability to record process parameters, it is necessary to propose a monitoring device and a monitoring method for multiple welding equipment, so that a set of monitoring devices can simultaneously monitor the process parameters of multiple welding equipment, realize distributed control of welding materials, welding plans and welding processes, and realize one-stop digital management of welding operations.

[0021] A monitoring device for multiple welding equipment comprises a field data acquisition component, a multi-channel serial port server, a multi-channel AI module and a monitoring terminal. The components are electrically connected to realize the transmission of data or information of the entire monitoring device; the field data acquisition component is used to collect various data that need to be monitored on site, the field data acquisition component is communicatively connected with the multi-channel serial port server to realize data transmission, the output end of the welding equipment is provided with the multi-channel AI module to collect output parameters of the welding equipment, and the monitoring terminal is used to display data from the field data acquisition component, data from the multi-channel AI module and for human-computer interaction.

[0022] This solution can collect the parameters of several welding equipment on site and the actual parameters of the welding operation at the same time, realize the simultaneous monitoring of the welding operations of multiple welding equipment, realize the digitization of data, improve the accuracy and timeliness of data, and realize the comprehensive monitoring of the welding process. The present invention solves the problems of scattered operations, poor information transmission, and inability to record process parameters caused by the inability to centrally monitor multiple welding equipment.

[0023] Furthermore, the field data acquisition component includes a power acquisition device for collecting power data, a temperature and vibration acquisition device for temperature and vibration, a speed acquisition device for collecting wire feeding speed, a flow acquisition device for collecting shielding gas flow, a current acquisition device for collecting welding equipment output current, etc., to realize the collection of actual values ​​of various parameters of the welding operation, that is, to realize the monitoring of welding parameters, to avoid deviation of the welding operation and cause unqualified weld quality.

[0024] Furthermore, the field data acquisition component and the multi-channel serial port server use an RS485 interface and a universal ModbusRTU protocol, and provide an RJ45 interface and ModbusTCP communication protocol, providing technical support for simultaneously monitoring several welding devices.

[0025] Furthermore, the output end of the multi-channel AI module is connected to Ethernet using the ModbusTCP communication protocol to achieve the purpose of uploading the collected data to the monitoring terminal.

[0026] Furthermore, the multi-channel AI module is used to collect the output current of the welding equipment. A voltage transmitter and a current transformer are provided at the output end of the AC welding equipment to convert the output AC voltage into a DC current and connect it to the multi-channel AI module to realize the collection of the output current; a current transformer is provided at the output end of the DC welding equipment to convert the output DC voltage into a DC current and connect it to the multi-channel AI module to realize the collection of the output current.

[0027] Furthermore, the external interface of the monitoring terminal is an RJ45 interface or a WIFI interface, which realizes communication with the on-site data acquisition component, the multi-channel serial port server and the multi-channel AI module.

[0028] Furthermore, the method for multi-channel AI module to collect data, that is, the method for multi-channel AI module to collect data, includes:

[0029] 1) If the voltage is monitored, specifically,

[0030] Use a voltage detection instrument to detect the voltage Xv output by the welding equipment;

[0031] In the voltage range of 0-100V, a quadratic curve of voltage variation is fitted with a voltage value at every 5V interval to obtain fitting coefficients K2v, K1v and K0v;

[0032] The corrected welding equipment output voltage Yv=K2v*Xv*Xv+K1v*Xv+K0v.

[0033] 2) If the current is monitored, specifically,

[0034] Use a current detection instrument to detect the voltage Xi output by the welding equipment;

[0035] In the voltage range of 0-100A, a quadratic curve of voltage variation is fitted with a voltage value at every 5A interval to obtain fitting coefficients K2i, K1i and K0i;

[0036] The corrected welding equipment output voltage Yi=K2i*Xi*Xi+K1i*Xi+K0i.

[0037] Through the above method, possible deviations in data collection can be effectively avoided and the accuracy of collected data can be improved.

[0038] In order to realize the systematization of data management, the monitoring device of the plurality of welding equipments further comprises a welding management device, which comprises a login management module, a welding rod management module, a plan viewing module, a quality inspection and reporting module, a process management module and an abnormality management module.

[0039] The login management module is used to support user login and logout, and realize information tracking of welding operators;

[0040] The welding rod management module is used to manage and track the welding rod usage process, including welding rod preheating equipment such as drying furnaces and holding furnaces;

[0041] The plan viewing module is used for welding operators to view the welding process of the workpiece to be welded;

[0042] The quality inspection and reporting module is used to save welding process data and welding completion inspection data, and generate welding record reports;

[0043] The process management module is used to load theoretical welding parameters of the workpiece to be welded, monitor the actual welding parameters, and compare the actual welding parameters with the theoretical welding parameters to understand the real-time status and operating parameters of the welding operation and realize the traceability of process data;

[0044] The abnormality management module is used to record abnormalities occurring during the welding process and to issue warnings and abnormality correction plans in a timely manner.

[0045] Furthermore, if the deviation between the actual welding parameters and the theoretical welding parameters is greater than the set threshold, the deviation value, deviation duration and deviation time are recorded, and a deviation warning is issued to guide the welding operator to adjust the welding parameters in time, thereby effectively managing the welding process and realizing closed-loop adjustable management of the welding process, thereby improving the welding quality and avoiding weld quality problems caused by detecting unqualified welding processes after the weld is formed.

[0046] Furthermore, the welding management device also includes an edge computing and statistical analysis module, which is used to statistically analyze various data that need to be controlled or monitored during the welding process of the workpiece, such as single-piece power consumption, shielding gas consumption, consumables usage and inventory, arc starting time, standby time, welding time, etc., which is used for statistical analysis of the welding process and realize digital management of the welding process.

[0047] The beneficial effects of the technical solution of the present invention are as follows: by comprehensively using various types of sensors and information modules in combination with control mechanisms, a cost-effective information transformation of welding operations in the foundry industry is achieved, the one-stop monitoring needs of welding operations are met, and information feedback and information distribution of the welding process are realized. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 It is a schematic diagram of a monitoring device for multiple welding equipment;

[0049] Figure 2 It is a schematic diagram of the welding management device. DETAILED DESCRIPTION

[0050] In order to more clearly illustrate the technical solution of the present invention, the technical solution of the invention content is described in detail in conjunction with the accompanying drawings. Obviously, the following descriptions are some typical embodiments of the present invention. For ordinary technicians in this field, other solutions can be obtained based on these embodiments without paying creative work.

[0051] The implementation method of the technical solution of the present invention is now described by taking the parallel centralized monitoring of five welding equipment as an example.

[0052] In one embodiment, the monitoring device for multiple welding devices includes a field data acquisition component, a multi-channel serial port server, a multi-channel AI module and a monitoring terminal. The various components are electrically connected to achieve the transmission of data or information of the entire monitoring device; the field data acquisition component is used to collect various types of data that need to be monitored on site, and the field data acquisition component is communicatively connected to the multi-channel serial port server to achieve data transmission. The output end of the welding equipment is provided with the multi-channel AI module to collect output parameters of the welding equipment, and the monitoring terminal is used to display data from the field data acquisition component, data from the multi-channel AI module, and for human-computer interaction.

[0053] In this embodiment, the field data acquisition components include a power acquisition device for collecting power data, a temperature and vibration acquisition device for temperature and vibration, a speed acquisition device for collecting wire feeding speed, a flow acquisition device for collecting shielding gas flow, a current acquisition device for collecting welding equipment output current, etc., to achieve the acquisition of actual values ​​of various parameters of the welding operation, that is, to achieve monitoring of welding parameters, to avoid deviation of welding operation and cause unqualified weld quality. The field data acquisition components all use RS485 interface and ModbusRTU communication protocol, which facilitates the connection with the multi-channel serial port server, and also realizes the universalization of the field connection interface, reduces the difficulty of operation, and improves the operation efficiency.

[0054] As a supplement to the present embodiment, the power collection device is an intelligent power meter, which can detect various power parameters such as three-phase AC voltage, current, power, electric energy, power factor, etc. The intelligent power meter is equipped with a current transformer and can be directly installed at the power input end of the welding equipment to realize the detection of the power used by the welding equipment; further, if it is necessary to detect the power consumption of several welding equipment at the same time, the intelligent power meter can be set at the power supply output end of the distribution cabinet, and then the output end of the intelligent power meter is connected to the power input end of the welding equipment respectively.

[0055] As a supplement to this embodiment, the temperature and vibration acquisition device is provided with a temperature sensor and a vibration sensor, and a magnetic base is provided at the bottom. The temperature and vibration acquisition device is set on the outer wall of the welding equipment through the magnetic base, specifically, on the outer wall of the high-temperature part of the welding equipment where a transformer and a rectifier are provided, so as to effectively detect the temperature changes and vibration conditions of the welding equipment, thereby realizing the monitoring of the internal temperature and howling abnormalities of the welding equipment.

[0056] As a supplement to this embodiment, the speed acquisition device is a wire feeding speed sensor, which is used to detect the travel speed of the welding rod or welding wire to ensure the welding quality of the weld.

[0057] As a supplement to this embodiment, the flow acquisition device is a gas flow meter, which is used to detect the usage or consumption of the shielding gas used in the gas shielded welding process, and ensure the quality of the weld by detecting the flow of the shielding gas.

[0058] As a supplement to this embodiment, the current acquisition device is a current sensor. For AC welding equipment, an AC voltage transmitter is provided on the welding equipment, which can convert the AC 0-100V voltage signal output by the welding equipment into a DC 4mA-20mA signal. The AC current sensor obtains the welding current and converts the obtained 0-500A AC current into a 4mA-20mA DC current; for DC welding equipment, the welding equipment outputs a DC voltage of 0-100V, the DC current sensor obtains the welding current, and converts the obtained 0-500A DC current into a 4mA-20mA DC current.

[0059] In this embodiment, the field data acquisition component is connected to the Ethernet via the ModbusTCP communication protocol to achieve data and information transmission between the two; the AC welding equipment uses a 4mA-20mA AC current signal to access the multi-channel AI module, and the DC welding equipment uses a 0-100V DC voltage signal to access the multi-channel AI module; the external interface of the multi-channel AI module uses the ModbusTCP communication protocol.

[0060] In this embodiment, the monitoring terminal is an industrial control integrated machine, and the external interface of the industrial control integrated machine is an RJ45 interface or a WIFI interface, which realizes communication with the on-site data acquisition component, the multi-channel serial port server and the multi-channel AI module; and the industrial control integrated machine is provided with an image acquisition instrument, an information storage module, an information reading module and an audio recognition module, so that the industrial control integrated machine can record the on-site images, the workpiece information, the voice input of the operator, etc., and realizes the digital management of the site. Specifically, the image acquisition instrument can be a camera set on the industrial control integrated machine, the information storage module can be a dual-frequency card reader, the information reading module can be a high-precision barcode recognition module, and the audio recognition module can be an audio IO port.

[0061] As a supplement to this implementation, the RJ45 interface of the industrial control integrated machine includes a LAN1 interface, a LAN2 interface and a WIFI interface, which are used to connect to the local area network of the work site to realize information transmission with the work site, and are also used to connect to the host computer to realize information transmission between the host computer. The LAN2 interface is used to connect to the field data acquisition component to obtain the collected data from the field data acquisition component, and the industrial control integrated machine then uploads the acquired collected data to the host computer to realize data analysis and storage. Specifically, the LAN1 interface and the WIFI interface use fixed IP addresses, and the network samples roaming terminals such as 4G, 5G and WIFI.

[0062] As a supplement to this embodiment, the image acquisition device is used to identify the face of the operator, and the information storage module is used to store various types of information. Through face recognition, the operator can quickly log in to the welding management device and record the login information, such as the login person, login time, logout time, etc.

[0063] As a supplement to this embodiment, the high-precision barcode recognition module is used to recognize the QR code or barcode on the workpiece, read the production and inspection information of the workpiece carried therein, and also facilitate the recording and connection of the transfer between processes.

[0064] As a supplement to this implementation, the audio IO port is used to connect to power amplifier devices such as speakers to realize the broadcasting functions of the industrial control integrated machine, such as voice reminders and alarms.

[0065] In this embodiment, the output end of the multi-channel AI module is connected to Ethernet using the ModbusTCP communication protocol to achieve the purpose of uploading the collected data to the monitoring terminal.

[0066] In this embodiment, the method for collecting voltage data by the multi-channel AI module includes:

[0067] 1) Use a voltage detection instrument to detect the voltage Xv output by the welding equipment;

[0068] 2) In the voltage range of 0-100V, a quadratic curve of voltage variation is fitted with a voltage value at every 5V interval to obtain fitting coefficients K2v, K1v and K0v;

[0069] 3) The output voltage of the welding equipment after correction is Yv=K2v*Xv*Xv+K1v*Xv+K0v.

[0070] In this embodiment, the method for collecting current data by the multi-channel AI module includes:

[0071] 1) Use a current detection instrument to detect the voltage Xi output by the welding equipment;

[0072] 2) In the voltage range of 0-100A, a voltage variation quadratic curve is fitted with a voltage value at every 5A interval to obtain fitting coefficients K2i, K1i and K0i;

[0073] 3) The output voltage of the welding equipment after correction is Yi=K2i*Xi*Xi+K1i*Xi+K0i.

[0074] Through the above method, possible deviations in data collection can be effectively avoided and the accuracy of collected data can be improved.

[0075] In another embodiment, the monitoring device for the plurality of welding devices further comprises a welding management device, wherein the welding management device comprises a login management module, a welding rod management module, a plan viewing module, a quality inspection and reporting module, a process management module and an abnormality management module.

[0076] The login management module is used to support user login and logout, and realize information tracking of welding operators; operators log in through face recognition scanning on the monitoring terminal, or operators log in through card recognition swiping on the monitoring terminal, so as to effectively match the current operators and realize personnel traceability in the production process;

[0077] The welding rod management module is used to manage and track the welding rod usage process, including welding rod preheating equipment such as drying furnaces and holding furnaces;

[0078] The plan viewing module is used for welding operators to view the welding process of the workpiece to be welded;

[0079] The quality inspection and reporting module is used to save welding process data and welding inspection data, and generate a welding record report; specifically, after welding is completed, the operator enters the welding process and weld inspection and other inspection data into the quality inspection and reporting module. After the inspection is qualified, the reporting of the current workpiece to be welded is completed, and a welding record report is generated; otherwise, the welding defect processing process is triggered;

[0080] The process management module is used to load theoretical welding parameters of the workpiece to be welded, monitor the actual welding parameters, and compare the actual welding parameters with the theoretical welding parameters to understand the real-time status and operating parameters of the welding operation and realize the traceability of process data;

[0081] The abnormality management module is used to record abnormalities occurring during the welding process, and to issue warnings and abnormality correction plans in a timely manner; for example, when the temperature and vibration acquisition device detects that the temperature value or the three-axis acceleration value of the welding equipment exceeds the standard for a period of time longer than the set period, the excessive temperature value and the three-axis acceleration value are transmitted to the abnormal data table, and the abnormality type is recorded, and the abnormality type is displayed in the human-computer interaction interface of the industrial control all-in-one machine, and an alarm prompt sound is issued. The operating personnel maintain the equipment according to the abnormality type of the alarm, thereby reducing the damage caused by the overload operation of the equipment, such as shortening the service life of the equipment and affecting the welding quality of the weld.

[0082] As a supplement to this embodiment, the welding rod management module can complete the management of the entire process of welding rod collection, preheating, insulation and returning to the warehouse. Specifically, the operator collects the welding rod from the welding rod warehouse to the drying process, and uses the information reading module of the industrial control integrated machine at the drying process to identify the QR code on the welding rod, read the information of the welding rod collected, such as the name of the welding rod, the model / brand of the welding rod, the batch number of the welding rod, etc., and enter the number of welding rods collected in the industrial control integrated machine. The welding management device matches the read welding rod information with the welding rod information to be collected, and gives the drying process of the welding rod, such as drying temperature, drying time, insulation temperature, insulation time, number of stacking layers, etc., to facilitate the operator to preheat the welding rod. The welding rods that have passed the preheating are stored in an insulation furnace or insulation cylinder, so that the welding rods can be taken and used at any time, which improves welding efficiency and avoids waiting time. The excess welding rods can be re-pasted with the QR code and returned to the welding rod warehouse.

[0083] As a supplement to this embodiment, in the plan viewing module, the operator clicks to obtain the welding plan or scans the QR code of the workpiece to be welded or enters the number information of the workpiece to be welded, and the welding management device automatically matches the information, defect information, welding process, quality control points, etc. of the workpiece to be welded, so as to realize the query and implementation of the welding process of the workpiece to be welded.

[0084] As a supplement to this embodiment, in the abnormal management module, if the deviation value between the actual welding parameters and the theoretical welding parameters is greater than the set threshold, the deviation value, deviation duration and deviation time are recorded, and a deviation warning is issued to guide the welding operators to adjust the welding parameters in time and implement welding process management, thereby realizing closed-loop adjustable management of the welding process, improving the welding quality, and avoiding weld quality problems caused by detecting unqualified welding processes after the weld is formed.

[0085] As a supplement to this implementation mode, the industrial control all-in-one machine displays the changes in the actual welding parameters obtained in the form of real-time waveform graphs and texts, so that the operators can view the current actual welding situation, ensure the smooth and normal progress of the welding operation, ensure the welding quality of the weld, and also record the changes in the welding process parameters, which facilitates the traceability of the welding process.

[0086] In this embodiment, the welding management device also includes an edge computing and statistical analysis module, which is used to statistically analyze various data that need to be controlled or monitored during the workpiece welding process, such as single-piece power consumption, shielding gas consumption, consumables usage and inventory, arc starting time, standby time, welding time, etc., which is used for statistical analysis of the welding process and realize digital management of the welding process.

[0087] The present invention realizes low-cost parallel control of multiple welding equipment by adopting a cost-effective multi-channel serial port server and a multi-channel AI module, thereby improving the digital management of welding equipment; by setting up an industrial control all-in-one monitoring terminal, it realizes the effective transmission and recording of production site data, and realizes traceable monitoring and recording of the production process; by setting up a welding management device, it realizes statistical analysis and quality analysis of the welding process, and realizes the transparency and objectivity of the welding process.

[0088] The above embodiments are merely descriptions of a typical application of the technical solution of the present invention, and reasonable expansion can be carried out on a reasonable basis without requiring creative work.

Claims

1. A monitoring device for multiple welding equipment, characterized in that: It includes field data acquisition components, multi-channel serial port servers, multi-channel AI modules and monitoring terminals. Each component is electrically connected to achieve the transmission of data or information of the entire monitoring device; The field data acquisition component is used to collect various data that need to be monitored on site, and the field data acquisition component is communicatively connected with the multi-channel serial port server to realize data transmission; The output end of the welding equipment is provided with the multi-channel AI module for collecting the output parameters of the welding equipment; the monitoring terminal is used to display the data from the on-site data acquisition component, the data from the multi-channel AI module and for human-computer interaction.

2. The monitoring device for multiple welding equipment according to claim 1, characterized in that: The field data acquisition component includes a power acquisition device for collecting power data, a temperature and vibration acquisition device for temperature and vibration, a speed acquisition device for collecting wire feeding speed, a flow acquisition device for collecting shielding gas flow, a current acquisition device for collecting welding equipment output current, etc., to realize the collection of actual numerical values ​​of various parameters of the welding operation.

3. The monitoring device for multiple welding equipment according to claim 1, characterized in that: The field data acquisition component and the multi-channel serial port server are connected via RS485 interface and ModbusRTU universal protocol to achieve data transmission.

4. The monitoring device for multiple welding equipment according to claim 1, characterized in that: The output end of the multi-channel AI module is connected to Ethernet using the ModbusTCP communication protocol to upload the collected data to the monitoring terminal.

5. The monitoring device for multiple welding equipments as claimed in claim 4, characterized in that: The multi-channel AI module is used to collect the output current of the welding equipment; a voltage transmitter and a current transformer are provided at the output end of the AC welding equipment to convert the output AC voltage into a DC current, and connected to the multi-channel AI module to realize the collection of the output current; a current transformer is provided at the output end of the DC welding equipment to convert the output DC voltage into a DC current, and connected to the multi-channel AI module to realize the collection of the output current.

6. The monitoring device for multiple welding equipment according to claim 5, characterized in that: The method for collecting voltage data by the multi-channel AI module includes: Use a voltage detection instrument to detect the voltage Xv output by the welding equipment; In the voltage range of 0-100V, a quadratic curve of voltage variation is fitted with a voltage value at every 5V interval to obtain fitting coefficients K2v, K1v and K0v; The corrected welding equipment output voltage Yv=K2v*Xv*Xv+K1v*Xv+K0v.

7. The monitoring device for multiple welding equipment according to claim 5, characterized in that: The method for collecting current data by the multi-channel AI module includes: Use a current detection instrument to detect the voltage Xi output by the welding equipment; In the voltage range of 0-100A, a quadratic curve of voltage variation is fitted with a voltage value at every 5A interval to obtain fitting coefficients K2i, K1i and K0i; The corrected welding equipment output voltage Yi=K2i*Xi*Xi+K1i*Xi+K0i.

8. The monitoring device for multiple welding equipments according to claim 1, characterized in that: It also includes a welding management device, which includes a login management module, a welding rod management module, a plan review module, a quality inspection and reporting module, a process management module and an abnormality management module. The login management module is used to support user login and logout, and realize information tracking of welding operators; The welding rod management module is used to manage and track the welding rod usage process, including welding rod preheating equipment such as drying furnaces and holding furnaces; The plan viewing module is used for welding operators to view the welding process of the workpiece to be welded; The quality inspection and reporting module is used to save welding process data and welding completion inspection data, and generate welding record reports; The process management module is used to load theoretical welding parameters of the workpiece to be welded, monitor the actual welding parameters, and compare the actual welding parameters with the theoretical welding parameters to understand the real-time status and operating parameters of the welding operation and realize the traceability of process data; The abnormality management module is used to record abnormalities occurring during the welding process and to issue warnings and abnormality correction plans in a timely manner.

9. The monitoring device for multiple welding equipment according to claim 8, characterized in that: The welding rod management module can complete the management of the entire process of welding rod collection, preheating, insulation and return to the warehouse. The operation process includes: The operator takes the welding rods from the welding rod warehouse to the drying process, and uses the information reading module of the industrial control integrated computer at the drying process to identify the QR code on the welding rod and read the information of the welding rod taken; The number of welding rods received is input into the industrial control integrated machine, and the welding management device matches the read welding rod information with the welding rod information to be received, and provides the drying process of the welding rod; After the welding rods are preheated and qualified, they are stored in a heat preservation furnace or heat preservation cylinder, so that the welding rods can be taken and used at any time. Excess welding rods can be returned to the welding rod library by re-pasting the QR code.

10. The monitoring device for multiple welding equipments according to claim 8, characterized in that: In the abnormal management module, if the deviation between the actual welding parameters and the theoretical welding parameters is greater than the set threshold, the deviation value, deviation duration and deviation time are recorded, and a deviation warning is issued to guide the welding operator to adjust the welding parameters in time, thereby effectively managing the welding process and realizing closed-loop adjustable management of the welding process.

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