Welding quality digital management method

Abstract

The invention discloses a digital management method for welding quality. The method comprises the following steps: 1) electrifying equipment; 2) installing acquisition equipment; 3) connecting a collector; 4) software operation; 5) remote controller operation; 6) process monitoring; and (7) welding is finished. Welding data acquisition and comparison and real-time reporting of abnormal conditions are achieved, real-time analysis and feedback of data such as voltage and current, wire feeding speed and gas flow during welding are achieved, meanwhile, real-time warning of abnormal operation is achieved, the welding quality is optimized, and the welding risk is reduced.

Description

Technical Field

[0001] The invention relates to the field of welding, and in particular to a digital management method for welding quality. Background Art

[0002] In the welding industry, the quality of welds is a long-standing problem. Conventional welding monitoring relies on manual self-control and patrol mutual control, and the control rate of the problem cannot meet the demand. Usually, it is necessary to use non-destructive means and rational means in the later stage to ensure the quality of welds. It is time-consuming and labor-intensive, affecting work efficiency.

[0003] Therefore, it is necessary to develop a new type of digital management method for welding quality in a targeted manner, to collect, record and analyze the voltage, current, wire feeding speed, gas flow, etc. in real time, and to discover abnormalities in the welding process through control system analysis, so as to facilitate the analysis and tracing of welding parameters. Summary of the invention

[0004] Purpose of the invention: In view of the shortcomings and defects of the prior art, the present invention provides a digital management method for welding quality, which can realize welding data collection and comparison and real-time reporting of abnormal situations, realize real-time analysis and feedback of data such as voltage and current, wire feeding speed, gas flow rate, etc. during welding, and provide real-time warnings for abnormal operations, optimize welding quality, and reduce welding risks.

[0005] Technical solution: A digital management method for welding quality of the present invention is characterized by comprising the following steps:

[0006] 1) Power on the equipment: Power on the host computer, open the welding quality digital management system, and start the welding data acquisition box;

[0007] 2) Install the data acquisition equipment: Connect the welding data acquisition box to the host computer and welding machine, use a cable to connect the "+" cable on the welding machine to the black quick socket on the welding data acquisition box, i.e., current acquisition interface 1; the red terminal, i.e., current acquisition interface 2, is connected to the workpiece or welding gun;

[0008] 3) Connect the collectors: connect the wire feed speed collector to the third RS485 communication interface on the welding data collection box, connect the shielding gas flow collector to the first RS485 communication interface on the welding data collection box, and connect the equipment energy consumption collector to the second RS485 communication interface on the welding data collection box; check the connection status of each collector;

[0009] 4) Software operation: Import the production task in the production management of the management software, click WPS in the production task to import the process parameters, and send it to the terminal software after three-level approval confirmation, select the corresponding task in the terminal software, and start collection;

[0010] 5) Remote control operation: Use the HMI screen of the welding control system to open the corresponding welding mode; view the corresponding process through the upper computer interface and fill in the corresponding position on the HMI; after preparation, click to start the arc; during the welding process, click the option of changing the welding wire to activate the code scan to identify whether the replaced welding material meets the requirements;

[0011] 6) Process monitoring: During the welding process, the system automatically compares the collected data with the set values ​​in the WPS to see if they are consistent; if there is a deviation, it will be pushed to the corresponding account through the system;

[0012] 7) End of welding: After the welding of the workpiece is completed, click the Submit button on the host computer to save the data of the entire production process to this workpiece data.

[0013] Among them, the welding quality digital management system in the step 1) includes an arc welding power supply, a welding data acquisition box, a workstation terminal and a PLC system connected in sequence; the PLC system is connected to the arc welding power supply, and the welding data acquisition box is provided with a wire feeding speed collector, an equipment energy consumption collector, a shielding gas flow collector, a welding environment temperature and humidity collector and a welding speed collector.

[0014] Among them, the welding data acquisition box is equipped with a voltage acquisition interface, an airflow acquisition interface, a current acquisition interface 1, a current acquisition interface 2, a 220V power supply interface, an RS485 communication interface, an I / O interface, an RJ45 communication interface, a WIFI antenna and a fault buzzer.

[0015] Wherein, the voltage acquisition interface is connected to the “-” cable of the external welding machine.

[0016] Among them, the current collection interface 1 is a black quick socket, and the current collection interface 1 is connected to the "+" cable of the external welding machine.

[0017] Among them, the current collection interface 2 is a red terminal seat, and the current collection interface 2 is connected to an external workpiece or welding gun.

[0018] Among them, the number of the RS485 communication interfaces is 4.

[0019] Among them, the four RS485 communication interfaces are arranged in sequence from left to right and from top to bottom.

[0020] Among them, the number of the I / O interfaces is 2.

[0021] Wherein, in step 2), the cable has a cross-sectional area of ​​95 mm 2 of cable.

[0022] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages: the present invention realizes welding data collection and comparison and real-time reporting of abnormal situations, realizes real-time analysis and feedback of data such as voltage and current, wire feeding speed, gas flow rate, etc. during welding, and at the same time gives real-time warnings for abnormal operations, optimizes welding quality, and reduces welding risks.

[0023] The welding data acquisition box of the present invention is equipped with a wire feeding speed collector, an equipment energy consumption collector, a shielding gas flow collector, a welding environment temperature and humidity collector, and a welding speed collector; it collects, records, and analyzes voltage, current, wire feeding speed, gas flow, etc. in real time, and discovers abnormalities in the welding process through control system analysis, which is convenient for analyzing and checking welding parameters; it saves time and effort and improves work efficiency. It realizes real-time monitoring and alarming of welding quality, provides effective and real data for the analysis of welding quality problems, and provides effective support for optimizing welding quality and reducing welding costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural schematic diagram of the present invention;

[0025] Figure 2 The structure of the welding data acquisition box of the present invention is shown in FIG. Figure 1 ;

[0026] Figure 3 The structure of the welding data acquisition box of the present invention is shown in FIG. Figure 2 ;

[0027] Figure 4 The structure of the welding data acquisition box of the present invention is shown in FIG. Figure 3 ;

[0028] Figure 5 It is a structural schematic diagram of the wire feeding speed collector of the present invention;

[0029] In the figure, 1 is the voltage acquisition interface; 2 is the airflow acquisition interface; 3 is the current acquisition interface 1; 4 is the current acquisition interface 2; 5 is the RS485 interface; 6 is the RS485 communication interface; 7 is the I / O interface; 8 is the RJ45 communication interface; 9 is the WIFI antenna; and 10 is the fault buzzer. DETAILED DESCRIPTION

[0030] The technical solution of the present invention is further described below in conjunction with the accompanying drawings and specific implementation methods.

[0031] A welding quality digital management method of the present invention is characterized by comprising the following steps:

[0032] 1) Power on the equipment: Power on the host computer, open the welding quality digital management system, and start the welding data acquisition box. The welding quality digital management system includes an arc welding power supply, a welding data acquisition box, a workstation terminal and a PLC system connected in sequence; the PLC system is connected to the arc welding power supply, and the welding data acquisition box is provided with a wire feeding speed collector, an equipment energy consumption collector, a shielding gas flow collector, a welding environment temperature and humidity collector and a welding speed collector. The welding data acquisition box is provided with a voltage acquisition interface 1, an airflow acquisition interface 2, a current acquisition interface 1 3, a current acquisition interface 2 4, a 220V power supply interface 5, an RS485 communication interface 6, an I / O interface 7, an RJ45 communication interface 8, a WIFI antenna 9 and a fault buzzer 10. The voltage acquisition interface 1 is connected to the "-" cable of the external welding machine. The current acquisition interface 1 3 is a black fast socket, and the current acquisition interface 1 3 is connected to the "+" cable of the external welding machine. The current acquisition interface 2 4 is a red terminal seat, and the current acquisition interface 2 4 is connected to the external workpiece or welding gun. The number of RS485 communication interfaces 6 is 4. The four RS485 communication interfaces 6 are arranged in sequence from left to right and from top to bottom. The number of I / O interfaces 7 is 2.

[0033] 2) Install the data acquisition equipment: Connect the welding data acquisition box to the host computer and welding machine, use the cable to connect the "+" cable on the welding machine to the black quick socket on the welding data acquisition box, that is, the current acquisition interface 1-3; the red terminal, that is, the current acquisition interface 2-4, is connected to the workpiece or welding gun. The cable has a cross-sectional area of ​​95mm 2 of cable.

[0034] 3) Connect the collectors: connect the wire feeding speed collector to the third RS485 communication interface 6 on the welding data collection box, connect the shielding gas flow collector to the first RS485 communication interface 6 on the welding data collection box, and connect the equipment energy consumption collector to the second RS485 communication interface 6 on the welding data collection box; check the connection status of each collector.

[0035] 4) Software operation: Import the production task in the production management of the management software, click WPS in the production task to import the process parameters, and send it to the terminal software after three-level approval confirmation. Select the corresponding task in the terminal software to start collection.

[0036] 5) Remote control operation: Use the HMI screen of the welding control system to open the corresponding welding mode; view the corresponding process through the host computer interface and fill in the corresponding position on the HMI; after preparation, click to start the arc; during the welding process, click the option to change the welding wire to activate the code scan to identify whether the replaced welding material meets the requirements.

[0037] 6) Process monitoring: During the welding process, the system automatically compares the collected data with the set values ​​in the WPS to see if they are consistent; if there is a deviation, it will be pushed to the corresponding account through the system.

[0038] 7) End of welding: After the welding of the workpiece is completed, click the Submit button on the host computer to save the data of the entire production process to this workpiece data.

[0039] The wire feeding speed information is collected through the wire feeding speed collector, the energy consumption information is collected through the equipment energy consumption collector, the shielding gas information is collected through the shielding gas flow collector, the temperature and humidity information is collected through the welding environment temperature and humidity collector, the welding speed information is collected through the welding speed collector, and the voltage information is collected through the voltage collection interface 1. The voltage, current, wire feeding speed, gas flow, etc. are collected, recorded and analyzed in real time and compared with the set values ​​of the process parameters. The abnormalities in the welding process are discovered through PLC system analysis, which is convenient for analyzing and tracing back the welding parameters.

[0040] Example:

[0041] Using the welding quality digital management method of the present invention:

[0042] 1) Upload welding process: Open the EI5000 digital workshop management system in the host computer; click Production Management, create a new production task, click WPS in the production task again, upload the WPS file edited according to the template, review and approve it, and the system will automatically generate a production plan.

[0043] 2) Workpiece collection: Open the welding station terminal software in the host computer, click the workstation in the software, click login to select the workpiece or scan the code to select the workpiece, confirm the collection. Click the corresponding task to view the WPS.

[0044] 3) Handheld controller settings: Set WPS in the device controller according to the required settings.

[0045] 4) Preparation before welding: Carry out preparation before welding on the workpiece at the workstation to ensure that the workpiece meets the pre-welding requirements and is confirmed by the team leader in the system.

[0046] 5) Start welding: The workstation terminal software collects and uploads welding data to the management software.

[0047] 6) Data acquisition: This acquisition box is equipped with a current transformer 0-500A and a voltage acquisition module 0-30v. It collects real-time welding current / voltage and converts it into a 0-5v analog signal. The external module wire feeding speed acquisition module collects the wire feeding speed from the real-time encoder and converts it into RS485 protocol data through the wire feeding speed acquisition board and uploads it to the acquisition box. It is then converted into RJ45 protocol data through the acquisition box acquisition board and uploaded to the host computer for storage and analysis, and real-time comparison.

[0048] 7) Software analysis: The management software analyzes and compares the uploaded information to ensure that the collected equipment welding data meets the requirements.

[0049] 8) Abnormal warning: When the management software finds an abnormality, it will send an abnormal warning to the relevant account.

[0050] 9) Stop welding: After welding, submit the workpiece through the terminal software and save it to the corresponding workpiece directory for easy reverse retrieval.

Claims

1. A welding quality digital management method, characterized in that: The steps include: 1) Power on the equipment: Power on the host computer, open the welding quality digital management system, and start the welding data acquisition box; 2) Install the data acquisition equipment: Connect the welding data acquisition box to the host computer and the welding machine. Use a cable to connect the "+" cable on the welding machine to the black quick socket on the welding data acquisition box, i.e., the current acquisition interface 1 (3); and the red terminal, i.e., the current acquisition interface 2 (4), to the workpiece or welding gun. 3) Connect the collectors: connect the wire feed speed collector to the third RS485 communication interface (6) on the welding data collection box, connect the shielding gas flow collector to the first RS485 communication interface (6) on the welding data collection box, and connect the equipment energy consumption collector to the second RS485 communication interface (6) on the welding data collection box; check the connection status of each collector; 4) Software operation: Import the production task in the production management of the management software, click WPS in the production task to import the process parameters, and send it to the terminal software after three-level approval confirmation, select the corresponding task in the terminal software, and start collection; 5) Remote control operation: Use the HMI screen of the welding control system to open the corresponding welding mode; view the corresponding process through the host computer interface and fill in the corresponding position on the HMI; after preparation, click to start the arc; During the welding process, click the option to change the welding wire to activate the code scanning to identify whether the replaced welding material meets the requirements; 6) Process monitoring: During the welding process, the system automatically compares the collected data with the set values ​​in the WPS to see if they are consistent; if there is a deviation, it will be pushed to the corresponding account through the system; 7) End of welding: After the welding of the workpiece is completed, click the Submit button on the host computer to save the data of the entire production process to this workpiece data.

2. The welding quality digital management method according to claim 1 is characterized in that: The welding quality digital management system in step 1) includes an arc welding power supply, a welding data acquisition box, a workstation terminal and a PLC system connected in sequence; the PLC system is connected to the arc welding power supply, and the welding data acquisition box is provided with a wire feeding speed collector, an equipment energy consumption collector, a shielding gas flow collector, a welding environment temperature and humidity collector and a welding speed collector.

3. The welding quality digital management method according to claim 2 is characterized in that: The welding data acquisition box is provided with a voltage acquisition interface (1), an airflow acquisition interface (2), a current acquisition interface 1 (3), a current acquisition interface 2 (4), a 220V power supply interface (5), an RS485 communication interface (6), an I / O interface (7), an RJ45 communication interface (8), a WIFI antenna (9) and a fault buzzer (10).

4. The welding quality digital management method according to claim 3 is characterized in that: The voltage collection interface (1) is connected to the "-" cable of an external welding machine.

5. The welding quality digital management method according to claim 3 is characterized in that: The current collection interface 1 (3) is a black quick socket, and the current collection interface 1 (3) is connected to the "+" cable of the external welding machine.

6. The welding quality digital management method according to claim 3 is characterized in that: The current collection interface 2 (4) is a red terminal seat, and the current collection interface 2 (4) is connected to an external workpiece or welding gun.

7. The welding quality digital management method according to claim 3 is characterized in that: The number of the RS485 communication interfaces (6) is 4.

8. The welding quality digital management method according to claim 4 is characterized in that: The four RS485 communication interfaces (6) are arranged in sequence from left to right and from top to bottom.

9. The welding quality digital management method according to claim 3 is characterized in that: The number of the I / O interfaces (7) is 2.

10. The welding quality digital management method according to claim 1, characterized in that: In step 2), the cable has a cross-sectional area of ​​95 mm 2 of cable.

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