Stud welding quality monitoring system and computer storage medium

Abstract

The invention discloses a stud welding quality monitoring system and a computer storage medium, the stud welding quality monitoring system comprises a code carrier fixedly arranged on a vehicle body, and the code carrier comprises vehicle body information; the code reader is used for reading information from the code carrier and writing the information into the code carrier, and the stud welding machine is used for executing stud welding operation and outputting a first signal; the robot is in communication connection with the stud welding machine, and the robot receives the first signal through the stud welding machine and outputs a second signal based on the first signal; the controller is in communication connection with the robot, the controller receives a second signal through the robot, the controller controls the code reader to execute reading and / or writing operation based on the received second signal, the controller comprises a first storage unit, and the first storage unit is used for storing information read by the code reader; the server is in communication connection with the controller, and the server receives the information stored by the first storage unit through the controller; and the display is in communication connection with the server, and displays the information stored in the first storage unit in response to an instruction of the server.

Description

Technical Field

[0001] The invention relates to the technical field of stud welding quality monitoring devices, and in particular to a stud welding quality monitoring system and a computer storage medium. Background Art

[0002] Since the vehicle quality inspection standard of the Conglomerate has cancelled the hammering method, there is no quick verification method for stud welding strength testing. Compared with the effective use of the PSQ function of the weld point, there is no automatic alarm function for the stud welding quality. Relying on personnel inspection cannot meet the full coverage requirements within a single beat. Due to the different qualities and status of personnel, there are large differences in standard cognition, recognition ability, and initiative, and there are huge risks in quality control. At the same time, the inspection and rework time is increased. There is no relevant information on the various existing welding alarms and quality status, which makes it impossible to retrieve relevant process information for vehicles with defects at this stage, which means that it is impossible to meet the traceability requirements and cannot perform data accumulation, defect analysis, and technical optimization. Summary of the invention

[0003] To solve at least one aspect of the above problems, the present invention provides a stud welding quality monitoring system, comprising: a tag carrier, the tag carrier is fixedly arranged on a vehicle body, and the tag carrier includes vehicle body information; a code reader, the code reader is used to read information from the tag carrier, and write information to the tag carrier; a stud welder, the stud welder is used to perform a stud welding operation and output a first signal; a robot, the robot is communicatively connected to the stud welder, the robot receives the first signal through the stud welder, and outputs a second signal based on the first signal; a controller, the controller is communicatively connected to the robot, the controller receives the second signal through the robot, the controller controls the code reader to perform a read and / or write operation based on the received second signal, the controller includes a first storage unit, and the first storage unit is used to store information read by the code reader; a server, the server is communicatively connected to the controller, and the server receives the information stored in the first storage unit through the controller; a display, the display is communicatively connected to the server, and the display displays the information stored in the first storage unit in response to an instruction of the server.

[0004] Preferably, it also includes a plurality of the robots and a plurality of the stud welders, each of the plurality of the robots is connected to at least one stud welder, the robot identifies the stud welder and its stud welding status based on the first signal, and the controller identifies the robot and its workstation information, the stud welder and its stud welding status based on the second signal.

[0005] Preferably, the code carrier includes an identification area, a writing area and an integration area, the identification area is used to store vehicle body information, the writing area is used to receive update information written by the code reader, and the integration area is used to store the update information received by the writing area as historical information.

[0006] Preferably, the workstation information includes process workstations and final inspection workstations.

[0007] Preferably, the controller controls the code reader at the process station to read the historical information of the integration area, obtains the current information corresponding to the process station through the robot, and merges the historical information and the current information into update information and writes it into the writing area of ​​the code carrier.

[0008] Preferably, the controller controls the code reader at the final inspection station to obtain the historical information of the integration area and the vehicle body information of the identification area and store them in the first storage unit.

[0009] Preferably, the server controls the display to display the historical information and vehicle body information stored in the first storage unit, and controls the display to delete the displayed historical information and vehicle body information in response to a completion signal from the final inspection station.

[0010] Preferably, the server includes a second storage unit, and the second storage unit is used to store the historical information and vehicle body information received by the server through the first storage unit.

[0011] Preferably, the stud welding status includes stud qualification information and stud fault information, and the stud welder outputs stud fault information in response to a welding fault signal, and the welding fault signal includes any one or a combination of the following: welding current exceeding tolerance, welding energy exceeding tolerance, welding molten pool depth exceeding tolerance, and stud false welding.

[0012] On the other hand, a computer storage medium is provided, comprising computer program instructions, wherein the computer program instructions, when executed by a processor, implements a stud welding quality monitoring system as described above.

[0013] The stud welding quality monitoring system of the present invention has the following beneficial effects: by displaying defect information on the screen, targeted confirmation is performed on the defect information, the man-hours of stud quality inspection personnel are reduced, and the inspection personnel are optimized. The stud rework rate of the final assembly body is reduced, and the rework rate of the whole vehicle is reduced. Technical data accumulation is achieved, a database is established, welding data is accumulated, stud welding data accumulation is achieved, and an analysis data source is provided, which greatly increases the traceability of stud information. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to better understand the above and other purposes, features, advantages and functions of the present invention, reference may be made to the embodiments shown in the accompanying drawings. The same reference numerals in the accompanying drawings refer to the same components. It should be understood by those skilled in the art that the accompanying drawings are intended to schematically illustrate the preferred embodiments of the present invention and have no limiting effect on the scope of the present invention, and the components in the drawings are not drawn to scale.

[0015] Figure 1 A structural block diagram of a stud welding quality monitoring system according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0016] The following is a description of exemplary embodiments of the present disclosure in conjunction with the accompanying drawings, including various details of the embodiments of the present disclosure to facilitate understanding, which should be considered as merely exemplary. Therefore, it should be recognized by those of ordinary skill in the art that various changes and modifications may be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, descriptions of well-known functions and structures are omitted in the following description.

[0017] As used herein, the term "including" and its variations mean open inclusion, i.e., "including but not limited to". Unless otherwise stated, the term "or" means "and / or". The term "based on" means "based at least in part on". The terms "an example embodiment" and "an embodiment" mean "at least one example embodiment". The term "another embodiment" means "at least one additional embodiment". The terms "first", "second", etc. may refer to different or the same objects. Other explicit and implicit definitions may also be included below.

[0018] In order to at least partially solve one or more of the above-mentioned problems and other potential problems, an embodiment of the present disclosure proposes a stud welding quality monitoring system, comprising: a code carrier, the code carrier is fixedly arranged on a vehicle body, and the code carrier includes vehicle body information; a code reader, the code reader is used to read information from the code carrier, and write information to the code carrier; a stud welder, the stud welder is used to perform a stud welding operation and output a first signal; a robot, the robot is communicatively connected to the stud welder, the robot receives a first signal through the stud welder, and outputs a second signal based on the first signal; a controller, the controller is communicatively connected to the robot, the controller receives a second signal through the robot, the controller controls the code reader to perform a read and / or write operation based on the received second signal, the controller includes a first storage unit, and the first storage unit is used to store information read by the code reader; a server, the server is communicatively connected to the controller, and the server receives information stored in the first storage unit through the controller; a display, the display is communicatively connected to the server, and the display displays the information stored in the first storage unit in response to an instruction of the server.

[0019] Specifically, Figure 1 As shown, the vehicle body information stored in the tag carrier is used to uniquely identify the vehicle. The tag carrier is fixed on the vehicle body to move with the vehicle. The vehicle body information includes the current vehicle body pin code, production location, production date, production serial number, vehicle model, etc. The code reader has reading and writing functions. The code reader is set at each station. The code reader receives instructions through the controller to perform reading and writing operations.

[0020] The stud welding machine includes a stud welding control unit, and the stud welding machine is connected to the robot through the stud welding control unit. The stud welding machine includes a welding execution program unit for the controller to execute the welding operation, and the stud welding control unit has a data acquisition unit for acquiring the stud welding state, and the stud welding control unit outputs a first signal according to the acquired stud welding state. In some embodiments, the stud welding state signal output by the stud welding machine includes a stud qualified signal and a stud fault signal, and the stud welding machine outputs a stud fault signal in response to the welding fault signal, and the welding fault signal includes any one or a combination of the welding current exceeding the tolerance, the welding energy exceeding the tolerance, the welding pool depth exceeding the tolerance, and the stud false welding.

[0021] The robot adopts a multi-degree-of-freedom mechanical arm, and the robot is fixedly connected to the stud welder to move the stud welder to perform a welding operation. The robot and the stud welder are connected to each other through a stud welding control unit to receive a first signal. The robot identifies the stud welder and the stud welding state according to the first signal, and further, the robot outputs a second signal according to the received first signal. In some embodiments, the robot also includes an alarm unit, and when the robot determines that the stud welding state fails according to the first signal, an alarm message is output.

[0022] The controller adopts a PLC (Programmable Logic Controller), and the controller receives the second signal output by the robot through a communication connection with the robot. The controller identifies the robot information, the stud welding machine, and the stud welding state according to the second signal output by the robot. The controller controls the code reader to perform reading and writing operations on the tag carrier according to the identified robot information. The controller stores the information obtained through the tag carrier according to the robot information.

[0023] The server connects the controller and the display and displays the information obtained through the tag on the display to visualize the stud welding status.

[0024] In some embodiments, it also includes multiple robots and multiple stud welders, each of the multiple robots is connected to at least one stud welder, the robot identifies the stud welder and its stud welding status based on a first signal, and the controller identifies the robot and its workstation information, the stud welder and its stud welding status based on a second signal.

[0025] Specifically, the first signal includes a plurality of preset signals output by the stud welder, and the second signal includes a plurality of preset signals output by the robot. The robot connects stud welder a and stud welder b. For example, the first signal includes a1, a2, b1 and b2, and the second signals corresponding to the first signals include A1, A2, B1 and B2 in sequence. Among them, when a welding failure occurs in stud welder a, stud welder a outputs a1, and the robot outputs A1 according to a1; when the welding of stud welder a is qualified, stud welder a outputs a2, and the robot outputs A2 according to a2. When a welding failure occurs in stud welder b, stud welder b outputs b1, and the robot outputs B1 according to b1; when the welding of stud welder b is qualified, stud welder b outputs b2, and the robot outputs B2 according to b2.

[0026] The stud welding workshop includes multiple workstations, each of which includes at least one robot. Each robot is communicated with the controller respectively. The controller identifies the robot number and its corresponding workstation information, the stud welding machine number and its corresponding stud welding status according to the second signal output by the robot.

[0027] In some embodiments, a robot carries two stud welding machines. When a welding failure occurs, the stud welding control unit sends a welding quality alarm to the robot. The communication address for the robot to receive the failure of the first stud welding gun BZ1 is E1737, and the communication address for the failure of the second stud welding gun BZ2 is E1738. After the robot receives the welding failure signal from the stud welding control unit, it needs to send a signal to the controller immediately. Two instructions BZ1: A170 = E1737 and BZ2: A171 = E1738 are added to the robot program. The robot sends the failure signals of the two stud welding guns to the controller, where A170 and A171 are the communication signals between the controller and the robot.

[0028] In some embodiments, the code carrier includes an identification area, a writing area and an integration area. The identification area is used to store vehicle body information, the writing area is used to receive update information written by a code reader, and the integration area is used to store the update information received in the writing area as historical information.

[0029] Specifically, the vehicle body information stored in the identification area includes the current vehicle body pin code, production location, production date, production serial number, vehicle model, etc. The write area is used to receive information written by the code reader. The integration area is used to store the information received in the write area in a specified location. Each stud welding state on the vehicle body needs to specify a storage address in the tag carrier, and it cannot be repeated. This storage address needs to be completed by the robot and the controller. The controller needs to determine the storage area, for example: DB114.DBW225; the robot needs to specify a specific location, for example: DB114.DBX225.0. In order for the robot to realize the function of specifying a specific location, it is necessary to add a new binary output variable bin21 with a length of 8 bits. Each time a stud is welded, the robot bin21 will send the controller the number of the current welding stud, that is, the specific location where the stud status is stored in the tag carrier.

[0030] In some embodiments, the workstation information includes process workstations and final inspection workstations.

[0031] Specifically, the stud welding process includes multiple stations, including multiple process stations and at least one final inspection station, the process station is used to perform welding operations, and the final inspection station is used to perform inspection operations. At least one robot is set at each station, and the robot can be uniquely identified by the robot number and station information.

[0032] In some embodiments, the controller controls the code reader at the process station to read the historical information of the integration area, obtains the current information corresponding to the process station through the robot, and merges the historical information and the current information into the update information and writes it into the writing area of ​​the code carrier.

[0033] Specifically, the information of the tag body needs to be read by an RFID (Radio Frequency Identification) wireless scanning device, and the controller and RFID are connected using a profinet (automation bus standard) network.

[0034] When the car body arrives at the process station, the controller controls the code reader to read the information in the tag carrier and put it into the specified first storage unit block. At the same time, the READ part of the read information is saved as the WRITE part through the FB2 function block. The main function of this work is to retain the information of the previous stud welding station to avoid the problem of clearing the stud welding information of other stations after updating the stud welding status information of this station. After the stud welding of this station is completed, all the stud welding status information is packaged and rewritten into the tag carrier.

[0035] In some embodiments, the controller controls the barcode reader at the final inspection station to obtain the historical information of the integration area and the vehicle body information of the identification area and store them in the first storage unit.

[0036] Specifically, the controller of the final inspection station controls the code reader to perform a reading operation in response to the received station information. The historical information of the final inspection station includes the stud status information and stud welding machine information, robot information and station information of all process stations. The acquired vehicle body information and historical information are stored in the first storage unit.

[0037] In some embodiments, the server controls the display to display the historical information and vehicle body information stored in the first storage unit, and controls the display to delete the displayed historical information and vehicle body information in response to a completion signal from the final inspection station.

[0038] Specifically, the completion signal of the final inspection station is issued by the final inspection operator. When the final inspection operator completes the inspection operation, a completion signal is generated and output. The completion signal passes through the controller in turn and is received by the server. The server deletes the information displayed on the display based on the received completion signal to facilitate the display of the next vehicle body information entering the final inspection station.

[0039] In some embodiments, the server includes a second storage unit, and the second storage unit is used to store the historical information and vehicle body information received by the server through the first storage unit.

[0040] Specifically, the second storage unit of the server can be used for data query for fault analysis by storing historical information and vehicle body information of all vehicle bodies that have passed the final inspection station.

[0041] In some embodiments, the stud welding status includes stud qualification information and stud failure information. The stud welder outputs stud failure information in response to a welding failure signal. The welding failure signal includes any one or a combination of the welding current exceeding tolerance, the welding energy exceeding tolerance, the welding pool depth exceeding tolerance, and stud false welding.

[0042] Specifically, during the welding process, each stud welding status information needs to be recorded in the first data storage unit through the controller. When a stud has a problem, the stud welding control unit will send a welding fault signal to the robot, and the robot will send the welding fault signal and specific position information bin21 to the controller. The controller will write the stud welding fault information into the first storage unit, that is, the storage address of the stud welding status information in the first storage unit is marked as 1.

[0043] If no stud fault signal occurs during the welding process, the robot will also send the welding status information and specific position information bin21 to the controller, and the controller will write the stud welding information into the first storage unit, that is, the storage address of the stud welding status information in the first storage unit is marked as 0.

[0044] On the other hand, a computer storage medium is provided, comprising computer program instructions, which, when executed by a processor, implement any of the above stud welding quality monitoring systems.

[0045] The embodiments of the present disclosure have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The selection of terms used herein is intended to best explain the principles of the embodiments, practical applications, or technical improvements in the market, or to enable other persons of ordinary skill in the art to understand the present invention.

Claims

1. A stud welding quality monitoring system, characterized in that: include: A tag carrier, the tag carrier is fixedly mounted on the vehicle body, and the tag carrier includes vehicle body information; A code reader, the code reader is used to read information from the code carrier and write information to the code carrier; A stud welding machine, the stud welding machine is used to perform a stud welding operation and output a first signal; a robot, the robot being communicatively connected to the stud welding machine, the robot receiving the first signal through the stud welding machine, and outputting a second signal based on the first signal; a controller, the controller being in communication with the robot, the controller receiving the second signal through the robot, the controller controlling the code reader to perform a reading and / or writing operation based on the received second signal, the controller comprising a first storage unit, the first storage unit being used to store information read by the code reader; A server, the server is in communication with the controller, and the server receives the information stored in the first storage unit through the controller; A display is communicatively connected to the server, and displays the information stored in the first storage unit in response to an instruction from the server.

2. The system according to claim 1, characterized in that It also includes a plurality of the robots and a plurality of the stud welders, each of the plurality of the robots is connected to at least one stud welder, the robot identifies the stud welder and its stud welding status based on the first signal, and the controller identifies the robot and its workstation information, the stud welder and its stud welding status based on the second signal.

3. The system according to claim 2, characterized in that The tag carrier includes an identification area, a writing area and an integration area. The identification area is used to store vehicle body information, the writing area is used to receive update information written by the code reader, and the integration area is used to store the update information received by the writing area as historical information.

4. The system according to claim 3, characterized in that The workstation information includes process workstations and final inspection workstations.

5. The system according to claim 4, characterized in that The controller controls the code reader to read the historical information of the integration area at the process station, obtains the current information corresponding to the process station through the robot, and merges the historical information and the current information into update information and writes it into the writing area of ​​the code carrier.

6. The system according to claim 5, characterized in that The controller controls the code reader at the final inspection station to obtain the historical information of the integration area and the vehicle body information of the identification area and store them in the first storage unit.

7. The system according to claim 6, characterized in that The server controls the display to display the historical information and vehicle body information stored in the first storage unit, and controls the display to delete the displayed historical information and vehicle body information in response to a completion signal of the final inspection station.

8. The system according to claim 7, characterized in that The server includes a second storage unit for storing the history information and vehicle body information received by the server through the first storage unit.

9. The system according to claim 8, characterized in that The stud welding status includes stud qualification information and stud fault information. The stud welding machine outputs stud fault information in response to a welding fault signal. The welding fault signal includes any one or a combination of the following: welding current exceeding tolerance, welding energy exceeding tolerance, welding molten pool depth exceeding tolerance, and stud false welding.

10. A computer storage medium, characterized in that: It comprises computer program instructions, and when the computer program instructions are executed by a processor, the stud welding quality monitoring system as claimed in any one of claims 1 to 9 is implemented.

Images