Welding rod production intelligent control system and method

Abstract

The invention belongs to the technical field of welding rod production control, and relates to an intelligent control system and method for welding rod production. According to the method, potential defect signs of the welding core are found in time by analyzing the coincidence condition of the welding core preparation process of the target welding rod type, generation of poor welding cores is reduced, and the production quality of the whole welding rod is improved; according to the method, the component proportion of the coating and the component proportion and solution concentration of a binder needed for coating preparation can be accurately controlled, it is guaranteed that various additives, alloy elements and the like in the coating are mixed according to a preset formula, it is guaranteed that the metallurgical performance and the physical performance of the welding rod meet the design requirements, and the quality and stability of the welding rod are improved; by analyzing the forming process coincidence condition of each specified welding rod, the abnormal conditions of the welding rods in the forming and drying processes in the production process are found in time, and automatic control is carried out after the abnormal conditions are found, so that the dependence on manual intervention is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of welding rod production control, and relates to an intelligent control system and method for welding rod production. Background Art

[0002] With the continuous development of materials science, various new metal materials such as high-strength steel, nickel-based alloys, titanium alloys, etc. are widely used. For the welding of these new materials, it is necessary to develop welding rods that are suitable for them. For example, nickel-based alloy welding rods are used to weld high-temperature alloy components, which can meet the welding requirements of high-temperature components such as aircraft engines and gas turbines, and promote the application of these high-performance materials in advanced equipment manufacturing. The research and development and production of welding rods provide technical support for the promotion and use of new materials and promote the innovative development in the field of materials. Therefore, the intelligent production control system based on nickel-based alloy welding rods is of great significance and role.

[0003] In the prior art, there are also some related solutions involving welding rod production, for example, the invention patent application for a high-speed drawing and high-speed cutting welding rod production line control method and control system with Chinese patent publication number CN102629130B, which includes: when the equipment is powered on and started, the PLC first initializes the communication module to make it reach the initial state; after the communication module is initialized, the PLC then initializes the mold parameters in each inverter to restore the parameters in each inverter to the initial value; during the initialization process, the PLC will detect the equipment signal, and when an interrupt signal is encountered, the initialization program stops and the interrupt program runs; it can automatically control the production speed of the wire drawing machine, can monitor the welding rod production process in real time, and can make preliminary judgments in case of unexpected situations.

[0004] Another invention patent application for a production control method and system with a Chinese patent publication number of CN103676855B includes: obtaining the connection relationship between the field operation equipment at the production site and the field process parameters configured by each field operation equipment; establishing a production control model using the connection relationship and the field process parameters; selecting the process parameters to be adjusted related to the energy consumption of the production control model from the simulated process parameters, and adjusting the values ​​of the process parameters to be adjusted according to the predetermined step length within the predetermined threshold interval to obtain the energy consumption of the production control model corresponding to each value of the process parameter to be adjusted; selecting the values ​​of the process parameters to be adjusted corresponding to the energy consumption below the energy consumption threshold in the obtained energy consumption, and using the selected values ​​of the process parameters to be adjusted to update the field process parameters configured by the corresponding field operation equipment in the production site. The present invention solves the problem of excessive energy consumption in the production control process and achieves the effect of reducing energy consumption.

[0005] Although the above schemes have proposed some solutions for welding rod production, there are still certain limitations: the existing schemes mainly focus on real-time monitoring of the wire drawing steps in the production process of welding rods, or focus on solving the problem of excessive energy consumption in the production control process. However, the existing schemes do not solve the problems that traditional welding rod production mainly relies on manual operation and simple mechanical equipment and has a low degree of automation. As a result, it is impossible to accurately control the various parameters of the welding rod in the production process, and thus it is impossible to ensure the quality stability and product consistency of the welding rod. Once a problem occurs in a certain link, the adjustment and recovery time of the entire production line is relatively long, which seriously affects production efficiency. Summary of the invention

[0006] In view of this, in order to solve the problems raised in the above background technology, an intelligent control system and method for welding rod production is proposed.

[0007] The purpose of the present invention can be achieved through the following technical solutions: The first aspect of the present invention provides an intelligent control system for welding rod production, including: a production raw material preparation analysis module, a welding rod forming analysis module, a control terminal and an information library.

[0008] The production raw material preparation analysis module is used to record the welding rod type that needs to be produced as the target welding rod type, and then perform real-time detection on the preparation process of various production raw materials of the target welding rod type, obtain the data parameters of the preparation process of various production raw materials of the target welding rod type, and analyze the compliance of the preparation process of various production raw materials of the target welding rod type. If it is not compliant, the control terminal is executed.

[0009] The production raw material preparation and analysis module includes a welding core preparation and analysis unit and a coating preparation and analysis unit.

[0010] The welding core preparation analysis unit is used to obtain welding core preparation process data parameters of the target welding rod type and analyze the welding core preparation process compliance of the target welding rod type.

[0011] The coating preparation analysis unit is used to obtain coating preparation process data parameters of the target welding rod type and analyze the compliance of the coating preparation process of the target welding rod type.

[0012] The welding rod forming analysis module is used to record the welding rods produced by various types of production raw materials prepared according to the target welding rod type as designated welding rods, and perform real-time detection on the production process to obtain the forming process data parameters of each designated welding rod, analyze the conformity of the forming process of each designated welding rod, and execute the control terminal if it does not conform.

[0013] The control terminal is used to control the preparation process of various production materials of the target welding rod type and the forming process of each designated welding rod.

[0014] The information base is used to store the binder solution concentration corresponding to each binder solution density and the minimum dryness of the electrode coating corresponding to the moisture content of the electrode coating, store the standard value and threshold value of each parameter in the data parameters of the production raw material preparation process of each type of target electrode type, and store the standard value and threshold value of each parameter in the forming process data parameters of each specified electrode.

[0015] The second aspect of the present invention provides an intelligent control method for welding rod production, including: S1, analysis of production raw material preparation: recording the welding rod type to be produced as the target welding rod type, and then performing real-time detection on the preparation process of various types of production raw materials of the target welding rod type, obtaining data parameters of the preparation process of various types of production raw materials of the target welding rod type, analyzing the compliance of the preparation process of various types of production raw materials of the target welding rod type, and if it is not compliant, executing the control terminal.

[0016] The content of S1 includes: S11, welding core preparation analysis: obtaining welding core preparation process data parameters of the target welding rod type, and analyzing the compliance of the welding core preparation process of the target welding rod type.

[0017] S12. Coating preparation analysis: Obtain the coating preparation process data parameters of the target electrode type, and analyze the compliance of the coating preparation process of the target electrode type.

[0018] S2. Welding rod forming analysis: The welding rods obtained by producing various types of production raw materials prepared according to the target welding rod type are recorded as designated welding rods, and the production process is detected in real time to obtain the forming process data parameters of each designated welding rod, and the conformity of the forming process of each designated welding rod is analyzed. If it is not conforming, the control terminal is executed.

[0019] S3, control terminal, used to control the preparation process of various production raw materials of the target welding rod type and the forming process of each designated welding rod.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The present invention obtains the welding core preparation process data parameters of the target welding rod type and analyzes the welding core preparation process compliance of the target welding rod type, which helps to timely discover potential defects of the welding core, helps to reduce the generation of poor welding core, and improves the overall welding rod production quality.

[0021] 2. The present invention obtains the data parameters of the coating preparation process of the target welding rod type and analyzes the compliance of the coating preparation process of the target welding rod type, which helps to accurately control the component ratio of the coating and the component ratio and solution concentration of the binder required for coating preparation, ensures that various additives, alloy elements, etc. in the coating are mixed according to a predetermined formula, and ensures that the metallurgical properties and physical properties of the welding rod meet the design requirements, thereby improving the quality and stability of the welding rod, and helping to timely discover potential quality problems, take preventive measures before problems occur, and avoid the production of unqualified welding rods.

[0022] 3. The present invention obtains the forming process data parameters of each designated welding rod and analyzes the conformity of the forming process of each designated welding rod, which helps to promptly discover abnormal conditions in the forming and drying processes of the welding rod during the production process, and automatically controls after the abnormality is discovered, thereby reducing dependence on manual intervention, avoiding the production of unqualified products, reducing waste of resources, and protecting the company's reputation and brand image. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0024] Figure 1 It is a schematic diagram of system module connection of the present invention.

[0025] Figure 2 It is a schematic diagram for implementing the method steps of the present invention.

[0026] Figure 3 It is a schematic diagram of the control operation of the coating preparation process of the target welding rod type of the present invention. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] Example 1 See also Figure 1As shown, the present invention provides an intelligent control system for welding rod production, and the specific modules are distributed as follows: production raw material preparation analysis module, welding rod forming analysis module, control terminal and information library. Among them, the connection mode between the modules is: the production raw material preparation analysis module is connected with the welding rod forming analysis module, and the control terminal and the information library are respectively connected with the production raw material preparation analysis module and the welding rod forming analysis module.

[0029] The production raw material preparation analysis module is used to record the welding rod type that needs to be produced as the target welding rod type, and then perform real-time detection on the preparation process of various production raw materials of the target welding rod type, obtain the data parameters of the preparation process of various production raw materials of the target welding rod type, and analyze the compliance of the preparation process of various production raw materials of the target welding rod type. If it is not compliant, the control terminal is executed.

[0030] The production raw material preparation and analysis module includes a welding core preparation and analysis unit and a coating preparation and analysis unit.

[0031] The connection between the units is as follows: the welding core preparation analysis unit is connected with the coating preparation analysis unit.

[0032] The welding core preparation analysis unit is used to obtain welding core preparation process data parameters of the target welding rod type and analyze the welding core preparation process compliance of the target welding rod type.

[0033] As a preferred feasibility example, the welding core preparation process data parameters of the target welding rod type include the purity of the welding core preparation material and the diameter of each prepared welding core.

[0034] It should be further explained that the reasons for using the purity of the core material and the diameter of each prepared core as the core preparation process data parameters of the target electrode type are: (1) The purity of the core material directly affects the composition and properties of the weld metal. If the core contains impurities, such as harmful elements such as sulfur and phosphorus, they will enter the weld during the welding process, thereby affecting the mechanical properties and corrosion resistance of the weld. High-purity core materials can reduce unstable factors in the welding process, such as arc instability, molten pool instability, etc., thereby improving the stability and reliability of welding.

[0035] (2) The diameter of the welding core directly affects the deposition efficiency and weld quality during welding. Increasing the welding core diameter can improve the deposition efficiency and increase the welding speed, but it will also affect the size and shape of the weld. The change in welding core diameter will also affect the selection of welding current and arc voltage, and thus affect the parameters of the weld such as penetration depth, width and excess height.

[0036] It needs to be further explained that the specific method of obtaining the purity of the weld core preparation material in the weld core preparation process of the target welding rod type and the diameter of each prepared weld core is: directly extracting the purity of the weld core preparation material in the weld core preparation process of the target welding rod type from the detailed quality inspection report provided by the supplier.

[0037] A laser diameter measuring instrument is arranged at the outlet of the welding core drawing machine to measure the diameter of each finished welding core in the welding core preparation process of the target welding rod type to obtain the diameter of each finished welding core in the welding core preparation process of the target welding rod type.

[0038] As a preferred feasibility example, the specific analysis method for whether the welding core preparation process of the target welding rod type meets the requirements is: extracting the purity of the welding core preparation materials and the diameter of each prepared welding core in the welding core preparation process of the target welding rod type, comparing the diameter of each prepared welding core in the welding core preparation process of the target welding rod type with the standard diameter of the welding core of the target welding rod type stored in the information database, screening out each prepared welding core in the welding core preparation process of the target welding rod type whose diameter meets the standard diameter, recording them as each qualified prepared welding core in the welding core preparation process of the target welding rod type, and counting the number of qualified prepared welding cores in the welding core preparation process of the target welding rod type. .

[0039] It needs to be further explained that the specific screening method for each completed welding core in the welding core preparation process of the target welding rod type whose diameter meets the standard diameter is: extract the diameter of each completed welding core in the welding core preparation process of the target welding rod type, subtract it from the standard diameter of the welding core of the target welding rod type, and obtain the difference between the diameter of each completed welding core in the welding core preparation process of the target welding rod type and the standard diameter, and take the absolute value to obtain the absolute value of the difference between the diameter of each completed welding core in the welding core preparation process of the target welding rod type and the standard diameter, and compare it with the set threshold value of the difference between the diameter and the standard diameter, if the absolute value of the difference between the diameter of a certain completed welding core in the welding core preparation process of the target welding rod type and the standard diameter is less than or equal to the set threshold value of the difference between the diameter and the standard diameter, then the completed welding core in the welding core preparation process of the target welding rod type is recorded as the completed welding core in the welding core preparation process of the target welding rod type whose diameter meets the standard diameter.

[0040] Analyze the compliance coefficient of the core preparation process for the target electrode type ,in The purity of the core preparation materials and the total number of cores prepared during the core preparation process of the target electrode type, They are respectively the purity threshold of the core preparation material of the target welding rod type extracted from the information database and the threshold of the proportion of qualified prepared cores.

[0041] When the compliance coefficient of the weld core preparation process of the target welding rod type is 1, it means that the compliance of the weld core preparation process of the target welding rod type is compliant; when the compliance coefficient of the weld core preparation process of the target welding rod type is 0, it means that the compliance of the weld core preparation process of the target welding rod type is non-compliant.

[0042] The control terminal is used to control the preparation process of various production materials of the target welding rod type and the forming process of each designated welding rod.

[0043] As a preferred feasibility example, the specific operation of controlling the preparation process of various types of production raw materials of the target welding rod type includes: according to the compliance of the welding core preparation process of the target welding rod type, further analyzing the reasons why the compliance of the welding core preparation process of the target welding rod type is not met; if it is due to the non-compliance of the purity of the welding core preparation material, the welding core preparation material is replaced; if it is due to the non-compliance of the proportion of qualified prepared welding cores, the welding core drawing of the welding core drawing machine is further controlled.

[0044] In a specific example, the specific operation of controlling the core drawing of the core drawing machine includes but is not limited to controlling the speed or force of the core drawing.

[0045] The present invention obtains the welding core preparation process data parameters of the target welding rod type and analyzes the welding core preparation process compliance of the target welding rod type, which helps to timely discover potential defects of the welding core, helps to reduce the generation of poor welding core, and improves the overall welding rod production quality.

[0046] The coating preparation analysis unit is used to obtain coating preparation process data parameters of the target welding rod type and analyze the compliance of the coating preparation process of the target welding rod type.

[0047] As a preferred feasibility example, the coating preparation process data parameters of the target welding rod type include binder data parameters and coating data parameters.

[0048] The binder data parameters include the proportion of each component material and the concentration of the binder solution.

[0049] It should be further explained that the reason for using the ratio of each component and the concentration of the binder solution as the binder data parameters in the flux coating preparation process data parameters of the target electrode type is: (1) The binder is an important component of the flux coating, and the ratio of its components directly affects the uniformity, density and stability of the flux coating. The appropriate ratio of components can ensure that the flux coating maintains structural integrity during the pressing, drying and baking processes, and is not easy to fall off or crack, thereby improving the overall quality of the electrode.

[0050] (2) The concentration of the binder solution directly affects its viscosity and fluidity, which in turn affects the distribution of the binder in the coating and the bonding effect. A binder solution with too low a concentration may not provide sufficient bonding force, resulting in a weak bond between the coating and the welding core. A binder solution with too high a concentration may increase the brittleness of the coating and reduce its crack resistance.

[0051] It needs to be further explained that the specific method for obtaining the proportion of each component substance in the binder preparation process of the target welding rod type and the concentration of the binder solution is: use a weighing device to weigh each component substance in the binder preparation process of the target welding rod type to obtain the mass of each component substance in the binder preparation process of the target welding rod type, and divide them by the total mass of the component substances in the binder preparation process of the target welding rod type, and the quotient obtained is recorded as the proportion of each component substance in the binder preparation process of the target welding rod type.

[0052] The density of the binder solution in the binder preparation process of the target welding rod type is measured by using a densitometer, and the density of the binder solution in the binder preparation process of the target welding rod type is obtained, which is then compared with the binder solution concentrations corresponding to the densities of each binder solution stored in the information library to obtain the binder solution concentration in the binder preparation process of the target welding rod type.

[0053] The coating data parameters include the quality, particle size and water content of various coating materials and the viscosity of the coating mixture.

[0054] It should be further explained that the reasons for using the quality, particle size and water content of various coating materials and the viscosity of the coating mixture as the coating data parameters in the coating preparation process data parameters of the target electrode type are: (1) The quality of the coating material directly determines the overall quality and performance of the electrode. High-quality coating materials can ensure stable welding effect and high weld quality of the electrode.

[0055] (2) The particle size of the coating material directly affects its distribution in the electrode and the reaction speed during welding. The particle size also affects the strength and toughness of the electrode.

[0056] (3) Excessive water content in the coating material will cause defects such as pores and cracks during welding, seriously affecting the welding quality.

[0057] (4) The viscosity of the coating mixture determines the uniformity and stability of the coating material during the mixing process. The viscosity also affects the preparation process and processing performance of the welding rod. Too high or too low viscosity may cause the welding rod to break, deform or stick during the preparation process, thereby affecting the preparation quality and production efficiency of the welding rod.

[0058] It needs to be further explained that the specific method of obtaining the quality, particle size and water content of various types of coating materials in the coating preparation process of the target welding rod type and the viscosity of the coating mixture is: using a weighing device to weigh the various types of coating materials in the coating preparation process of the target welding rod type to obtain the quality of the various types of coating materials in the coating preparation process of the target welding rod type.

[0059] A laser particle size analyzer is used to detect various types of coating materials in the coating preparation process of the target welding rod type, and the particle size distribution curves of various types of coating materials in the coating preparation process of the target welding rod type are obtained. The particle size with the largest proportion is further obtained as the particle size of various types of coating materials in the coating preparation process of the target welding rod type.

[0060] The moisture content of various coating materials in the coating preparation process of the target welding rod type is directly detected by using a moisture meter.

[0061] The viscosity of the coating mixture in the coating preparation process of the target welding rod type is directly detected by using a viscometer.

[0062] As a preferred feasibility example, the specific analysis method of the coating preparation process of the target electrode type is as follows: extract the proportion of each component substance and the concentration of the binder solution in the coating preparation process of the target electrode type, and record them as ,in , is the number of each component substance, Analyze the binder compliance index in the coating preparation process of the target electrode type for the quantity of the composition substance ,and .

[0063] The mass, particle size and water content of various coating materials in the coating preparation process of the target electrode type are extracted and recorded as ,in , The serial numbers of various types of coating materials. is the number of types of coating materials, based on which the qualification of various coating materials in the coating preparation process of the target electrode type is determined , extract the coating mixture viscosity of the coating preparation process of the target electrode type , analyze the coating compliance index during the coating preparation process of the target electrode type ,and .

[0064] It should be further explained that the specific method for obtaining the qualification of various coating materials in the coating preparation process of the target electrode type is: according to the analysis formula Obtain the qualification of various coating materials in the coating preparation process of the target electrode type ,in are the first The standard quality of the coating material, the standard particle size and the permissible moisture content of the coating material, They are the permissible difference between the set quality and the standard quality, and the permissible difference between the particle size and the standard particle size. This is the minimum value set to prevent the denominator from being 0, and its unit is percentage. is a natural constant.

[0065] If the binder compliance index and the coating compliance index in the coating preparation process of the target welding rod type are both 1, it means that the coating preparation process of the target welding rod type is compliant. If one of the binder compliance index and the coating compliance index in the coating preparation process of the target welding rod type is 0, it means that the coating preparation process of the target welding rod type is not compliant.

[0066] As a preferred feasibility example, the specific analysis method of the binder compliance index and the coating compliance index in the coating preparation process of the target electrode type is: according to the analysis model Obtain the binder compliance index during the coating preparation process of the target electrode type ,in are the first The standard proportions of the constituent materials and the standard concentration of the binder solution, They are respectively the allowable difference between the set ratio and the standard ratio and the allowable difference between the binder solution concentration and the standard concentration of the binder solution.

[0067] According to the analysis model Obtain the coating compliance index during the coating preparation process of the target electrode type ,in The qualification threshold of the coating material and the viscosity threshold of the coating mixture of the target electrode type extracted from the information library, It is the allowable difference between the set coating mixture viscosity and the coating mixture viscosity threshold.

[0068] As a preferred feasibility example, the specific operation of controlling the preparation process of various types of production raw materials of the target welding rod type also includes: according to the compliance of the coating preparation process of the target welding rod type, further analyzing the reasons why the coating preparation process of the target welding rod type is non-compliant; if it is the non-compliance of the binder in the coating preparation process of the target welding rod type, further analyzing the reasons why the binder in the coating preparation process of the target welding rod type is non-compliant; if it is the non-compliance of the proportion of the constituent substances, adjusting and controlling the proportion of the constituent substances; if it is the non-compliance of the concentration of the binder solution, adjusting and controlling the concentration of the binder solution.

[0069] In a specific example, the specific operation of adjusting and controlling the ratio of constituent substances includes, but is not limited to, increasing or decreasing the mass of certain constituent substances to achieve a standard ratio of each constituent substance.

[0070] The specific operation of adjusting and controlling the concentration of the binder solution includes but is not limited to increasing the mass of constituent substances or adding the mass of pure water.

[0071] If the flux coating does not meet the requirements during the flux coating preparation process of the target welding rod type, the reasons for the non-compliance of the flux coating during the flux coating preparation process are further analyzed; if the flux coating material does not meet the requirements, the flux coating material is reprocessed and controlled; if the viscosity of the flux coating mixture does not meet the requirements, the binder preparation is adjusted and controlled.

[0072] As a specific example, the specific operations of reprocessing and controlling the coating materials include but are not limited to re-drying or crushing the coating or re-weighing various types of coating materials.

[0073] The specific operation of adjusting and controlling the preparation of the binder includes but is not limited to adjusting the constituent materials or concentration of the binder.

[0074] It is necessary to further explain that the schematic diagram of the control operation of the coating preparation process of the target electrode type is as follows: Figure 3 shown.

[0075] The present invention obtains data parameters of the coating preparation process of the target welding rod type and analyzes the compliance of the coating preparation process of the target welding rod type, which helps to accurately control the component ratio of the coating and the component ratio and solution concentration of the binder required for coating preparation, ensures that various additives, alloy elements, etc. in the coating are mixed according to a predetermined formula, ensures that the metallurgical properties and physical properties of the welding rod meet the design requirements, thereby improving the quality and stability of the welding rod, and helps to timely discover potential quality problems, take preventive measures before problems occur, and avoid the production of unqualified welding rods.

[0076] The welding rod forming analysis module is used to record the welding rods produced by various types of production raw materials prepared according to the target welding rod type as designated welding rods, and perform real-time detection on the production process to obtain the forming process data parameters of each designated welding rod, analyze the conformity of the forming process of each designated welding rod, and execute the control terminal if it does not conform.

[0077] The forming process data parameters of each designated welding rod include the uniformity and thickness of the coating and the dryness of the coating.

[0078] It should be further explained that the reasons for using the uniformity and thickness of the coating and the dryness of the coating as the forming process data parameters of each specified welding rod are: (1) The uniformity of the coating directly affects the metallurgical reaction and physical and chemical changes of the welding rod during the welding process. If the coating is uneven, it may lead to inconsistent composition and properties of the weld metal during welding, thus affecting the welding quality.

[0079] (2) The thickness of the coating has an important influence on the degree of welding spatter. High-quality electrodes with thick coatings usually have better arc stability than electrodes with thin coatings, which helps to ensure a smooth welding process. The coating thickness also affects the formation of the weld. The appropriate thickness of the coating can ensure a smooth weld surface and fine and beautiful corrugations.

[0080] (3) Too much water in the electrode coating will have a serious impact on the welding quality. If the coating is not dry enough, pores may be generated during welding, which will reduce the crack resistance and mechanical properties of the weld.

[0081] It needs to be further explained that the specific method of obtaining the uniformity and thickness of the flux coating and the dryness of the flux coating in the forming process of each designated welding rod is: using the deployed ultrasonic thickness gauge to detect the forming process of each designated welding rod, to obtain the thickness of the flux coating at each measuring point in the forming process of each designated welding rod, and to average the average thickness of the flux coating at the measuring points in the forming process of each designated welding rod, and record it as the thickness of the flux coating in the forming process of each designated welding rod.

[0082] Extract the coating thickness at each measuring point during the forming process of each specified electrode ,in , is the number of each designated welding rod, To specify the number of electrodes, , is the number of each measuring point, Analyze the uniformity of the coating during the forming process of each specified electrode for the number of measurement points ,in It is the set allowable thickness deviation value.

[0083] Use an infrared moisture meter to detect the coating of each designated welding rod during the forming process to obtain the moisture content of the coating of each designated welding rod during the forming process. , analyze the coating dryness of each specified electrode during the forming process ,in The minimum dryness of the electrode coating extracted from the information database corresponds to the coating moisture content. This is the minimum value that is set to prevent the denominator from being 0, and its unit is percentage.

[0084] As a preferred feasibility example, the specific analysis method of the forming process of each designated welding rod is as follows: the uniformity and thickness of the coating of each designated welding rod in the forming process are extracted and recorded as ,in , is the number of each designated welding rod, The number of electrodes is specified, and the coating compliance of the forming process of each specified electrode is analyzed based on this.

[0085] It should be further explained that the specific analysis method of the coating compliance of the forming process of each specified welding rod is: according to the analysis formula Obtain the coating compliance of the forming process of each specified electrode ,in are the uniformity threshold and standard thickness of the electrode coating extracted from the information library, It is the allowable difference between the set thickness and the standard thickness.

[0086] Extract the coating dryness of the forming process of each specified electrode.

[0087] If the flux coating compliance and flux coating dryness of the forming process of a specified welding rod are greater than or equal to the preset flux coating compliance threshold and flux coating dryness threshold, the conformity of the forming process of the specified welding rod is recorded as conforming; otherwise, the conformity of the forming process of the specified welding rod is marked as non-conforming, and then the conformity of the forming process of each specified welding rod is obtained.

[0088] As a preferred feasibility example, the specific operation of controlling the forming process of each designated welding rod includes: analyzing the conformity of the forming process of each designated welding rod as the cause of non-conformity according to the conformity of the forming process of each designated welding rod; if it is the non-conformity of the coating, adjusting and controlling the coating; if it is the non-conformity of the coating dryness, adjusting and controlling the drying after coating.

[0089] In a specific example, the specific operation of adjusting and controlling the coating of the coating includes but is not limited to adjusting the pressure during pressure coating.

[0090] The specific operation of adjusting and controlling the drying after coating includes but is not limited to adjusting the drying time and drying temperature of the drying machine.

[0091] The information database is used to store the binder solution concentration corresponding to each binder solution density and the minimum dryness of the electrode coating corresponding to the moisture content of the electrode coating, store the standard value and threshold value of each parameter in the data parameters of the production raw material preparation process of each type of target electrode type, and store the standard value and threshold value of each parameter in the forming process data parameters of each specified electrode.

[0092] It needs to be further explained that the standard values ​​and thresholds of various parameters in the various production raw material preparation process data parameters of the target welding rod type include but are not limited to the standard diameter of the welding core of the target welding rod type, the purity threshold of the welding core preparation material and the threshold of the proportion of qualified prepared welding core, the standard proportion of each component of the target welding rod type, the standard concentration of the binder solution, the qualification threshold of the coating material and the viscosity threshold of the coating mixture, as well as the standard quality of various coating materials of the target welding rod type, the standard particle size and allowable water content of the coating material.

[0093] The standard value and threshold value of each parameter in the forming process data parameters of each designated welding rod include but are not limited to the uniformity threshold value and standard thickness of the welding rod coating.

[0094] The present invention obtains the forming process data parameters of each designated welding rod and analyzes the conformity of the forming process of each designated welding rod, which helps to promptly discover abnormal conditions in the forming and drying processes of the welding rod during the production process, and automatically controls after the abnormality is discovered, thereby reducing dependence on manual intervention, avoiding the production of unqualified products, reducing waste of resources, and protecting the company's reputation and brand image.

[0095] Example 2 See also Figure 2 As shown, the present invention provides a CNC machine tool processing control method, and the specific steps are as follows: S1, production raw material preparation analysis: the welding rod type to be produced is recorded as the target welding rod type, and then the preparation process of various production raw materials of the target welding rod type is detected in real time, the data parameters of the preparation process of various production raw materials of the target welding rod type are obtained, and the compliance of the preparation process of various production raw materials of the target welding rod type is analyzed. If it is not compliant, the control terminal is executed.

[0096] The content of S1 includes: S11, welding core preparation analysis: obtaining welding core preparation process data parameters of the target welding rod type, and analyzing the compliance of the welding core preparation process of the target welding rod type.

[0097] S12. Coating preparation analysis: Obtain the coating preparation process data parameters of the target electrode type, and analyze the compliance of the coating preparation process of the target electrode type.

[0098] S2. Welding rod forming analysis: The welding rods obtained by producing various types of production raw materials prepared according to the target welding rod type are recorded as designated welding rods, and the production process is detected in real time to obtain the forming process data parameters of each designated welding rod, and the conformity of the forming process of each designated welding rod is analyzed. If it is not conforming, the control terminal is executed.

[0099] S3, control terminal, used to control the preparation process of various production raw materials of the target welding rod type and the forming process of each designated welding rod.

[0100] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they shall all fall within the protection scope of the present invention.

Claims

1. An intelligent control system for welding rod production, characterized in that: include: The production raw material preparation parsing module is used to record the welding rod type to be produced as the target welding rod type, and then perform real-time detection on the preparation process of various production raw materials of the target welding rod type, obtain the data parameters of the preparation process of various production raw materials of the target welding rod type, and analyze the compliance of the preparation process of various production raw materials of the target welding rod type. If it is not compliant, the control terminal is executed; The production raw material preparation and analysis module includes a welding core preparation and analysis unit and a coating preparation and analysis unit; The welding core preparation analysis unit is used to obtain welding core preparation process data parameters of the target welding rod type and analyze the welding core preparation process compliance of the target welding rod type; The coating preparation analysis unit is used to obtain the coating preparation process data parameters of the target electrode type and analyze the compliance of the coating preparation process of the target electrode type; The welding rod forming analysis module is used to record the welding rods obtained by producing various types of production raw materials according to the target welding rod type as designated welding rods, and to perform real-time detection on the production process to obtain the forming process data parameters of each designated welding rod, analyze the conformity of the forming process of each designated welding rod, and execute the control terminal if it is not conformity; A control terminal is used to control the preparation process of various production materials of the target welding rod type and the forming process of each designated welding rod; The information base is used to store the binder solution concentration corresponding to each binder solution density and the minimum dryness of the electrode coating corresponding to the moisture content of the electrode coating, store the standard value and threshold value of each parameter in the data parameters of the production raw material preparation process of each type of target electrode type, and store the standard value and threshold value of each parameter in the forming process data parameters of each specified electrode.

2. The intelligent control system for welding rod production according to claim 1, characterized in that: The welding core preparation process data parameters of the target welding rod type include the purity of the welding core preparation material and the diameter of each prepared welding core; The coating preparation process data parameters of the target electrode type include binder data parameters and coating data parameters; Wherein, the binder data parameters include the proportion of each component material and the concentration of the binder solution; The coating data parameters include the quality, particle size and water content of various coating materials and the viscosity of the coating mixture; The forming process data parameters of each designated welding rod include the uniformity and thickness of the coating and the dryness of the coating.

3. The intelligent control system for welding rod production according to claim 1 is characterized in that: The specific analysis method for the welding core preparation process of the target welding rod type is as follows: Extract the purity of the welding core preparation material and the diameter of each prepared welding core in the welding core preparation process of the target welding rod type, compare the diameter of each prepared welding core in the welding core preparation process of the target welding rod type with the standard diameter of the welding core of the target welding rod type stored in the information database, screen out each prepared welding core in the welding core preparation process of the target welding rod type whose diameter meets the standard diameter, record them as each qualified prepared welding core in the welding core preparation process of the target welding rod type, and count the number of qualified prepared welding cores in the welding core preparation process of the target welding rod type ; Analyze the compliance coefficient of the core preparation process for the target electrode type ,in The purity of the core preparation materials and the total number of cores prepared during the core preparation process of the target electrode type, They are respectively the purity threshold of the welding core preparation material and the percentage threshold of the qualified prepared welding core of the target welding rod type extracted from the information database; When the compliance coefficient of the weld core preparation process of the target welding rod type is 1, it means that the compliance of the weld core preparation process of the target welding rod type is compliant; when the compliance coefficient of the weld core preparation process of the target welding rod type is 0, it means that the compliance of the weld core preparation process of the target welding rod type is non-compliant.

4. The intelligent control system for welding rod production according to claim 3 is characterized in that: The specific analysis method for the coating preparation process of the target electrode type is as follows: The proportion of each component and the concentration of the binder solution in the coating preparation process of the target electrode type are extracted and recorded as ,in , is the number of each component substance, Analyze the binder compliance index in the coating preparation process of the target electrode type for the quantity of the composition substance ,and ; The mass, particle size and water content of various coating materials in the coating preparation process of the target electrode type are extracted and recorded as ,in , The serial numbers of various types of coating materials. is the number of types of coating materials, based on which the qualification of various coating materials in the coating preparation process of the target electrode type is determined , extract the coating mixture viscosity of the coating preparation process of the target electrode type , analyze the coating compliance index during the coating preparation process of the target electrode type ,and ; If the binder compliance index and the coating compliance index in the coating preparation process of the target welding rod type are both 1, it means that the coating preparation process of the target welding rod type is compliant. If one of the binder compliance index and the coating compliance index in the coating preparation process of the target welding rod type is 0, it means that the coating preparation process of the target welding rod type is not compliant.

5. The intelligent control system for welding rod production according to claim 4 is characterized in that: The specific analysis method of the binder compliance index and the coating compliance index in the coating preparation process of the target electrode type is as follows: According to the analysis model Obtain the binder compliance index during the coating preparation process of the target electrode type ,in are the first The standard proportions of the constituent materials and the standard concentration of the binder solution, They are the permissible difference between the set ratio and the standard ratio and the permissible difference between the concentration of the binder solution and the standard concentration of the binder solution; According to the analysis model Obtain the coating compliance index during the coating preparation process of the target electrode type ,in The qualification threshold of the coating material and the viscosity threshold of the coating mixture of the target electrode type extracted from the information library, It is the allowable difference between the set coating mixture viscosity and the coating mixture viscosity threshold.

6. The intelligent control system for welding rod production according to claim 4, characterized in that: The specific operations of controlling the preparation process of various production raw materials of the target welding rod type include: According to the compliance of the welding core preparation process of the target welding rod type, the reasons why the compliance of the welding core preparation process of the target welding rod type is not met are further analyzed. If it is because the purity of the welding core preparation material is not met, the welding core preparation material is replaced. If it is because the proportion of qualified prepared welding cores is not met, the welding core drawing of the welding core drawing machine is further controlled.

7. The intelligent control system for welding rod production according to claim 6, characterized in that: The specific operations of controlling the preparation process of various production raw materials of the target welding rod type also include: According to the compliance of the coating preparation process of the target welding rod type, further analyze the reasons why the compliance of the coating preparation process of the target welding rod type is not in compliance. If it is the non-compliance of the binder in the coating preparation process of the target welding rod type, further analyze the reasons why the binder in the coating preparation process of the target welding rod type is not in compliance. If it is the non-compliance of the proportion of the constituent materials, adjust and control the proportion of the constituent materials. If it is the non-compliance of the concentration of the binder solution, adjust and control the concentration of the binder solution. If the flux coating does not meet the requirements during the flux coating preparation process of the target welding rod type, the reasons for the non-compliance of the flux coating during the flux coating preparation process are further analyzed; if the flux coating material does not meet the requirements, the flux coating material is reprocessed and controlled; if the viscosity of the flux coating mixture does not meet the requirements, the binder preparation is adjusted and controlled.

8. The intelligent control system for welding rod production according to claim 2, characterized in that: The specific analysis method of the forming process of each designated welding rod is as follows: The uniformity and thickness of the coating during the forming process of each specified electrode are extracted and recorded as ,in , is the number of each designated welding rod, The number of designated welding rods is used to analyze the coating compliance of the forming process of each designated welding rod; Extract the coating dryness of the forming process of each specified welding rod; If the flux coating compliance and flux coating dryness of the forming process of a specified welding rod are greater than or equal to the preset flux coating compliance threshold and flux coating dryness threshold, the conformity of the forming process of the specified welding rod is recorded as conforming; otherwise, the conformity of the forming process of the specified welding rod is marked as non-conforming, and then the conformity of the forming process of each specified welding rod is obtained.

9. The intelligent control system for welding rod production according to claim 8, characterized in that: The specific operations of controlling the forming process of each designated welding rod include: According to the conformity of the forming process of each designated welding rod, the conformity of the forming process of each designated welding rod is analyzed as the cause of non-conformity. If it is the non-conformity of the coating, the coating is adjusted and controlled. If it is the non-conformity of the coating dryness, the drying after coating is adjusted and controlled.

10. An intelligent control method for welding rod production, characterized in that: include: S1. Production raw material preparation analysis: record the welding rod type to be produced as the target welding rod type, and then perform real-time detection on the preparation process of various production raw materials of the target welding rod type, obtain data parameters of the preparation process of various production raw materials of the target welding rod type, analyze the compliance of the preparation process of various production raw materials of the target welding rod type, and execute the control terminal if it is not compliant; The content of S1 includes: S11, welding core preparation analysis: obtaining welding core preparation process data parameters of the target welding rod type, and analyzing the compliance of the welding core preparation process of the target welding rod type; S12, coating preparation analysis: obtaining the coating preparation process data parameters of the target electrode type, and analyzing the compliance of the coating preparation process of the target electrode type; S2. Welding rod forming analysis: each welding rod produced by various types of production raw materials prepared according to the target welding rod type is recorded as each designated welding rod, and the production process is detected in real time to obtain the forming process data parameters of each designated welding rod, and the conformity of the forming process of each designated welding rod is analyzed. If it is not conformity, the control terminal is executed; S3, control terminal, used to control the preparation process of various production raw materials of the target welding rod type and the forming process of each designated welding rod.

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