Multi-equipment welding spot parallel counting device and method

Abstract

The invention relates to the technical field of welding detection, in particular to a multi-equipment welding spot parallel counting device and method. The trigger module is used for receiving a welding completion signal, identifying a welding completion signal station number and feeding back a signal state to the logic module; the logic module is used for judging a signal mode, generating a corresponding station number counting pulse and sending to the first counting unit; the first counting unit judges in the comparator after receiving the counting pulse, if the counting number at the moment does not reach the welding spot number set by the station number, the first counting unit updates the counting value of the current station number, if the counting number reaches the set number, the counting value is fed back to the logic module, and the logic module generates an upward counting pulse and buzzes an indicator light for indication; the second counting unit receives the upward counting pulse to count the workpieces; the system is simple in structure, can be connected with a plurality of welding controllers at the same time to count welding spots in parallel, changes the number of welding spots of workpieces according to specific weldments, can be used for counting the yields of different workpieces, and improves the production efficiency.

Description

Technical Field

[0001] The invention belongs to the technical field of welding detection, and in particular to a device and method for parallel counting of welding points of multiple devices. Background Art

[0002] In modern industrial production, especially in the welding and assembly production link in the field of automobile manufacturing, welding process is a key step in the assembly of parts. At present, welding methods are diversified, mainly including automatic welding, semi-automatic welding and manual welding. Among them, manual operation still occupies a vital position at this stage.

[0003] In the production process of automobile parts, due to their complex structure and diverse functional requirements, there are often many welding points. For example, the number of welding points of the body parts of an ordinary family car may be as many as thousands. The quality and quantity of these welding points are directly related to the overall structural strength and safety of the car.

[0004] However, there are many problems in the existing practice of solder joint counting. On the one hand, for a long time, the counting of solder joints mostly relied on manual visual inspection or simple counters. In the case of manual visual inspection, operators need to rely on naked eye observation and experience to judge the number of solder joints on a busy production line. This method is easily affected by human factors, such as operator fatigue and distraction. Moreover, with the increase in production speed and the number of solder joints, the efficiency of manual visual inspection will be greatly reduced, and it is difficult to ensure the accuracy of the counting. Even if a simple counter is used, it only accumulates the number of solder joints, which cannot meet the various needs in a complex production environment.

[0005] On the other hand, from the perspective of existing technology, although some welding point counting devices already exist, these devices have obvious limitations. They can often only realize simple welding point counting functions, but cannot complete the workpiece counting that is crucial to the entire production process. This results in the company being unable to accurately grasp the production quantity of workpieces during the production management process, making it difficult to carry out effective production planning and quality control. In addition, the existing single counter can usually only count for one welding controller, which means that in large-scale production, a large number of counters are required, which not only increases the equipment cost, but also takes up more production space. Moreover, different welding controllers may require different counting settings and management methods. The existing counting devices lack sufficient flexibility to adapt to such diverse needs, further increasing the detection cost, and are not conducive to improving the overall production efficiency and quality. Summary of the invention

[0006] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a device and method for parallel counting of weld points of multiple devices, which can realize automatic and accurate parallel counting of weld points of multiple welding controllers, improve processing production efficiency and reduce enterprise production costs.

[0007] The present invention solves the technical problem by adopting the following technical solutions:

[0008] A multi-device welding point parallel counting device, comprising:

[0009] A trigger module, which is connected to the welding controller, includes a signal receiver for capturing the level change or pulse signal of the welding completion signal, and a station number decoder for converting the received signal into a specific welding station number according to a preset coding rule;

[0010] a logic module connected to the trigger module, comprising a signal type identifier for determining whether the received signal is an NPN type or a PNP type, a counter controller for controlling the counting process according to the station number information and the welding point setting value, and a pulse generator for generating corresponding counting pulses according to the instruction of the counting controller;

[0011] A first counting unit, which is connected to the logic module and includes a comparator for comparing a current counting value with a welding point setting value, and a first counter for recording the number of welding points;

[0012] A second counting unit, connected to the logic module, comprises a second counter for receiving an upward counting pulse from the logic module and accumulating the count to count the workpieces;

[0013] The terminal module is connected to the logic module and includes a reset button for clearing the count, a count / re-welding knob for switching between the count state and the re-welding state, a buzzer indicator light for sending a prompt signal, and a fishtail switch for confirming the completion of the welding point count.

[0014] Furthermore, if the welding controller sends a welding completion signal, the trigger module immediately responds, parses the station number information, and passes the station number information and signal status to the logic module, wherein the signal status includes a completion signal status and a failure signal status.

[0015] Moreover, the first counter of the first counting unit records the number of welds of the received station number. If the weld point count of the station number does not reach the weld point setting value, a pulse is sent to the first counting unit through the pulse generator; if the weld point count of the station number reaches the weld point setting value, the buzzer indicator light sends a prompt signal.

[0016] Furthermore, if the first counting unit receives a counting pulse, the first counter increases the count value, and the comparator compares the current count value with the welding point setting value in real time;

[0017] If the current count value does not reach the welding point set value, the first counting unit continues to wait for the next pulse;

[0018] If the current count value reaches the welding point set value, the first counting unit sends a feedback signal to the logic module, indicating that the welding point counting of the station number has been completed, and the buzzer indicator sends a prompt signal.

[0019] Furthermore, if the logic module generates an upward counting pulse, the second counter of the second counting unit increases the count value, thereby realizing the counting of the total number of workpieces.

[0020] Moreover, after the buzzer indicator sends a prompt signal, the operator determines whether the workpiece meets the quality requirements based on the appearance of the weld. If the workpiece does not meet the quality requirements, the operator turns the counting / repairing knob to the repairing state, and the device does not count at this time. After the repairing is completed, the counting / repairing knob is turned back to the counting state to continue the welding count of the next workpiece;

[0021] If the workpiece meets the quality requirements, the operator turns on the fishtail switch, the second counter counts the workpieces, and the first counter resets the welding point count to achieve the total number of workpieces and start welding the next workpiece.

[0022] A counting method of a multi-device welding point parallel counting device comprises the following steps:

[0023] S1. Connect the multi-device welding point parallel counting device to the welding controller network, and determine the welding point setting value for each welding controller of each station number;

[0024] S2. When the welding controller completes a welding operation, it will send out a welding completion signal. The signal receiver in the trigger module receives the welding completion signal, and parses the station number information contained in the completion signal through the station number decoder, and transmits the signal status to the logic module.

[0025] S3, the signal type identifier in the logic module determines the signal type, and the counter controller determines whether a counting pulse needs to be generated according to the station number information and the welding point setting value, and further processes the counting pulse;

[0026] S4, the first counter of the first counting unit increases the count value after receiving the count pulse, and the comparator compares the current count value with the solder joint set value in real time to determine whether to continue waiting for the next pulse or send a signal indicating that the solder joint counting is completed;

[0027] S5. The operator determines whether the workpiece meets the quality requirements based on the appearance of the welding spot, so as to determine whether to repair the workpiece or turn on the fishtail switch to make the second counter count the workpieces, and at the same time, the welding spot count of the first counting unit is reset to zero, so as to realize the statistics of the total number of workpieces;

[0028] S6. When all welding of the workpiece model is completed, the reset button can be pressed to clear the values ​​of the first counting unit and the second counting unit, reset the number of welding points of the corresponding station workpiece, and start a new round of counting.

[0029] The advantages and positive effects of the present invention are:

[0030] 1. The present invention can automatically and accurately count solder joints through precise module design. The logic module controls the counting process according to precise signal type recognition and station number information judgment. The comparator of the first counting unit compares the count value with the solder joint set value in real time, effectively avoiding counting errors and greatly improving the accuracy of solder joint counting.

[0031] 2. The present invention can be connected to multiple welding controllers at the same time to count weld points. In a large-scale production environment, multiple welding operations can be carried out at the same time, and the device can count these weld points at the same time without delays caused by counting one by one, which effectively speeds up the production rhythm and improves the production efficiency per unit time.

[0032] 3. The present invention realizes workpiece counting through the second counting unit. Enterprises can reasonably arrange production plans and optimize production processes according to accurate workpiece counting data to ensure that production tasks are completed on time.

[0033] 4. The present invention not only accurately counts the weld points, but also combines it with the workpiece counting to perform weld point integrity inspection and count confirmation after each workpiece is welded. The operator checks the workpiece quality according to the prompt of the buzzer indicator light. If there is a problem, it can be repaired in time, thus ensuring the quality of the weld points of each workpiece and further improving the overall quality level of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a structural schematic diagram of the present invention.

[0035] Figure 2 It is the work flow chart of the present invention.

[0036] Figure 3 It is a flow chart of the steps of the present invention.

[0037] Reference numerals

[0038] 1- counting device, 2- welding controller, 3- trigger module, 4- logic module, 5- first counting unit, 6- second counting unit, 7- terminal module, 8- station number decoder, 9- signal receiver, 10- signal type identifier, 11- counter controller, 12- pulse generator, 13- comparator, 14- first counter, 15- second counter, 16- buzzer indicator, 17- counting / re-welding knob, 18- fishtail switch, 19- reset button. DETAILED DESCRIPTION

[0039] The present invention is further described in detail below through specific examples. The following examples are only illustrative and not restrictive, and the protection scope of the present invention cannot be limited thereto.

[0040] See also Figure 1-Figure 3 As shown, a multi-device welding point parallel counting device comprises:

[0041] A trigger module 3, which is connected to the welding controller 2, includes a signal receiver 9 for capturing the level change or pulse signal of the welding completion signal, and a station number decoder 8 for converting the received signal into a specific welding station number according to a preset coding rule;

[0042] A logic module 4, which is connected to the trigger module 3, includes a signal type identifier 10 for determining whether the received signal is an NPN type or a PNP type, a counter controller 11 for controlling the counting process according to the station number information and the welding point setting value, and a pulse generator 12 for generating corresponding counting pulses according to the instruction of the counting controller;

[0043] A first counting unit 5, which is connected to the logic module 4, comprises a comparator 13 for comparing a current counting value with a welding point setting value, and a first counter 14 for recording the number of welding points;

[0044] A second counting unit 6, which is connected to the logic module 4, comprises a second counter 15 for receiving an upward counting pulse from the logic module 4 and accumulating the count to count the workpieces;

[0045] The terminal module 7 is connected to the logic module 4, and includes a reset button 19 for clearing the count, a count / re-welding knob 17 for switching between the count state and the re-welding state, a buzzer indicator light 16 for issuing a prompt signal, and a fishtail switch 18 for confirming the completion of the welding point count.

[0046] If the welding controller 2 sends a welding completion signal, the trigger module 3 responds immediately, parses the station number information, and transmits the station number information and signal status to the logic module 4. The signal status includes a completion signal status and a failure signal status.

[0047] The first counter 14 of the first counting unit 5 records the number of welds of the received station number. If the weld count of the station number does not reach the weld setting value, a pulse is sent to the first counting unit 5 through the pulse generator 12; if the weld count of the station number reaches the weld setting value, the buzzer indicator light 16 sends a prompt signal.

[0048] If the first counting unit 5 receives a counting pulse, the first counter 14 increases the count value, and the comparator 13 compares the current count value with the welding point setting value in real time;

[0049] If the current count value does not reach the welding point set value, the first counting unit 5 continues to wait for the next pulse;

[0050] If the current count value reaches the welding point setting value, the first counting unit 5 sends a feedback signal to the logic module 4, indicating that the welding point counting of the station number has been completed, and the buzzer indicator light 16 sends a prompt signal.

[0051] If the logic module 4 generates an upward counting pulse, the second counter 15 of the second counting unit 6 increases the count value to realize the counting of the total number of workpieces.

[0052] After the buzzer indicator 16 sends out a prompt signal, the operator determines whether the workpiece meets the quality requirements based on the appearance of the weld. If the workpiece does not meet the quality requirements, the operator turns the counting / repairing knob 17 to the repairing state, and the device does not count at this time. After the repairing is completed, the counting / repairing knob 17 is turned back to the counting state to continue the welding count of the next workpiece;

[0053] If the workpiece meets the quality requirements, the operator turns on the fishtail switch 18, the second counter 15 counts the workpieces, and the first counter 14 resets the welding point count to achieve the total number of workpieces and start welding the next workpiece.

[0054] A counting method of a multi-device welding point parallel counting device 1 comprises the following steps:

[0055] S1, connecting the multi-device welding point parallel counting device 1 to the welding controller 2 network, and determining the welding point setting value for each welding controller 2 of each station number;

[0056] S2. When the welding controller 2 completes a welding operation, it will send out a welding completion signal. The signal receiver 9 in the trigger module 3 receives the welding completion signal, and parses the station number information contained in the completion signal through the station number decoder 8, and transmits the signal status to the logic module 4.

[0057] S3, the signal type identifier 10 in the logic module 4 determines the signal type, and the counter controller 11 determines whether a counting pulse needs to be generated according to the station number information and the welding point setting value, and further processes the counting pulse;

[0058] S4, the first counter 14 of the first counting unit 5 increases the count value after receiving the count pulse, and the comparator 13 compares the current count value with the solder point set value in real time to determine whether to continue waiting for the next pulse or send a signal that the solder point counting is completed;

[0059] S5, the operator determines whether the workpiece meets the quality requirements according to the appearance of the welding spot, so as to determine whether to repair the workpiece or turn on the fishtail switch 18 to make the second counter 15 count the workpieces, and at the same time, the welding spot count of the first counting unit 5 is reset to zero, so as to realize the statistics of the total number of workpieces;

[0060] S6. When all the welding of the workpiece model is completed, the reset button 19 can be pressed to clear the values ​​counted by the first counting unit 5 and the second counting unit 6, reset the number of welding points of the corresponding station workpiece, and start a new round of counting.

[0061] The working process of the multi-device welding point parallel counting device 1 of the present invention is as follows:

[0062] First, the multi-device welding point parallel counting device 1 is connected to the welding controller 2 network, and the number of workpiece welding points is set in the first counting unit 5 for each welding controller 2 of each station number;

[0063] Secondly, the operator performs welding work. When the welding controller 2 completes a welding operation, it will send a welding completion signal. The signal receiver 9 receives the welding completion signal and parses the station number information contained in the completion signal through the station number encoder 8, and sends the signal status information to the logic module 4;

[0064] The signal type identifier 10 determines whether the signal is NPN type or PNP type. The pulse generator 12 generates corresponding counting pulses according to the signal type and station number information. These pulses will be sent to the first counting unit 5 for further processing;

[0065] After the first counting unit 5 receives the counting pulse, the comparator 13 will compare the current counting value with the preset number of workpiece welding points in real time.

[0066] If the current count value does not reach the set value, the solder joint count value of the corresponding station number will be updated and continue to wait for the arrival of the next count pulse.

[0067] If the current count value reaches the set value, the first counting unit 5 will send a feedback signal to the logic module 4, indicating that the counting of the workpiece welding points at the station has been completed;

[0068] After the counter controller 11 receives the feedback signal from the first counting unit 5 , the logic module 4 controls the buzzer indicator light 16 to send out a prompt signal to inform the operator that the counting of the welding points of the workpiece at the station has been completed.

[0069] The operator confirms whether the workpiece has leaked welding. If there is leaked welding, the counting / repairing knob 17 can be turned to the repairing gear to perform repairing welding. At this time, no counting will be done. After the repairing welding is completed, the counting gear will be turned back to continue counting. After the workpiece is confirmed to be correct, the fishtail switch 18 can be pressed to confirm. The logic module 4 will generate an upward counting pulse, which will be sent to the second counting unit 6 for workpiece counting. At this time, the workpiece count is updated, and the welding point count of the first counting unit 5 is reset to zero, and the next workpiece welding starts;

[0070] When all the workpieces of the changed model are welded, the reset button 19 can be pressed to clear the count values ​​of the first counting unit 5 and the second counting unit 6, and the number of welding points of the corresponding station workpiece can be reset to start a new round of counting.

[0071] Although the embodiments of the present invention are disclosed for illustrative purposes, those skilled in the art will appreciate that various substitutions, changes and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments.

Claims

1. A device for parallel counting of welding points of multiple devices, characterized in that: include: A trigger module, which is connected to the welding controller, includes a signal receiver for capturing the level change or pulse signal of the welding completion signal, and a station number decoder for converting the received signal into a specific welding station number according to a preset coding rule; a logic module connected to the trigger module, comprising a signal type identifier for determining whether the received signal is an NPN type or a PNP type, a counter controller for controlling the counting process according to the station number information and the welding point setting value, and a pulse generator for generating corresponding counting pulses according to the instruction of the counting controller; A first counting unit, which is connected to the logic module and includes a comparator for comparing a current counting value with a welding point setting value, and a first counter for recording the number of welding points; A second counting unit, connected to the logic module, comprises a second counter for receiving an upward counting pulse from the logic module and accumulating the count to count the workpieces; The terminal module is connected to the logic module and includes a reset button for clearing the count, a count / re-welding knob for switching between the count state and the re-welding state, a buzzer indicator light for sending a prompt signal, and a fishtail switch for confirming the completion of the welding point count.

2. The device for parallel counting of multiple welding points of equipment according to claim 1, characterized in that: If the welding controller sends a welding completion signal, the trigger module responds immediately, parses the station number information, and passes the station number information and signal status to the logic module, wherein the signal status includes a completion signal status and a failure signal status.

3. The device for parallel counting of multiple welding points of equipment according to claim 2, characterized in that: The first counter of the first counting unit records the number of welds of the received station number. If the weld point count of the station number does not reach the weld point setting value, a pulse is sent to the first counting unit through the pulse generator; if the weld point count of the station number reaches the weld point setting value, the buzzer indicator light sends a prompt signal.

4. The device for parallel counting of multiple welding points of equipment according to claim 3, characterized in that: If the first counting unit receives a counting pulse, the first counter increases the count value, and the comparator compares the current count value with the welding point setting value in real time; If the current count value does not reach the welding point set value, the first counting unit continues to wait for the next pulse; If the current count value reaches the welding point set value, the first counting unit sends a feedback signal to the logic module, indicating that the welding point counting of the station number has been completed, and the buzzer indicator sends a prompt signal.

5. The device for parallel counting of multiple welding points of equipment according to claim 4, characterized in that: If the logic module generates an upward counting pulse, the second counter of the second counting unit increases the count value to realize the counting of the total number of workpieces.

6. The device for parallel counting of multiple welding points of equipment according to claim 5, characterized in that: After the buzzer indicator sends a prompt signal, the operator determines whether the workpiece meets the quality requirements based on the appearance of the weld. If the workpiece does not meet the quality requirements, the operator turns the counting / repairing knob to the repairing state, and the device does not count at this time. After the repairing is completed, the counting / repairing knob is turned back to the counting state to continue the welding count of the next workpiece; If the workpiece meets the quality requirements, the operator turns on the fishtail switch, the second counter counts the workpieces, and the first counter resets the welding point count to achieve the total number of workpieces and start welding the next workpiece.

7. A counting method for a multi-device welding point parallel counting device according to any one of claims 1 to 6, characterized in that: The steps include: S1. Connect the multi-device welding point parallel counting device to the welding controller network, and determine the welding point setting value for each welding controller of each station number; S2. When the welding controller completes a welding operation, it will send out a welding completion signal. The signal receiver in the trigger module receives the welding completion signal, and parses the station number information contained in the completion signal through the station number decoder, and transmits the signal status to the logic module. S3, the signal type identifier in the logic module determines the signal type, and the counter controller determines whether a counting pulse needs to be generated according to the station number information and the welding point setting value, and further processes the counting pulse; S4, the first counter of the first counting unit increases the count value after receiving the count pulse, and the comparator compares the current count value with the solder joint set value in real time to determine whether to continue waiting for the next pulse or send a signal indicating that the solder joint counting is completed; S5. The operator determines whether the workpiece meets the quality requirements based on the appearance of the welding spot, so as to determine whether to repair the workpiece or turn on the fishtail switch to make the second counter count the workpieces, and at the same time, the welding spot count of the first counting unit is reset to zero, so as to realize the statistics of the total number of workpieces; S6. When all welding of the workpiece model is completed, the reset button can be pressed to clear the values ​​of the first counting unit and the second counting unit, reset the number of welding points of the corresponding station workpiece, and start a new round of counting.

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