Parameter synchronization system and method for resistance spot welding equipment

Abstract

The invention relates to a parameter synchronization system and method for resistance spot welding equipment, the parameter synchronization system comprises resistance welding equipment, a welding parameter management system and an MQTT Broker, the resistance welding equipment mainly comprises a resistance welding controller, a resistance welding machine head and a welding operation screen, the resistance welding controller serves as the core of the welding equipment, and the resistance welding machine head is connected with the MQTT Broker. And communicating with the welding operation screen, the welding process parameter management system and the MQTT Broker at the same time through the Ethernet. After the parameters of a certain resistance spot welding device are modified, the function of synchronizing the parameters of other devices in a network can be achieved, a fault-tolerant mechanism is achieved, the method is suitable for the scenes that real-time synchronous parameter updating is needed, part of the devices are possibly offline or parameters are not suitable for a resistance spot welding machine system, and while the consistency of the welding parameters is guaranteed, the system reliability is improved. And the operation convenience and flexibility of parameter modification of the welding equipment are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of resistance welding, and in particular to a parameter synchronization system and method for resistance spot welding equipment. Background Art

[0002] The present invention belongs to the field of resistance spot welding data processing technology. With the increasing development of resistance spot welding technology and process research, its application scenarios are becoming more and more complex, and various setting parameters of welding machines are also increasing. Some of these parameters, such as equipment data management and communication configuration parameters, need to be set for all equipment on the welding production line at the same time. The traditional method is to modify the equipment one by one, or to broadcast the data to the equipment for modification through a centralized data management system. However, due to the high degree of automation of the welding line and the existence of multiple networks (such as robot networks, data acquisition networks, etc.), network instability or offline scenarios may occur during data synchronization, resulting in data synchronization failure and affecting use. Summary of the invention

[0003] The purpose of the present invention is to overcome the shortcomings of the prior art and propose a parameter synchronization system and method for resistance spot welding equipment. When the parameters of a certain resistance spot welding equipment are modified, the parameter synchronization function of other devices in the network can be realized, and a fault-tolerant mechanism is provided. The system and method are suitable for scenarios such as resistance spot welding systems that require real-time synchronization of parameter updates and where some devices may be offline or parameters are not applicable. While ensuring the consistency of welding parameters, the operational convenience and flexibility of parameter modification of welding equipment are improved.

[0004] The present invention solves the technical problem by adopting the following technical solutions:

[0005] A parameter synchronization system for resistance spot welding equipment comprises resistance welding equipment, a welding parameter management system and an MQTT Broker, wherein the resistance welding equipment mainly comprises a resistance welding controller, a resistance welding machine head and a welding operation screen. The resistance welding controller, as the core of the welding equipment, communicates with the welding operation screen, the welding process parameter management system and the MQTT Broker simultaneously through Ethernet; the welding operation screen is integrated on the welding equipment and is used to display the current welding parameters and information of the equipment to meet the welding operator's needs for confirming and modifying the parameters of the current equipment; the welding parameter management system is located at the workstation or line corresponding to the welding equipment and is used for centralized management and data collection of parameters of multiple welding equipment; the MQTT Broker is located in the centralized control room of the welding production workshop, and the welding equipment and the welding process parameter management system are both linked to the MQTT Broker deployed on site as MQTT Clients, and mutual communication is achieved by subscribing to corresponding topics.

[0006] Moreover, the data transmission between the resistance welding equipment, the welding parameter management system and the MQTT Broker adopts the JSON data format.

[0007] Moreover, the welding parameter management system adopts a CRDT method based on LWW-Register to define the LWW-Register of each welding internal parameter.

[0008] A synchronization method for a parameter synchronization system of a resistance spot welding device comprises the following steps:

[0009] Step 1: Initialize the synchronization system and connect the device;

[0010] Step 2: Change parameters of welding equipment;

[0011] Step 3: Determine whether it is synchronized. If it is synchronized, proceed to step 4. Otherwise, stop the update process and the device startup is completed.

[0012] Step 4: Update parameters and broadcast;

[0013] Step 5, determine whether the message timestamp is newer, the timestamp is a UNIX timestamp, if the timestamp value is larger, it means the timestamp is updated, if the timestamp is newer, the parameter synchronization is completed, an acceptance signal is sent, and step 6 is performed; otherwise, the modification is ignored, a rejection signal is sent, and step 6 is performed;

[0014] Step 6: The welding management system records the synchronization results and is responsible for recording and managing the synchronization status of all equipment on site.

[0015] The specific implementation method of step 1 is as follows: each welding machine device and welding parameter management system are registered as MQTT nodes and connected to the MQTT Broker server, each welding machine device node subscribes to the parameter update topic weld / sync and the centralized management topic weld / main; each welding machine device node is responsible for maintaining a local copy so that the latest updated value can be selected in case of conflict based on the latest timestamp; the welding parameter management system subscribes to the parameter update topic weld / sync and the completion confirmation topic weld / result, and is responsible for tracking the update status of the parameters.

[0016] Moreover, the specific implementation method of step 3 is: when the welding machine node needs to update the parameters, the value and timestamp of the corresponding parameters in the local LWW-Register will be updated first; after the update, the operator manually confirms whether to synchronize the parameters. If synchronization is confirmed, the welding machine node broadcasts the updated structure to the weld / sync topic through the MQTTT server.

[0017] Furthermore, the step 4 comprises the following steps:

[0018] Step 4.1: After receiving the message from the weld / sync topic, the other welding machine nodes follow the following process:

[0019] (1) First check the update timestamp of each parameter. If the timestamp of the message is newer, the device performs operation (2). If the timestamp of the message is older, the device performs operation (3).

[0020] (2) The current welding machine node updates the local parameter value and publishes the update result to the topic weld / result;

[0021] (3) The device node ignores the message, keeps the current parameter LWW-Register unchanged, and publishes the update result to the topic weld / result;

[0022] Step 4.2, after receiving the message of weld / sync topic, the welding parameter management system node checks the timestamp of each parameter. If the timestamp of the message is newer, the local parameter value is updated; if the timestamp of the message is older, the message is ignored and the current update is maintained.

[0023] Moreover, the specific implementation method of step 6 is as follows: when the welding parameter management system receives the weld / sync message, when it is determined that the timestamp is newer, the local parameters are updated, and the parameter modification status is recorded in the log for easy traceability; at the same time, the welding parameter management system periodically publishes the local parameter status to the weld / main topic, and after each welding machine device receives the message, it performs the same processing as when receiving the message of the weld / sync topic; when the welding parameter management system receives the weld / result message returned by the device, it first determines the value of the result field. If it is Acceptance, the update status of the device can be directly recorded in the log. If it is Refusal, it means that the current synchronization parameters are not the latest status of the current parameters in the entire system. Therefore, the welding parameter management system needs to update the local parameters and also record the parameter modification status in the log.

[0024] The advantages and positive effects of the present invention are:

[0025] The present invention includes resistance welding equipment, a welding parameter management system and an MQTT Broker, wherein the resistance welding equipment mainly includes a resistance welding controller, a resistance welding head and a welding operation screen. The resistance welding controller, as the core of the welding equipment, communicates with the welding operation screen, the welding process parameter management system and the MQTT Broker simultaneously through Ethernet. When the parameters of a certain resistance spot welding equipment are modified, the present invention can realize the parameter synchronization function of other devices in the network, and has a fault-tolerant mechanism. It is suitable for scenarios such as resistance spot welding systems that require real-time synchronous parameter updates, and some equipment may be offline or the parameters are not applicable. While ensuring the consistency of welding parameters, it improves the operational convenience and flexibility of parameter modification of welding equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a structural diagram of the system of the present invention;

[0027] Figure 2 is a flow chart of the synchronization method of the present invention;

[0028] Figure 3 This is a message processing flow chart of the welding parameter management system of the present invention. DETAILED DESCRIPTION

[0029] The present invention is further described in detail below with reference to the accompanying drawings.

[0030] A parameter synchronization system for resistance spot welding equipment, such as Figure 1 As shown, it includes resistance welding equipment, welding parameter management system and MQTT Broker, wherein the resistance welding equipment mainly includes resistance welding controller, resistance welding head and welding operation screen. The resistance welding controller, as the core of the welding equipment, communicates with the welding operation screen, welding process parameter management system and MQTT Broker through Ethernet at the same time; the welding operation screen is integrated on the welding equipment to display the current welding parameters and information of the equipment, to meet the welding operator's current equipment parameter confirmation and modification needs, and is responsible for executing the modification and synchronous broadcasting tasks of the welding machine parameters in this system.

[0031] The welding parameter management system is located at the workstation or line corresponding to the welding equipment. It is used for centralized management and data collection of parameters of multiple welding equipment. In this system, it is responsible for tracking the welding synchronization and ensuring consistency.

[0032] The MQTT Broker is located in the centralized control room of the welding production workshop. The welding equipment and welding process parameter management system are both linked to the MQTT Broker deployed on site as MQTT Clients, and communicate with each other by subscribing to corresponding topics.

[0033] The data transmission between resistance welding equipment, welding parameter management system and MQTT Broker adopts JSON data format.

[0034] Assume that there are n welding machines in the welding system, marked as W n (n=1,2......n). In order to achieve the consistency and reliability of the synchronization of welding machine parameters, the CRDT (Conflict-Free Replicated Data Type) collaborative algorithm is adopted. The present invention adopts the CRDT method based on LWW-Register (Last-Write-WinsRegister) to define the LWW-Register representation structure of each welding internal parameter (taking the data sampling frequency parameter as an example) as follows:

[0035]

[0036] Among them: parameter represents the parameter name t.

[0037] value: The latest value of the parameter.

[0038] timestamp: The updated timestamp, used to resolve conflicts, takes the value of the last updated time.

[0039] device_id: The ID of the node that initiates the update.

[0040] A synchronization method for a parameter synchronization system of a resistance spot welding device, such as Figure 2 As shown, with device W 1 The update process for updating parameters and synchronizing them is described below, including the following steps:

[0041] Step 1: Initialize the synchronization system and connect the device.

[0042] Each welding machine device and welding parameter management system are registered as MQTT nodes and connected to the MQTT Broker server (such as MQTT or message queue). Each welding machine device node subscribes to the parameter update topic weld / sync and the centralized management topic weld / main as shown in Table 1. Each welding machine device node is responsible for maintaining a local copy so that the latest updated value can be selected in case of conflict based on the latest timestamp. The welding parameter management system subscribes to the parameter update topic weld / sync and the completion confirmation topic weld / result, and is responsible for tracking the update of the parameters.

[0043] Table 1 MQTT topic description

[0044]

[0045] Step 2: Change the parameters of welding equipment.

[0046] When W 1 When the welding machine node needs to update the parameters, it will first update the value and timestamp of the corresponding parameters in the local LWW-Register. After the update, the operator manually confirms whether to synchronize the parameters. If synchronization is confirmed, the W1 welding machine node will broadcast the updated structure to the weld / sync topic through the MQTTT server.

[0047] Step 3: Determine whether it is synchronized. If it is synchronized, proceed to step 4. Otherwise, stop the update process and the device startup is completed.

[0048] Step 4: Update parameters and broadcast.

[0049] Step 4.1: After receiving the message from the weld / sync topic, the other welding machine nodes follow the following process:

[0050] (1) First check the update timestamp of each parameter. If the timestamp of the message is newer, the device performs operation (2). If the timestamp of the message is older, the device performs operation (3).

[0051] (2) The current welding machine node updates the local parameter value and publishes the update result to the topic weld / result. The corresponding structure format is:

[0052] {

[0053] "parameter":"SamplingRate",

[0054] "value":1000,

[0055] "timestamp":1682994920,

[0056] "device_id":"W2",

[0057] "result":"Acceptance" / / Data synchronization result

[0058] }

[0059] The value and timestamp values ​​are the results of the corresponding device node being updated.

[0060] (3) The device node ignores the message, keeps the current parameter LWW-Register unchanged, and publishes the update result to the topic weld / result. The corresponding structure format is:

[0061] {

[0062] "parameter":"SamplingRate",

[0063] "value":1000,

[0064] "timestamp":1682994920,

[0065] "device_id":"W2",

[0066] "source_id":"W1", / / The device that initiates data synchronization

[0067] "result":"Refusal" / / Data synchronization result

[0068] }

[0069] The value and timestamp values ​​are the values ​​currently stored in the corresponding device node.

[0070] Step 4.2, after receiving the message of weld / sync topic, the welding parameter management system node checks the timestamp of each parameter. If the timestamp of the message is newer, the local parameter value is updated; if the timestamp of the message is older, the message is ignored and the current update is maintained.

[0071] Step 5, determine whether the message timestamp is newer. The timestamp is a UNIX timestamp. If the timestamp value is larger, it means that the timestamp is updated. If the timestamp is newer, the parameter synchronization is completed, an acceptance signal is sent, and step 6 is performed; otherwise, the modification is ignored, a rejection signal is sent, and step 6 is performed.

[0072] Step 6: The welding management system records the synchronization results and is responsible for recording and managing the synchronization status of all equipment on site.

[0073] The welding parameter management system node receives the results of the weld / result topic and records them in the log, and then ensures the consistency logic of the data.

[0074] like Figure 3 As shown, when the welding parameter management system receives the weld / sync message, it is consistent with the operation of the welding equipment node. When it is determined that the timestamp is newer, it updates the local parameters and records the parameter modification in the log for easy traceability.

[0075] When the welding parameter management system receives the weld / result message, it first determines the value of the result field. If it is Acceptance, the update status of the device can be directly recorded in the log. If it is Refusal, it means that the current synchronization parameters are not the latest status of the current parameters in the entire system. Therefore, the welding parameter management system needs to update the local parameters and also record the parameter modification status in the log. The welding parameter management system can achieve complete traceability of the equipment synchronization status, including the synchronization time of the parameters, the device that initiated the synchronization, and the synchronization value, etc. At the same time, the network connection fluctuation of the device can be obtained through the update record of the synchronized device.

[0076] The welding parameter management system periodically publishes the local parameter status to the weld / main topic. After receiving the message, each welding device has the same processing logic as when receiving the message from the weld / sync topic.

[0077] Through the above method and system, when the network is unstable or offline during the data synchronization process, resulting in synchronization failure, the consistency of the data can be ensured, which can be divided into three specific situations:

[0078] 1. When the network of the welding equipment initiating synchronization is abnormal, that is, the welding equipment is offline for updating, the equipment will broadcast its updated parameters to the weld / sync topic after it comes back online, and other nodes will decide whether to adopt the value based on the timestamp as described above. If the modified value is no longer the latest value, the welding data management system can update it through the weld / main topic.

[0079] 2. When the network of the welding machine equipment receiving the parameter synchronization message is abnormal, after it comes back online, the welding data management system can update it through the weld / main topic.

[0080] 3. When the welding parameter management system is out of network, it will not affect the data synchronization logic between welding machines. After the network is restored, when the welding parameter management system publishes its parameter status through the weld / main topic, if it is no longer the latest parameter, it will receive a synchronization rejection message published by the device through weld / result, and then update its own welding parameters according to the logic described above.

[0081] Therefore, through the above method, it can be effectively guaranteed that the data of all welding nodes in the network are eventually consistent. As long as the network is restored, the parameters of all nodes will eventually be synchronized to the consistent latest state.

[0082] It should be emphasized that the embodiments described in the present invention are illustrative rather than restrictive. Therefore, the present invention includes but is not limited to the embodiments described in the specific implementation manner. Any other implementation manners derived by those skilled in the art based on the technical solution of the present invention also fall within the scope of protection of the present invention.

Claims

1. A parameter synchronization system for resistance spot welding equipment, characterized in that: It includes resistance welding equipment, welding parameter management system and MQTT Broker, wherein the resistance welding equipment mainly includes resistance welding controller, resistance welding head and welding operation screen. The resistance welding controller, as the core of the welding equipment, communicates with the welding operation screen, welding process parameter management system and MQTT Broker through Ethernet at the same time; the welding operation screen is integrated on the welding equipment to display the current welding parameters and information of the equipment to meet the welding operator's needs for confirming and modifying the parameters of the current equipment; the welding parameter management system is located at the workstation or line corresponding to the welding equipment, and is used for centralized management and data collection of parameters of multiple welding equipment; the MQTT Broker is located in the centralized control room of the welding production workshop, and the welding equipment and welding process parameter management system are both linked to the MQTT Broker deployed on site as MQTT Clients, and communicate with each other by subscribing to corresponding topics.

2. A parameter synchronization system for resistance spot welding equipment according to claim 1, characterized in that: The data transmission between the resistance welding equipment, the welding parameter management system and the MQTT Broker adopts the JSON data format.

3. A parameter synchronization system for resistance spot welding equipment according to claim 1, characterized in that: The welding parameter management system adopts a CRDT method based on LWW-Register to define the LWW-Register of each welding internal parameter.

4. A synchronization method for a parameter synchronization system for a resistance spot welding device according to any one of claims 1 to 3, characterized in that: The following steps are involved: Step 1: Initialize the synchronization system and connect the device; Step 2: Change parameters of welding equipment; Step 3: Determine whether it is synchronized. If it is synchronized, proceed to step 4. Otherwise, stop the update process and the device startup is completed. Step 4: Update parameters and broadcast; Step 5, determine whether the message timestamp is newer, the timestamp is a UNIX timestamp, if the timestamp value is larger, it means the timestamp is updated, if the timestamp is newer, the parameter synchronization is completed, an acceptance signal is sent, and step 6 is performed; otherwise, the modification is ignored, a rejection signal is sent, and step 6 is performed; Step 6: The welding management system records the synchronization results and is responsible for recording and managing the synchronization status of all equipment on site.

5. A synchronization method for a parameter synchronization system of a resistance spot welding device according to claim 4, characterized in that: The specific implementation method of step 1 is as follows: each welding machine device and welding parameter management system are registered as MQTT nodes and connected to the MQTT Broker server, each welding machine device node subscribes to the parameter update topic weld / sync and the centralized management topic weld / main; each welding machine device node is responsible for maintaining a local copy so that the latest updated value can be selected in case of conflict according to the latest timestamp; The welding parameter management system subscribes to the parameter update topic weld / sync and the completion confirmation topic weld / result, and is responsible for tracking the update status of the parameters.

6. A synchronization method for a parameter synchronization system of a resistance spot welding device according to claim 4, characterized in that: The specific implementation method of step 3 is as follows: when the welding machine node needs to update the parameters, the value and timestamp of the corresponding parameters in the local LWW-Register will be updated first; after the update, the operator manually confirms whether to synchronize the parameters. If synchronization is confirmed, the welding machine node broadcasts the updated structure to the weld / sync topic through the MQTTT server.

7. A synchronization method for a parameter synchronization system of a resistance spot welding device according to claim 4, characterized in that: The step 4 comprises the following steps: Step 4.1: After receiving the message from the weld / sync topic, the other welding machine nodes follow the following process: (1) First check the update timestamp of each parameter. If the timestamp of the message is newer, the device performs operation (2). If the timestamp of the message is older, the device performs operation (3). (2) The current welding machine node updates the local parameter value and publishes the update result to the topic weld / result; (3) The device node ignores the message, keeps the current parameter LWW-Register unchanged, and publishes the update result to the topic weld / result; Step 4.2, after receiving the message of weld / sync topic, the welding parameter management system node checks the timestamp of each parameter. If the timestamp of the message is newer, the local parameter value is updated; if the timestamp of the message is older, the message is ignored and the current update is maintained.

8. A synchronization method for a parameter synchronization system of a resistance spot welding device according to claim 4, characterized in that: The specific implementation method of step 6 is as follows: when the welding parameter management system receives the weld / sync message, when it is determined that the timestamp is newer, the local parameters are updated, and the parameter modification is recorded in the log for easy tracing; at the same time, the welding parameter management system periodically publishes the local parameter status to the weld / main topic, and after each welding machine device receives the message, it performs the same processing as when receiving the message of the weld / sync topic; When the welding parameter management system receives the weld / result message returned by the device, it first determines the value of the result field. If it is Acceptance, the update status of the device can be directly recorded in the log. If it is Refusal, it means that the current synchronization parameters are not the latest status of the current parameters in the entire system. Therefore, the welding parameter management system needs to update the local parameters and also record the parameter changes in the log.

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