A method for preventing errors and leaks in projection welding equipment

Abstract

The invention discloses a method for preventing errors and leaking for projection welding equipment. During welding, the system for preventing errors and leaking is used to detect welding errors and leaking. The system for preventing errors and leaking includes a sensor, a communication module, a PLC, a grating and a display. The sensor and the grating communicate with the PLC through the communication module respectively, and the PLC is connected to the display. The sensor includes an electrode displacement sensor, a welding point number detection sensor, a counting sensor and an anti-flying sensor. The method for preventing errors and leaking for projection welding equipment of the invention prevents leakage of welding workpiece counts during the production process, and prevents errors of welding workpieces by monitoring the stroke through an electrode displacement sensor. After receiving a complete set of signals, the projection welding equipment can perform the next sequence. If the signal is incomplete and does not match the set value, the projection welding equipment buzzer alarm cannot perform the next sequence. The workpiece is tested for leak and error prevention welding from the source, which reduces the scrap rate of project products, avoids the outflow of defective products, reduces manufacturing costs, and improves the product qualification rate.

Description

Technical Field

[0001] The invention relates to an error-proofing and leakage-proofing method for projection welding equipment. Background Art

[0002] At present, in the manufacturing process of instrument panel cross beam products, it is a serious problem that the assembly is scrapped due to welding defects and wrong welding of workpieces. Preventing employees from welding defects and wrong welding of workpieces is now a quality and production safety issue that companies focus on.

[0003] In order to prevent employees from leaking or wrongly welding workpieces during the manufacturing process, the welding fixture is usually installed with a proximity switch to detect leaks on the workpiece. However, the substantial increase in the signal points of the welding fixture will cause the equipment to fail to work during the production process due to the unstable feedback of the NG signal from a single proximity switch detection signal, affecting production efficiency and capacity, resulting in a high scrap rate for finished products, high labor costs, high fixture manufacturing costs, and a substantial increase in proximity switches that seriously affects the welding space. Summary of the invention

[0004] The purpose of the present invention is to overcome the defects of the prior art and provide a method for preventing errors and leaks for projection welding equipment. In the production process, the welding workpiece count is prevented from leaking, and the welding workpiece is prevented from errors by monitoring the stroke through an electrode displacement sensor. After receiving a complete set of signals, the projection welding equipment can proceed to the next sequence. If the signal is incomplete and does not match the set value, the projection welding equipment buzzer alarm cannot proceed to the next sequence. The workpiece is inspected for leak and error prevention from the source, thereby reducing the scrap rate of project products, avoiding the outflow of defective products, reducing manufacturing costs, and improving the product qualification rate.

[0005] The technical scheme for achieving the above-mentioned purpose is: a method for preventing errors and leaking for projection welding equipment, wherein during welding, a system for preventing errors and leaking is used to perform welding detection, wherein the system for preventing errors and leaking comprises a sensor, a communication module, a PLC, a grating and a display, wherein the sensor and the grating communicate with the PLC respectively through the communication module, and the PLC is connected to the display; the sensor comprises an electrode displacement sensor, a welding spot number detection sensor, a counting sensor and an anti-flying sensor, and the method for preventing errors and leaking comprises the following steps:

[0006] S1, the error prevention and leakage prevention system communicates with the projection welding equipment, first performs zero position calibration according to the workpiece to be welded, and sets the number of welding points, welding position, welding penetration, upper and lower tolerances, preloading time, welding time, welding current and welding voltage of the workpiece to be welded in the error prevention and leakage prevention system, and then the operator takes out the workpiece to be welded from the raw material box and triggers the error prevention and leakage prevention system at the same time;

[0007] S2, the operator installs the workpiece to be welded, presses the start button of the projection welding equipment, and the welding cylinder is pressed down;

[0008] S3, then the electrode displacement sensor detects the downward pressure position of the welding cylinder and sends it to the PLC of the error prevention and leakage prevention system. The PLC compares the pre-pressure position according to the preset welding position and / or welding penetration value. If the pre-pressure position comparison is abnormal, the welding cylinder rises, and an abnormal position alarm is issued, and a reset alarm is issued to prompt the operator to check whether the workpiece is placed correctly or incorrectly, and return to step S2; if the pre-pressure position comparison is normal, the projection welding equipment performs welding, and the counting sensor detects the number of workpieces corresponding to the welding during the welding process, and the anti-flying sensor monitors in real time whether the workpiece is flying;

[0009] S4, each time welding is completed, the electrode displacement sensor detects the descending height of the welding cylinder to obtain the penetration height on the workpiece, and sends it to the PLC of the error prevention and leakage prevention system. The PLC compares the penetration height according to the preset welding penetration value. If the penetration height comparison is abnormal, it is classified as a defective workpiece. The operator puts the defective workpiece in the defective material frame, and the defective count in the defective material frame is increased by 1; if the penetration height comparison is normal, the welding cylinder rises;

[0010] S5, the welding spot quantity detection sensor detects the number of welding spots on the workpiece and sends it to the PLC of the error prevention and leakage prevention system. The PLC continues to compare the number of welding spots according to the preset number of welding spots. If the number of welding spots is insufficient, the welding cylinder rises and prompts an alarm for abnormal welding spot quantity. If the number of welding spots is sufficient, the qualified product frame cover opens, and the operator puts the qualified product into the qualified product frame and triggers the grating at the same time. After the hand leaves the grating, the qualified product frame cover automatically closes, completing a welding program cycle.

[0011] In the above-mentioned error-proofing and leakage-proofing method for projection welding equipment, in step S1, the zero-position calibration includes the following process: performing the first projection welding, recording the corresponding position values ​​of the pre-stressing position and the welding position of the first welding, and then performing the second projection welding, recording the corresponding position values ​​of the pre-stressing position and the welding position of the second welding, and the PLC gives the tolerance values ​​of the pre-stressing position and the welding position according to the two recorded position values.

[0012] In the above-mentioned error-proofing and leak-proofing method for projection welding equipment, zero position calibration must be performed again each time a workpiece is replaced, an electrode is replaced, or a mold is repaired.

[0013] The above-mentioned error prevention and leakage prevention method for projection welding equipment, wherein, during the welding process, when the error prevention and leakage prevention system performs over-welding, under-welding and leak detection, if the number of welding points of the current workpiece is equal to the preset number of welding points, the welding cylinder will not continue to press down and weld; if the number of welding points of the current workpiece is less than the preset number of welding points, an abnormal number of welding points alarm will be issued, indicating that the current workpiece has started welding production of another workpiece to be welded without welding a sufficient number of times.

[0014] The above-mentioned error prevention and leakage prevention method for projection welding equipment, wherein, when the error prevention and leakage prevention system performs wrong welding detection during the welding process, the downward position of the welding cylinder is obtained by the electrode displacement sensor, and the PLC compares the downward position with the preset welding position. If the downward position of the welding cylinder matches the preset welding position, welding is performed; if the downward position of the welding cylinder is different from the preset welding position, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is accurate.

[0015] The above-mentioned error prevention and leakage prevention method for projection welding equipment, wherein, during the welding process, when the workpiece reverse installation detection is performed by the error prevention and leakage prevention system, the pressing position of the welding cylinder is obtained by the electrode displacement sensor, and the PLC compares the pressing position with the preset welding position. If the pressing position of the welding cylinder is different from the preset welding position, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is correct;

[0016] If the downward pressure position of the welding cylinder matches the preset welding position, welding is performed, and the electrode displacement sensor detects the descending height of the welding cylinder to obtain the penetration height on the workpiece. The PLC compares the penetration height according to the preset welding penetration value. If the penetration position comparison is abnormal, it is classified as a defective workpiece, and an abnormal position alarm is issued at the same time. The operator confirms whether the workpiece is placed upside down; if the penetration position comparison is normal, welding is completed.

[0017] The above-mentioned error prevention and leakage prevention method for projection welding equipment, wherein, when the welding deviation is detected by the error prevention and leakage prevention system during the welding process, the downward position of the welding cylinder is obtained by the electrode displacement sensor, and the PLC compares the downward position with the preset welding position and welding penetration value. If the downward position of the welding cylinder is different from the preset welding position and welding penetration value, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is placed correctly; if the downward position of the welding cylinder matches the preset welding position and welding penetration value, welding is performed.

[0018] The error-proofing and leakage-proofing method for projection welding equipment of the present invention comprises the following steps: a counting sensor detects the number of workpieces corresponding to welding during welding, an anti-flying sensor monitors in real time whether the workpieces are flying off, a protective cover of a finished product box automatically opens after welding is completed, an operator puts qualified products into the finished product box and triggers a grating at the same time, and the protective cover automatically closes after the operator leaves the grating, completing a welding program cycle, thereby reducing the product scrap rate and manufacturing costs; according to the signal output by the sensor, the projection welding equipment receives the signal to determine the work result, and performs leakage-proof and error-proofing welding detection on the workpiece from the source. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a flow chart of the error-proofing and leak-proofing method for projection welding equipment of the present invention;

[0020] Figure 2 It is a structural diagram of the error-proofing and leak-proofing system;

[0021] Figure 3 This is a schematic diagram of the interface for preset values ​​in the error and leakage prevention system;

[0022] Figure 4 This is a schematic diagram of zero position calibration;

[0023] Figure 5 Schematic diagram for error prevention of over-welding, under-welding and missed welding (matching of number of solder joints);

[0024] Figure 6 It is the error-proofing schematic diagram for over-welding, under-welding and missed welding (insufficient number of solder joints);

[0025] Figure 7 This is the error prevention principle diagram for wrong welding;

[0026] Figure 8 This is the error-proofing principle diagram for reverse installation of workpieces;

[0027] Fig. 9 It is a schematic diagram of the melting depth height when the workpiece is installed forwardly or reversely;

[0028] Fig.10 This is the error-proofing principle diagram for welding deviation;

[0029] Fig.11 This is a schematic diagram when the workpiece is not placed correctly;

[0030] Fig.12 Schematic diagram of projection welding equipment. DETAILED DESCRIPTION

[0031] In order to enable those skilled in the art to better understand the technical solution of the present invention, the specific implementation methods thereof are described in detail below in conjunction with the accompanying drawings:

[0032] See also Figures 1 to 12 The best embodiment of the present invention is a method for preventing errors and leaking for projection welding equipment. During the welding process, the error-proofing and leak-proofing system is used to perform error-proofing and leak-proofing welding detection. The error-proofing and leak-proofing system includes a sensor 1, a communication module 2, a PLC 3, a grating 4 and a display 5. The sensor 1 and the grating 4 communicate with the PLC 3 through the communication module 2 respectively, and the PLC 3 is connected to the display 5; the sensor 1 includes an electrode displacement sensor 11, a welding point quantity detection sensor 12, a counting sensor 13 and an anti-flying sensor 14.

[0033] A method for preventing errors and leaks for projection welding equipment, specifically comprising the following steps:

[0034] S1, error proofing and leak proofing system and projection welding equipment 100 (see Fig.12 ) to communicate, first perform zero calibration according to the workpiece to be welded 200, and set the number of welding points, welding position, welding penetration, upper and lower tolerances, preloading time, welding time, welding current and welding voltage of the workpiece to be welded in the error prevention and leakage prevention system (see Figure 3 ), then the operator takes out the workpiece to be welded from the raw material frame and triggers the error prevention and leakage prevention system;

[0035] S2, the operator installs the workpiece to be welded, presses the start button of the projection welding equipment, and the welding cylinder is pressed down;

[0036] S3, then the electrode displacement sensor 11 detects the downward pressure position of the welding cylinder 101, and sends it to the PLC 3 of the error prevention and leakage prevention system. The PLC 3 compares the pre-pressure position according to the preset welding position and / or welding penetration value. If the pre-pressure position comparison is abnormal, the welding cylinder rises, and an abnormal position alarm is issued, and a reset alarm is issued to prompt the operator to check whether the workpiece is placed correctly or incorrectly, and return to step S2; if the pre-pressure position comparison is normal, the projection welding equipment performs welding, and the counting sensor 13 detects the number of workpieces corresponding to the welding during the welding process, and the anti-flying sensor 14 monitors in real time whether the workpiece is flying;

[0037] S4, each time welding is completed, the electrode displacement sensor 11 detects the descending height of the welding cylinder 101 to obtain the penetration height on the workpiece, and sends it to the PLC 3 of the error prevention and leakage prevention system. The PLC 3 compares the penetration height according to the preset welding penetration value. If the penetration height comparison is abnormal, it is classified as a defective workpiece. The operator puts the defective workpiece in the defective material frame, and the defective count in the defective material frame is increased by 1; if the penetration height comparison is normal, the welding cylinder 102 rises and the welding is completed;

[0038] S5, the welding spot number detection sensor 12 detects the number of welding spots on the workpiece and sends it to the PLC 3 of the error prevention and leakage prevention system. The PLC 3 continues to compare the number of welding spots according to the preset number of welding spots. If the number of welding spots is insufficient, the welding cylinder rises and prompts an alarm for abnormal welding spot number. If the number of welding spots is sufficient, the qualified product frame cover opens, and the operator puts the qualified product into the qualified product frame and triggers the grating 4 at the same time. After the hand leaves the grating, the qualified product frame cover automatically closes, completing a welding program cycle.

[0039] Please see again Figure 4In step S1, zero position calibration includes the following process: perform the first projection welding, record the corresponding position values ​​of the pre-pressing position C and the welding position D of the first welding, then perform the second projection welding, record the corresponding position values ​​of the pre-pressing position A and the welding position B of the second welding, and the PLC gives the tolerance values ​​of the pre-pressing position and the welding position according to the position values ​​recorded twice. Zero position calibration should be performed again every time the workpiece is replaced, the electrode is replaced, or the mold is repaired.

[0040] The error prevention and leakage prevention method for projection welding equipment of the present invention can detect over-welding, under-welding, missed welding, wrong welding, reverse installation of workpieces and welding deviation through the error prevention and leakage prevention system during welding, which is described in detail below.

[0041] Please see again Figure 5 and Figure 6 During the welding process, when the error prevention and leakage prevention system is used to detect over-welding, under-welding and leaked welding, if the number of welding points of the current workpiece is equal to the preset number of welding points, the welding cylinder will not continue to press down and weld; if the number of welding points of the current workpiece is less than the preset number of welding points, an abnormal number of welding points alarm will be issued, indicating that the welding production of another workpiece to be welded has started before the current workpiece has been welded enough times.

[0042] Please see again Figure 7 During the welding process, when the error-proofing and leak-proofing system is used to detect the wrong welding, the electrode displacement sensor 11 is used to obtain the downward pressure position of the welding cylinder, and the PLC 3 compares the downward pressure position with the preset welding position. If the downward pressure position of the welding cylinder matches the preset welding position, welding is performed; if the downward pressure position of the welding cylinder is different from the preset welding position, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is accurate. The height of standard parts of different specifications such as M6, M8, and M10 can be basically distinguished.

[0043] Please see again Figure 8 and Fig. 9 During the welding process, when the workpiece is reversely installed and detected by the error prevention and leakage prevention system, the electrode displacement sensor 11 is used to obtain the downward pressure position of the welding cylinder, and the PLC 3 compares the downward pressure position with the preset welding position. If the downward pressure position of the welding cylinder is different from the preset welding position, the welding cylinder rises and welding is not performed to avoid producing defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is accurate; if the downward pressure position of the welding cylinder matches the preset welding position, welding is performed, and the electrode displacement sensor is used to detect the descending height of the welding cylinder to obtain the depth of penetration on the workpiece. The PLC compares the depth of penetration height according to the preset welding depth value. If the depth of penetration position comparison is abnormal, it is classified as a defective workpiece, and an abnormal position alarm is issued at the same time, and the operator confirms whether the workpiece is placed upside down; if the depth of penetration position comparison is normal, the welding is completed.

[0044] Please see again Fig.10 and Fig.11 During the welding process, when the error-proofing and leakage-proofing system is used to detect welding deviation, the electrode displacement sensor 11 obtains the downward pressure position of the welding cylinder, and the PLC compares the downward pressure position with the preset welding position and welding penetration value. If the downward pressure position of the welding cylinder is different from the preset welding position and welding penetration value, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is placed correctly; if the downward pressure position of the welding cylinder matches the preset welding position and welding penetration value, welding is performed.

[0045] The error-proofing and leakage-proofing method for projection welding equipment of the present invention prevents leakage by counting welding workpieces during the production process and prevents errors by monitoring the stroke of welding workpieces through electrode displacement sensors. The projection welding equipment can perform subsequent work after receiving a complete set of signals. If the signal is incomplete and does not match the set value, the projection welding equipment buzzer alarms and subsequent work cannot be performed. The workpieces are inspected for leakage and error-proof welding from the source, thereby reducing the scrap rate of project products, avoiding the outflow of defective products, reducing manufacturing costs, and improving the product qualification rate.

[0046] In summary, the error-proofing and leakage-proofing method for projection welding equipment of the present invention can reduce product scrap rate and manufacturing cost. According to the signal output by the sensor, the projection welding equipment receives the signal to determine the working result, and performs leakage-proof and error-proof welding detection on the workpiece from the source.

[0047] Those skilled in the art should recognize that the above embodiments are only used to illustrate the present invention, and are not intended to limit the present invention. As long as they are within the spirit of the present invention, any changes or modifications to the above embodiments will fall within the scope of the claims of the present invention.

Claims

1. A method for preventing errors and leaks in projection welding equipment, characterized in that: During the welding process, error-proofing and leakage-proofing welding detection is performed through an error-proofing and leakage-proofing system, the error-proofing and leakage-proofing system comprises a sensor, a communication module, a PLC, a grating and a display, the sensor and the grating communicate with the PLC through the communication module respectively, and the PLC is connected to the display; the sensor comprises an electrode displacement sensor, a welding point quantity detection sensor, a counting sensor and an anti-flying sensor, and the error-proofing and leakage-proofing method comprises the following steps: S1, the error prevention and leakage prevention system communicates with the projection welding equipment, first performs zero position calibration according to the workpiece to be welded, and sets the number of welding points, welding position, welding penetration, upper and lower tolerances, preloading time, welding time, welding current and welding voltage of the workpiece to be welded in the error prevention and leakage prevention system, and then the operator takes out the workpiece to be welded from the raw material box and triggers the error prevention and leakage prevention system at the same time; S2, the operator installs the workpiece to be welded, presses the start button of the projection welding equipment, and the welding cylinder is pressed down; S3, then the electrode displacement sensor detects the downward pressure position of the welding cylinder and sends it to the PLC of the error prevention and leakage prevention system. The PLC compares the pre-pressure position according to the preset welding position and / or welding penetration value. If the pre-pressure position comparison is abnormal, the welding cylinder rises, and an abnormal position alarm is issued, and a reset alarm is issued to prompt the operator to check whether the workpiece is placed correctly or incorrectly, and return to step S2; if the pre-pressure position comparison is normal, the projection welding equipment performs welding, and the counting sensor detects the number of workpieces corresponding to the welding during the welding process, and the anti-flying sensor monitors in real time whether the workpiece is flying; S4, each time welding is completed, the electrode displacement sensor detects the descending height of the welding cylinder to obtain the penetration height on the workpiece, and sends it to the PLC of the error prevention and leakage prevention system. The PLC compares the penetration height according to the preset welding penetration value. If the penetration height comparison is abnormal, it is classified as a defective workpiece. The operator puts the defective workpiece in the defective material frame, and the defective count in the defective material frame is increased by 1; if the penetration height comparison is normal, the welding cylinder rises; S5, the welding spot quantity detection sensor detects the number of welding spots on the workpiece and sends it to the PLC of the error prevention and leakage prevention system. The PLC continues to compare the number of welding spots according to the preset number of welding spots. If the number of welding spots is insufficient, the welding cylinder rises and prompts an alarm for abnormal welding spot quantity. If the number of welding spots is sufficient, the qualified product frame cover opens, and the operator puts the qualified product into the qualified product frame and triggers the grating at the same time. After the hand leaves the grating, the qualified product frame cover automatically closes, completing a welding program cycle.

2. The error-proofing and leak-proofing method for projection welding equipment according to claim 1, characterized in that: In step S1, the zero position calibration includes the following process: perform the first convex welding, record the corresponding position values ​​of the pre-stressing position and the welding position of the first welding, then perform the second convex welding, record the corresponding position values ​​of the pre-stressing position and the welding position of the second welding, and the PLC gives the tolerance values ​​of the pre-stressing position and the welding position according to the position values ​​recorded twice.

3. A method for preventing errors and leaks for projection welding equipment according to claim 1 or 2, characterized in that: Zero position calibration must be performed again every time the workpiece is replaced, the electrode is replaced or the mold is repaired.

4. The error-proofing and leak-proofing method for projection welding equipment according to claim 1, characterized in that: During the welding process, when the error prevention and leakage prevention system is used to detect over-welding, under-welding and leaked welding, if the number of welding points of the current workpiece is equal to the preset number of welding points, the welding cylinder will not continue to press down and weld; if the number of welding points of the current workpiece is less than the preset number of welding points, an abnormal number of welding points alarm will be issued, indicating that the welding production of another workpiece to be welded has started without welding the current workpiece enough times.

5. The error-proofing and leak-proofing method for projection welding equipment according to claim 1, characterized in that: When the error-proofing and leakage-proofing system is used to detect wrong welding during the welding process, the electrode displacement sensor obtains the downward pressure position of the welding cylinder, and the PLC compares the downward pressure position with the preset welding position. If the downward pressure position of the welding cylinder matches the preset welding position, welding is performed; if the downward pressure position of the welding cylinder is different from the preset welding position, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is accurate.

6. The error-proofing and leak-proofing method for projection welding equipment according to claim 1, characterized in that: During the welding process, when the workpiece is reversely installed through the error prevention and leakage prevention system, the electrode displacement sensor obtains the downward pressure position of the welding cylinder, and the PLC compares the downward pressure position with the preset welding position. If the downward pressure position of the welding cylinder is different from the preset welding position, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is correct; If the downward pressure position of the welding cylinder matches the preset welding position, welding is performed, and the electrode displacement sensor detects the descending height of the welding cylinder to obtain the penetration height on the workpiece. The PLC compares the penetration height according to the preset welding penetration value. If the penetration position comparison is abnormal, it is classified as a defective workpiece, and an abnormal position alarm is issued at the same time. The operator confirms whether the workpiece is placed upside down; if the penetration position comparison is normal, welding is completed.

7. The error-proofing and leak-proofing method for projection welding equipment according to claim 1, characterized in that: When the error-proofing and leakage-proofing system is used to detect weld deviation during welding, the electrode displacement sensor is used to obtain the downward pressure position of the welding cylinder, and the PLC compares the downward pressure position with the preset welding position and welding penetration value. If the downward pressure position of the welding cylinder is different from the preset welding position and welding penetration value, the welding cylinder rises and welding is not performed to avoid the production of defective products. At the same time, an abnormal position alarm is issued, and the operator confirms whether the workpiece is placed correctly; if the downward pressure position of the welding cylinder matches the preset welding position and welding penetration value, welding is performed.

Images