Transformer wire automatic welding control management system and method

Abstract

The invention belongs to the technical field of transformer production and manufacturing, and particularly relates to a transformer wire automatic welding control management system which comprises an MES system used for forming a task work order according to task requirements of a production work order and issuing a welding task work order to a data acquisition and monitoring control system, a welding completion work order returned by the data acquisition and monitoring control system is received for data archiving; the data acquisition and monitoring control system imports corresponding welding control information according to the information in the task work order and sends the welding control information to an automatic welding system PLC; welding parameter information, returned by the PLC of the automatic welding system, of the workpiece is received, and a welding completion work order is formed and sent to the MES system; the automatic welding system PLC is used for automatically controlling the welding processing equipment in the welding work station to perform welding according to the task work order; the automatic welding system is used for replacing a traditional manual welding mode, the product manufacturing efficiency and the product quality are improved, and the management degree is improved in the welding process.

Description

Technical Field

[0001] The invention belongs to the technical field of transformer production and manufacturing, and in particular is a transformer wire automatic welding control management system and method. Background Art

[0002] In the field of UHV transformer manufacturing, copper wire is the basic component of the coil, the core component of the transformer. The welding quality of copper wire directly affects the quality of the transformer product. If there is a cold weld or false weld during the wire welding process, the DC resistance of the wire will increase, causing local heat concentration, insulation damage, coil short circuit, transformer explosion and other major quality accidents; or the wire will be broken by the electric force during the operation of the product, resulting in transformer failure. Since the wire welding defects exist inside the coil, when quality problems occur, the rework cost is high, the rework cycle is long, and the failure has a great impact, which will cause great harm to the transformer and substation, and have a great impact on the company's operating results and reputation.

[0003] The existing automatic welding control and management system has the following defects:

[0004] (1) The welding process lacks data-based control and is not quantifiable. The wire welding process is a special operation. The welding temperature, welding voltage, and current specified in the welding process parameters lack quantitative indicators. The quality of wire welding depends largely on the operator's experience and judgment.

[0005] (2) The welding quality is highly dispersed and the standard operation level is low. At present, wire welding operations are all manual operations. Therefore, each welding is affected by the operator's skill level and stability. The wire welding quality fluctuates greatly, the welding process cannot be standardized, and the welding quality is difficult to manage in a standardized manner.

[0006] (3) The status of finished products cannot be reviewed and traced. Currently, paper operation inspection records are used for product operations, which is difficult to review. At the same time, the welding parameters, welding time and other information used in the welding process cannot be traced and reviewed at all, making it difficult to conduct strict closed-loop management of product quality.

[0007] Therefore, in view of the process of upgrading the manual welding of wires to automatic welding in the transformer production process, it is particularly important to propose a management and control system and process method for automatic welding of transformer wires. Summary of the invention

[0008] The purpose of the present invention is to provide a transformer conductor automatic welding control management system and method according to the process of upgrading the conductor from manual welding to automatic welding in the transformer production process, so as to overcome the defects of the above automatic welding control management system.

[0009] The technical solution adopted by the present invention to achieve the above-mentioned purpose is: a transformer conductor automatic welding control and management system, including: MES system, data acquisition and monitoring control system, automatic welding system PLC and welding processing station;

[0010] The MES system is used to generate a task work order according to the task requirements of the production work order, and send the welding task work order to the data acquisition and monitoring control system, and receive the welding completion work order for the transformer conductor sent back by the data acquisition and monitoring control system for data archiving;

[0011] The data acquisition and monitoring control system is used to read the information in the welding task work order sent by the MES system, and call the corresponding welding control information in the form of code in the database of the MES system to send it to the automatic welding system PLC; and receive the welding parameter information of the workpiece returned by the automatic welding system PLC, and form a welding completion work order and send it to the MES system;

[0012] The automatic welding system PLC is used to realize automatic control of the welding processing equipment in the welding workstation to perform welding according to the task work order based on the corresponding welding control information in the form of code sent by the data acquisition and monitoring control system;

[0013] There are multiple welding processing stations, and each welding processing station is set in parallel and connected to the automatic welding system PLC to receive welding control information sent by the automatic welding system PLC to perform automatic welding operations.

[0014] The task work order includes: product technical code, product serial number, coil column number, wire gauge, procedure number, equipment number, operator serial number, and operation date.

[0015] The welding completion work order includes: product technical code, product serial number, coil column number, wire gauge, program number, equipment number, operator serial number, operation date, welding joint serial number, welding program parameters, actual welding parameters, and operator information confirmation.

[0016] The task work order is as follows: the process personnel compile the on-site welding construction process operation procedures according to the task requirements of the production work order and the information in the resource database, and submit them for review; after the review is passed, the process engineer forms the welding control information of the transformer wire welding program according to the process data and imports it into the MES system, and at the same time inspects it through automatic welding samples. After the inspection is passed, the transformer wire welding program is retained in the database of the MES system.

[0017] There are multiple welding processing stations, each of which includes: a hoisting platform and a mobile mounting frame arranged on the hoisting platform, a suspension mechanical arm, welding processing equipment, an induction power supply and a refrigeration device;

[0018] The hoisting platform is suspended below the overhead crane, and the hoisting platform is driven to move to the processing area by controlling the movement of the overhead crane;

[0019] There are two mobile mounting frames, which are symmetrically arranged on the hoisting platform; a suspension mechanical arm is fixedly arranged on the mounting platform of the mobile mounting frame, and a welding processing device is fixedly arranged at the end of the suspension mechanical arm; the welding processing device is connected to the induction power supply;

[0020] The refrigeration device is arranged on one side of the two mobile mounting frames and is used to cool the welding processing equipment on the suspension robot arm;

[0021] The top of the mobile mounting frame is provided with a plurality of Forma wheels for stabilizing on the hoisting platform to ensure that there is no shaking during the welding process;

[0022] The suspension robot arm is a pneumatic suspension robot arm, and a gas spring is provided between its main robot arm and its connecting arm, which is used to support the pneumatic spring so that it can hover at any position and keep the load output end stable.

[0023] A transformer conductor automatic welding control management method comprises the following steps:

[0024] 1) The MES system will generate a task order based on the task requirements of the production work order, and send the welding task order to the data acquisition and monitoring control system;

[0025] 2) The data acquisition and monitoring control system reads the information in the welding task work order sent by the MES system, and calls the corresponding welding control information in the form of code in the database of the MES system and sends it to the automatic welding system PLC;

[0026] 3) The automatic welding system PLC controls the welding equipment in the welding processing station to weld the workpiece according to the corresponding welding control information in the form of code sent by the data acquisition and monitoring control system and the set automatic welding algorithm;

[0027] 4) The data acquisition and monitoring control system collects the welding parameter information of the transformer conductor in real time and evaluates the welded transformer conductor. After the evaluation is completed, a welding completion work order is generated and sent back to the MES system for data archiving, completing the automatic welding closed loop of the transformer conductor.

[0028] The task work order is formed according to the task requirements of the production work order, specifically:

[0029] 1-1) The process engineer sets the welding process drawing of the transformer conductor according to the task requirements of the production work order and uploads it to the MES system for drawing signing;

[0030] 1-2) After each department completes the drawing signing on the MES system, the MES system will identify the production plan and issue all the procurement information required for the application;

[0031] 1-3) The process engineer will write the on-site welding construction process operation procedures and work instructions and upload them to the MES system database in a code format. The data acquisition and monitoring control system will call the automatic welding program and send it to the automatic welding system PLC to control the welding processing equipment in the welding processing station to produce automatic welding samples;

[0032] 1-4) Inspect the automatic welding samples. After passing the inspection, keep the automatic welding program in the MES system and wait for the data acquisition and monitoring control system to call it.

[0033] The automatic welding algorithm is specifically:

[0034] 2-1) Increase welding heat input:

[0035] Since the cross-sectional area of ​​the wire depends on the thickness and width of the wire, if the width-to-thickness ratio of the two sections is different but the cross-sectional area is the same, the cross-sectional area of ​​the wire is obtained. The larger the cross-sectional area of ​​the wire, the greater the heat input;

[0036] 2-2) Automatic welding gap:

[0037] During welding, the material will expand due to heat. Therefore, a certain gap should be left between the two copper wires when they are assembled. The gap between the sensor and the workpiece is set to 0.05mm-0.15mm, which is determined by the heating temperature. The thermal expansion coefficient of copper is 17.2*10-6 / ℃. According to the formula, the theoretical optimal gap is:

[0038] Theoretical optimum gap = temperature * thermal expansion coefficient * 10

[0039] In actual welding, the wire spacing is measured with a feeler gauge before welding to make the actual wire spacing close to the theoretical optimal spacing;

[0040] 2-3) Heating method:

[0041] The welding process is divided into: heating stage, constant temperature stage, and cooling stage;

[0042] The heating stage will directly affect the speed of heat dissipation. The slower the heating stage, the faster the heat dissipation. The constant temperature stage ensures that the solder is fully melted and flows, ensuring the welding quality inside the weld. During the welding process, the welding quality can be optimized by changing the heating method, extending the constant temperature stage time, and reducing the temperature reduction stage time.

[0043] In step 4), the welded transformer conductor is evaluated by performing the following steps:

[0044] (1) Tensile test: The tensile strength of the weld shall be at least 80% of the tensile strength of the parent material, and the fracture site shall not be at the joint;

[0045] (2) DC resistivity should not be greater than 0.01793Ω·㎜2·m -1 ; Repeat the above operation for each wire gauge sample until all are tested and qualified.

[0046] The welding completion work order, all information in the task work order, as well as the welding joint serial number, welding program parameters, welding actual parameters, and operator information confirmation;

[0047] The task work order includes: product technical code, product serial number, coil column number, wire gauge, procedure number, equipment number, operator serial number, and operation date.

[0048] The present invention has the following beneficial effects and advantages:

[0049] 1. The present invention uses an automatic welding system to replace the traditional manual welding method, thereby improving product manufacturing efficiency and product quality, and improving the management of the welding process.

[0050] 2. After the present invention is applied, it is expected to increase the welding efficiency by 20%, improve the coil manufacturing output efficiency, and without being restricted by other processes, it is expected to increase the annual output by more than 5-10 units (220kV).

[0051] 3. In the face of problems such as overheating and short circuit inside the coil, serious accidents are very likely to occur. The present invention can effectively improve the quality of wire welding and is expected to reduce 80% of accidents caused by coils. Successfully avoiding a major accident can save tens of millions of losses. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 This is a control principle diagram of the transformer conductor automatic welding control management system of the present invention;

[0053] Figure 2 It is a process flow chart of the present invention;

[0054] Figure 3a This is a schematic diagram of the overall structure of the welding processing station of the present invention;

[0055] Figure 3b This is a schematic diagram of the structure of the welding processing station of the present invention;

[0056] Figure 4 The present invention is a high frequency automatic welding embodiment experimental result;

[0057] Figure 5 These are the experimental results of the automatic welding algorithm embodiment independently developed by the present invention. DETAILED DESCRIPTION

[0058] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0059] (1) Carry out process research to address the problems in the current welding process. The main research content is the impact of wire thickness and width on welding parameters during the welding process. Wire thickness and width are graded in the full range, and the corresponding welding parameters and welding procedures are studied to form a welding procedure library. After using X-ray detection inside the wire, the boundaries of welding defects and welding defects inside the weld are divided, and inspection standards are formulated. Conduct a study on the process compliance of the welding process to ensure that the welding output parameters meet the welding procedure parameters corresponding to the current welding wire specifications.

[0060] (2) The main dimensional parameters of the wire specifications are thickness and width. As the thickness and width increase, the welding procedure should be adjusted and formulated. As the thickness of the wire increases, the welding current and voltage should be increased accordingly to ensure that the weld is fully melted through and there is no incomplete fusion or false welding. As the welding width increases, the welding time should be increased to ensure that the solder flows fully at high temperatures to avoid local solder loss and uneven welds. The welding procedure for the wire is formulated in this way, and the program is fine-tuned according to the results of the tensile force test, DC resistance test and non-destructive testing, and finally the program that best meets the process requirements for the wire gauge is obtained. The programs corresponding to different wire gauges are classified and sorted, all wire gauges are graded, and the corresponding relationship between the program and the wire gauge grade is formulated. A standard library of automatic welding programs is established, one of the parameters of width and thickness is fixed, and the minimum differential grade of the other parameter is explored to finally form a program library.

[0061] (3) Develop an automatic welding parameter control system, use welding procedures to control the welding process and monitor parameters. In addition to welding parameters, the heating method, the holding time at the highest power output, the cooling method, etc. are also controlled during the welding process. Use curve comparison to monitor welding process parameters, and set the oscillation frequency curve, output power curve, oscillation current curve, etc. Ensure that the welding process parameters are strictly in accordance with the process requirements; generate output parameter curves during the welding process, and generate welding program parameter curves at the same time. Formulate process requirements including the maximum deviation range, total deviation, etc. to ensure that the stability of welding process parameter output meets the deviation requirements specified in the process.

[0062] (4) If automatic welding is used instead of manual welding, the wire automatic welding system needs to have online programming and offline programming functions to compile welding procedures; it should have the function of recording welding parameters and comparing them with the welding procedures to ensure effective control of the welding process; it should have the function of program storage for subsequent calls; the central control machine should have the ability to connect to the MES system and the welding machine to realize work dispatch and completion traceability.

[0063] (5) The compilation of the program needs to rely on mature manual welding parameters as the basis, supplemented by the breaking force and DC resistance, and through a large number of sample production, repeated fine-tuning to achieve the best state of the program corresponding to a certain wire gauge. Then, through the welding process detection of the welding equipment, it is ensured that the most correct welding program is applied to the wire of the corresponding wire gauge, thereby ensuring the welding quality.

[0064] like Figure 1 As shown, it is a control principle diagram of the transformer conductor automatic welding control and management system of the present invention, and the transformer conductor automatic welding control and management system of the present invention comprises: MES system, data acquisition and monitoring control system (SCADA system, hereinafter collectively referred to as data acquisition and monitoring control system), automatic welding system PLC and welding processing station;

[0065] The MES system is used to generate a task work order according to the task requirements of the production work order, and send the welding task work order to the data acquisition and monitoring control system, and receive the welding completion work order for the transformer conductor sent back by the data acquisition and monitoring control system for data archiving;

[0066] The data acquisition and monitoring control system is used to read the information in the welding task work order sent by the MES system, and call the corresponding welding control information in the form of code in the database of the MES system to send it to the automatic welding system PLC; and receive the welding parameter information of the workpiece returned by the automatic welding system PLC, and form a welding completion work order and send it to the MES system;

[0067] The automatic welding system PLC is used to realize automatic control of the welding processing equipment in the welding workstation to perform welding according to the task work order based on the corresponding welding control information in the form of code sent by the data acquisition and monitoring control system;

[0068] There are multiple welding processing stations, and each welding processing station is set in parallel and connected to the automatic welding system PLC to receive welding control information sent by the automatic welding system PLC to perform automatic welding operations.

[0069] like Figure 2 As shown, it is a process flow chart of the present invention, wherein the task work order is: the process personnel compile the on-site welding construction process operation procedures according to the task requirements of the production work order and the information in the resource database, and submit them for review; after the review is passed, the process engineer forms the welding control information of the transformer wire welding program according to the process data and imports it into the MES system, and at the same time, the automatic welding sample is used for inspection. After the inspection is passed, the transformer wire welding program is retained in the database of the MES system.

[0070] In the method of the present invention, the task work order includes: product technical code, product serial number, coil column number, wire gauge, procedure number, equipment number, operator serial number, and operation date.

[0071] Welding completion work order, including: product technical code, product serial number, coil column number, wire gauge, program number, equipment number, operator serial number, operation date, welding joint serial number, welding program parameters, actual welding parameters, operator information confirmation.

[0072] The specific task work order and welding completion work order specifications are shown in Table 1:

[0073] Table 1 Task work order and welding completion work order specification table

[0074]

[0075]

[0076] like Figure 3a to Figure 3b As shown, it is a schematic diagram of the structure of the welding processing station of the present invention; there are multiple welding processing stations, each of which includes: a hoisting platform and a mobile mounting frame arranged on the hoisting platform, a suspension mechanical arm, a welding processing equipment, an induction power supply and a refrigeration device;

[0077] The hoisting platform is suspended under the overhead crane, and the hoisting platform is moved to the processing area by controlling the movement of the overhead crane;

[0078] There are two mobile mounting frames, which are symmetrically arranged on the hoisting platform; a suspension mechanical arm is fixedly arranged on the mounting platform of the mobile mounting frame, and a welding processing device is fixedly arranged at the end of the suspension mechanical arm; the welding processing device is connected to the induction power supply;

[0079] The refrigeration device is installed on one side of the two mobile mounting frames and is used to cool the welding processing equipment on the suspended robot arm;

[0080] There are several Foma wheels on the top of the mobile mounting frame to stabilize it on the lifting platform to ensure that there is no shaking during the welding process;

[0081] In this embodiment, the maximum thickness of a transformer wire is 5.1 mm, and the maximum width is 14 mm. The welding can be completed within 10 seconds in high-frequency welding. The high-frequency welding output terminal weighs about 2 kg. At the same time, due to the induction force generated during high-frequency induction welding, the handheld output terminal is very easy to shake, resulting in deviations in welding heat input, resulting in fluctuations in welding quality.

[0082] This embodiment is equipped with a suspended robotic arm instead of handheld. The robotic arm is supported by a pneumatic spring, which can load the output end and maintain stability, ensuring that there is no shaking during the welding process, the welding heat input is stable, and the welding quality consistency is high.

[0083] like Figure 1 As shown, the present invention is based on a method for a transformer conductor automatic welding control management system, comprising the following steps:

[0084] 1) The MES system will generate a task order based on the task requirements of the production work order, and send the welding task order to the data acquisition and monitoring control system;

[0085] 2) The data acquisition and monitoring control system reads the information in the welding task work order sent by the MES system, and calls the corresponding welding control information in the form of code in the database of the MES system and sends it to the automatic welding system PLC;

[0086] 3) The automatic welding system PLC controls the welding equipment in the welding processing station to weld the workpiece according to the corresponding welding control information in the form of code sent by the data acquisition and monitoring control system and the set automatic welding algorithm;

[0087] 4) The data acquisition and monitoring control system collects the welding parameter information of the transformer conductor in real time and evaluates the welded transformer conductor. After the evaluation is completed, a welding completion work order is generated and sent back to the MES system for data archiving, completing the automatic welding closed loop of the transformer conductor.

[0088] like Figure 2 As shown, a task work order is formed according to the task requirements of the production work order, specifically:

[0089] 1-1) The process engineer sets the welding process drawing of the transformer conductor according to the task requirements of the production work order and uploads it to the MES system for drawing signing;

[0090] 1-2) After each department completes the drawing signing on the MES system, the MES system will identify the production plan and issue all the procurement information required for the application;

[0091] 1-3) The process engineer will write the on-site welding construction process operation procedures and work instructions and upload them to the MES system database in a code format. The data acquisition and monitoring control system will call the automatic welding program and send it to the automatic welding system PLC to control the welding processing equipment in the welding processing station to produce automatic welding samples;

[0092] 1-4) Inspect the automatic welding samples. After passing the inspection, keep the automatic welding program in the MES system and wait for the data acquisition and monitoring control system to call it.

[0093] In this embodiment, an automatic welding algorithm is applied, including the following steps:

[0094] 2-1) Study on welding heat input

[0095] According to the research, it is found that the core basis for the preparation of automatic welding programs for wires is the cross-sectional area of ​​the wire, which in turn depends on the thickness and width of the wire. Although the width-to-thickness ratio of the two sections is different, the cross-sectional area is the same, so the same welding program should be used. Subsequent program preparation should be considered from the perspective of cross-sectional area, and the heat input should be increased for wires with large cross-sectional areas.

[0096] 2-2) Research on automatic welding gap

[0097] The sensor and the workpiece can be separated by a 2mm gap, or they can be fitted together, depending on the actual production conditions. According to the actual production conditions of our factory, tight fitting will not damage the sensor or the workpiece. In subsequent actual welding, the fitting method should be used to ensure the stability of heat input.

[0098] During welding, the material will expand due to heat, so a certain gap should be left between the two copper wires when they are assembled. The optimal gap should be between 0.05mm and 0.15mm, which is determined by the heating temperature. The thermal expansion coefficient of copper is 17.2*10 -6 / ℃, according to the formula:

[0099] Gap = temperature * thermal expansion coefficient * 10

[0100] According to the welding experience, the welding temperature is about 800℃. Therefore, the gap should be D=800*17.2*10 -6 *10=0.1376mm. That is, when welding at 800℃, the wire gap should be 0.1376mm.

[0101] During actual welding, the wire spacing should be measured with a feeler gauge before welding to ensure that the actual wire spacing is as consistent with the data as possible.

[0102] 2-3) Study on heating method

[0103] The programming process is mainly divided into three sections: heating section, constant temperature section and cooling section.

[0104] After research, it is found that the first stage of heating and the second stage of constant temperature are more important and should be paid special attention to when programming. The heating stage will directly affect the speed of heat dissipation. The slower the heating, the faster the heat dissipation. The constant temperature stage ensures that the solder is fully melted and flows, ensuring the welding quality inside the weld. In subsequent welding, try to change the heating method (step and ramp), extend the constant temperature stage time, and reduce the temperature reduction stage time, etc., in this way to optimize the welding quality.

[0105] In another embodiment of the present invention, welding is performed using the high frequency induction welding principle:

[0106] This system relies on automation equipment and information systems, and uses automatic welding technology to replace manual welding. The basic principle of welding is to complete the brazing of copper wires through the principle of induction heating. When the alternating current flows through the conductor, an induced current will be generated in the conductor, causing the current to spread to the surface of the conductor. That is, the current density on the surface of the conductor will be greater than the current density in the center.

[0107] At room temperature, the skin depth of copper can be calculated using the following formula:

[0108]

[0109] From the above, we can see that increasing the current and frequency can increase the heating effect, which means the heating object will heat up quickly. Therefore, the induction power supply usually needs to output high frequency and high current.

[0110] In step 4), the welded transformer wire is evaluated by performing the following steps:

[0111] (1) Tensile test: The tensile strength of the weld shall be at least 80% of the tensile strength of the parent material, and the fracture site shall not be at the joint;

[0112] (2) DC resistivity should not be greater than 0.01793Ω·㎜2·m -1 ; Repeat the above operation for each wire gauge sample until all are tested and qualified.

[0113] According to the experimental results in this embodiment, it can be seen that:

[0114] 1. If Figure 4 As shown, it is the experimental result of the high-frequency automatic welding embodiment. In the high-frequency automatic welding of one embodiment of the present invention, the breaking force and DC resistance of the high-frequency automatic welding sample can meet the requirements of our company's wire high-frequency welding qualification certification. Therefore, it can be considered that high-frequency automatic welding can be applied to the welding of transformer electromagnetic wires and can meet the quality requirements.

[0115] 2. If Figure 5 The figure shows the experimental results of the automatic welding algorithm embodiment. From the experimental results of multiple wire gauges, it can be concluded that the stability of automatic welding is better than that of manual welding, and the welding quality is more stable. According to the experimental results of wire gauges 1 and 3, the breaking force of some manual welding is close to or even lower than the horizontal line of 80% of the parent material (marked by the red circle). The use of automatic welding can effectively avoid such individual situations and avoid quality problems.

[0116] The above description is only an embodiment of the present invention and is not intended to limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, expansion, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.

Claims

1. A transformer conductor automatic welding control management system, characterized in that: include: MES system, data acquisition and monitoring control system, automatic welding system PLC and welding processing station; The MES system is used to generate a task work order according to the task requirements of the production work order, and send the welding task work order to the data acquisition and monitoring control system, and receive the welding completion work order for the transformer conductor sent back by the data acquisition and monitoring control system for data archiving; The data acquisition and monitoring control system is used to read the information in the welding task work order sent by the MES system, and call the corresponding welding control information in the form of code in the database of the MES system to send it to the automatic welding system PLC; and receive the welding parameter information of the workpiece returned by the automatic welding system PLC, and form a welding completion work order and send it to the MES system; The automatic welding system PLC is used to realize automatic control of the welding processing equipment in the welding workstation to perform welding according to the task work order based on the corresponding welding control information in the form of code sent by the data acquisition and monitoring control system; There are multiple welding processing stations, and each welding processing station is set in parallel and connected to the automatic welding system PLC to receive welding control information sent by the automatic welding system PLC to perform automatic welding operations.

2. A transformer conductor automatic welding control management system according to claim 1, characterized in that: The task work order includes: product technical code, product serial number, coil column number, wire gauge, procedure number, equipment number, operator serial number, and operation date.

3. The transformer conductor automatic welding control management system according to claim 1, characterized in that: The welding completion work order includes: product technical code, product serial number, coil column number, wire gauge, program number, equipment number, operator serial number, operation date, welding joint serial number, welding program parameters, actual welding parameters, and operator information confirmation.

4. The transformer conductor automatic welding control management system according to claim 1, characterized in that: The task work order is as follows: the process personnel compile the on-site welding construction process operation procedures according to the task requirements of the production work order and the information in the resource database, and submit them for review; after the review is passed, the process engineer forms the welding control information of the transformer wire welding program according to the process data and imports it into the MES system, and at the same time inspects it through automatic welding samples. After the inspection is passed, the transformer wire welding program is retained in the database of the MES system.

5. The transformer conductor automatic welding control management system according to claim 1, characterized in that: There are multiple welding processing stations, each of which includes: a hoisting platform and a mobile mounting frame arranged on the hoisting platform, a suspension mechanical arm, welding processing equipment, an induction power supply and a refrigeration device; The hoisting platform is suspended below the overhead crane, and the hoisting platform is driven to move to the processing area by controlling the movement of the overhead crane; There are two mobile mounting frames, which are symmetrically arranged on the hoisting platform; a suspension mechanical arm is fixedly arranged on the mounting platform of the mobile mounting frame, and a welding processing device is fixedly arranged at the end of the suspension mechanical arm; the welding processing device is connected to the induction power supply; The refrigeration device is arranged on one side of the two mobile mounting frames and is used to cool the welding processing equipment on the suspension robot arm; The top of the mobile mounting frame is provided with a plurality of Forma wheels for stabilizing on the hoisting platform to ensure that there is no shaking during the welding process; The suspension robot arm is a pneumatic suspension robot arm, and a gas spring is provided between its main robot arm and its connecting arm, which is used to support the pneumatic spring so that it can hover at any position and keep the load output end stable.

6. A transformer conductor automatic welding control management method, characterized in that: The following steps are involved: 1) The MES system will generate a task order based on the task requirements of the production work order, and send the welding task order to the data acquisition and monitoring control system; 2) The data acquisition and monitoring control system reads the information in the welding task work order sent by the MES system, and calls the corresponding welding control information in the form of code in the database of the MES system and sends it to the automatic welding system PLC; 3) The automatic welding system PLC controls the welding equipment in the welding processing station to weld the workpiece according to the corresponding welding control information in the form of code sent by the data acquisition and monitoring control system and the set automatic welding algorithm; 4) The data acquisition and monitoring control system collects the welding parameter information of the transformer conductor in real time and evaluates the welded transformer conductor. After the evaluation is completed, a welding completion work order is generated and sent back to the MES system for data archiving, completing the automatic welding closed loop of the transformer conductor.

7. A transformer conductor automatic welding control management method according to claim 6, characterized in that: The task work order is formed according to the task requirements of the production work order, specifically: 1-1) The process engineer sets the welding process drawing of the transformer conductor according to the task requirements of the production work order and uploads it to the MES system for drawing signing; 1-2) After each department completes the drawing signing on the MES system, the MES system will identify the production plan and issue all the procurement information required for the application; 1-3) The process engineer will write the on-site welding construction process operation procedures and work instructions and upload them to the MES system database in a code format. The data acquisition and monitoring control system will call the automatic welding program and send it to the automatic welding system PLC to control the welding processing equipment in the welding processing station to produce automatic welding samples; 1-4) Inspect the automatic welding samples. After passing the inspection, keep the automatic welding program in the MES system and wait for the data acquisition and monitoring control system to call it.

8. A transformer conductor automatic welding control management method according to claim 6, characterized in that: The automatic welding algorithm is specifically: 2-1) Increase welding heat input: Since the cross-sectional area of ​​the wire depends on the thickness and width of the wire, if the width-to-thickness ratio of the two sections is different but the cross-sectional area is the same, the cross-sectional area of ​​the wire is obtained. The larger the cross-sectional area of ​​the wire, the greater the heat input; 2-2) Automatic welding gap: During welding, the material will expand due to heat. Therefore, a certain gap should be left between the two copper wires when they are assembled. The gap between the sensor and the workpiece is set to 0.05mm-0.15mm, which is determined by the heating temperature. The thermal expansion coefficient of copper is 17.2*10-6 / ℃. According to the formula, the theoretical optimal gap is: Theoretical optimum gap = temperature * thermal expansion coefficient * 10 In actual welding, the wire spacing is measured with a feeler gauge before welding to make the actual wire spacing close to the theoretical optimal spacing; 2-3) Heating method: The welding process is divided into: heating stage, constant temperature stage, and cooling stage; The heating stage will directly affect the speed of heat dissipation. The slower the heating stage, the faster the heat dissipation. The constant temperature stage ensures that the solder is fully melted and flows, ensuring the welding quality inside the weld. During the welding process, the welding quality can be optimized by changing the heating method, extending the constant temperature stage time, and reducing the temperature reduction stage time.

9. A transformer conductor automatic welding control management method according to claim 6, characterized in that: In step 4), the welded transformer conductor is evaluated by performing the following steps: (1) Tensile test: The tensile strength of the weld shall be at least 80% of the tensile strength of the parent material, and the fracture site shall not be at the joint; (2) DC resistivity should not be greater than 0.01793Ω·㎜2·m -1 ; Repeat the above operation for each wire gauge sample until all are tested and qualified.

10. A transformer conductor automatic welding control management method according to claim 6, characterized in that: The welding completion work order, all information in the task work order, as well as the welding joint serial number, welding program parameters, welding actual parameters, and operator information confirmation; The task work order includes: product technical code, product serial number, coil column number, wire gauge, procedure number, equipment number, operator serial number, and operation date.

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