Electrical control system of welding workstation

Abstract

The invention relates to the field of welding equipment, and discloses an electrical control system of a welding workstation, which comprises an execution and control core module connected with a man-machine interaction module, the man-machine interaction module is connected with an automatic operation module, a manual operation module, a maintenance interface module, a parameter setting module, an alarm query module, an I / O monitoring module and a model selection module. The execution and control core module adopts a robot as a welding action execution mechanism, the welding process is accurately controlled, and a controller is used for controlling the robot. The method has the following advantages and effects that high automation and multi-equipment cooperative control are achieved, manual operation is reduced, the welding period is shortened, the production efficiency is effectively improved, equipment installation, maintenance and upgrading are facilitated through modular design, and the maintenance difficulty and cost are reduced; and the remote monitoring and fault diagnosis functions can find and solve equipment faults in time, so that the downtime is shortened, and the production loss is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of welding equipment, in particular to an electrical control system of a welding workstation. Background Art

[0002] Currently, traditional welding workstations face numerous challenges. In terms of automation, most require extensive manual labor to complete pre-welding preparation, parameter adjustments during welding, and post-weld inspection. This is not only inefficient but also prone to human error, leading to inconsistent welding quality. For example, when welding complex workpieces, manual positioning and parameter adjustments make it difficult to ensure consistent welds from one weld to the next, resulting in inconsistent product quality.

[0003] From an electrical control perspective, existing welding workstation electrical systems lack intelligence, making it difficult to achieve real-time monitoring and precise control of the welding process. When current or voltage fluctuates or welding speed changes occur during the welding process, these systems cannot automatically adjust in a timely manner, which can easily lead to welding defects such as cold welds and weld penetrations. Furthermore, the poor electrical compatibility between different brands and models of welding equipment makes it difficult to achieve multi-device collaboration, limiting the functional expansion and overall performance improvement of the welding workstation. Therefore, it is necessary to design an electrical control system for the welding workstation to address these issues.

[0004] The information disclosed in this background technology section is only intended to enhance understanding of the overall background of the invention and should not be regarded as an admission or any form of suggestion that the information constitutes the prior art already known to a person skilled in the art. Summary of the Invention

[0005] The object of the present invention is to provide an electrical control system for a welding workstation to solve the above problems.

[0006] The above technical objectives of the present invention are achieved through the following technical solutions: an electrical control system for a welding workstation, comprising:

[0007] An execution and control core module, wherein the execution and control core module is connected to a human-computer interaction module, and the human-computer interaction module is connected to an automatic operation module, a manual operation module, a maintenance interface module, a parameter setting module, an alarm query module, an I / O monitoring module, and a model selection module;

[0008] The execution and control core module uses a robot as the welding action actuator to accurately control the welding process and uses a controller to control the robot;

[0009] The human-computer interaction module is used for human-computer interaction.

[0010] The present invention is further configured as follows: the execution and control core module includes a safety fence, a welding wire barrel, a protective gas cylinder, a wire feeder, a welding robot, a gun cleaner, a PLC control cabinet, a robot control cabinet, a welding power supply, a safety light curtain, a head and tail rack positioner, a tooling chuck and an active end of the head and tail rack positioner, and the human-computer interaction module includes a touch screen.

[0011] The present invention is further configured such that the operation process of the automatic operation module includes the following contents:

[0012] The operator logs in with the corresponding account, enters the automatic operation interface, selects the product model of this production, and enters the welding pipe length. At this point, the product model corresponds to the robot program, and the system is ready for operation.

[0013] After the welding workstation is started, the robot works according to the preset program, and the production quantity counting module automatically accumulates the completed quantity, starting from the start to the end of welding. If a pause is required during operation;

[0014] When production is stopped or the walking axis needs to be moved to the end, press and hold the walking axis reset button, and the walking axis will automatically return to the end and stop. If the robot needs to return to the origin, press and hold the robot reset button. Wait until the red indicator light turns green and the robot will perform the return to origin operation.

[0015] The present invention is further configured as follows: the operation process of the manual operation module includes the following contents:

[0016] Modify the walking axis moving speed value, change the jog moving speed and automatic moving speed, and open the shielding safety door during maintenance and debugging. At this time, the safety door and grating trigger will not stop the robot operation.

[0017] The present invention is further configured as follows: the operation process of the maintenance interface module includes the following contents:

[0018] After logging in, enter the maintenance interface and perform maintenance work such as pausing the robot, calibrating the servo zero point, shielding the servo limit, shielding the safety door, forcibly opening the servo brake, and controlling the tail top valve and gun cleaning station valve. Finally, exit the maintenance interface.

[0019] The present invention is further configured as follows: the operation process of the parameter setting module includes the following contents:

[0020] Set the inner length of the flange pipe fitting. After entering the corresponding length value, the robot automatically performs laser scanning welding based on this parameter to provide accurate position information for welding.

[0021] Set the number of hooked workpieces on the workbench and the number of hooks on the workpieces, set the gun cleaning operation cycle, and set the oil injection time and gun cleaning time;

[0022] Save after completing the parameter settings.

[0023] The present invention is further configured as follows: the operation process of the alarm query module includes the following contents:

[0024] Real-time monitoring of all components and operating links of the welding workstation. When an abnormal situation occurs, the corresponding sensor will immediately capture it and generate corresponding alarm information;

[0025] Alarm information will be displayed on the alarm query interface of the touch screen, and the alarm information will be classified and sorted according to the alarm level, time or alarm type;

[0026] Click on a specific alarm information entry to view more detailed alarm information. After viewing and handling the alarm problem, confirm the alarm and store all alarm information to form a historical alarm record.

[0027] The present invention is further configured as follows: the operation process of the I / O monitoring module includes the following contents:

[0028] Scan each input port in real time to obtain input signals from various sensors and switch devices in the welding workstation, analyze the scanned input signals, convert them into digital signals or logical states that the system can understand, and display the current status of the input signals;

[0029] Receive output control instructions from the welding workstation control system, convert the received control instructions into corresponding electrical signals or other physical signals, and send them to the corresponding actuators through the output port, and monitor the execution of the actuators after the output signals are sent;

[0030] Monitor and analyze input and output signals to detect abnormal conditions or faults in a timely manner. Once an abnormality is detected, the I / O monitoring module will immediately issue an alarm signal and display the corresponding alarm information on the touch screen to inform the operator of the type and location of the fault;

[0031] Real-time recording of input and output signal status changes, control instruction sending status, and abnormal event occurrence time and type data.

[0032] The present invention is further configured such that the operation process of the model selection module includes the following contents:

[0033] A list of available pipe fitting models is displayed on the touch screen. Select the required pipe fitting model from the list. Once a pipe fitting model is selected, various parameters corresponding to the model will be automatically associated.

[0034] The associated parameters will be displayed on the interface. Check the detailed information of these parameters to confirm whether the selected model and set parameters are correct;

[0035] The selected model and set parameters are stored, and the next operation steps are prompted.

[0036] The beneficial effects of the present invention are:

[0037] 1. High degree of automation and multi-device collaborative control reduce manual operations, shorten welding cycles, and effectively improve production efficiency. Modular design facilitates equipment installation, maintenance, and upgrades, reducing maintenance difficulty and costs. Remote monitoring and fault diagnosis functions can promptly detect and resolve equipment failures, reduce downtime, and minimize production losses.

[0038] 2. Modular design combined with a unified communication protocol improves the system's compatibility and scalability. Users can flexibly configure and expand equipment according to their needs, reducing equipment procurement costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0040] Figure 1 The present invention provides a block diagram of the electrical control system of a welding workstation.

[0041] Figure 2 It is a structural schematic diagram of an electrical control system of a welding workstation proposed by the present invention.

[0042] In the figure, 1. Safety fence; 2. Welding wire barrel; 3. Shielding gas cylinder; 4. Wire feeder; 5. Welding robot; 6. Gun cleaner; 7. PLC control cabinet; 8. Robot control cabinet; 9. Welding power supply; 10. Touch screen; 11. Safety light curtain; 12. Head and tail frame positioner; 13. Tooling chuck; 14. Active end of the head and tail frame positioner. DETAILED DESCRIPTION

[0043] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be internal communication between two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood based on specific circumstances.

[0044] The technical solutions of the present invention will be described clearly and completely below with reference to specific embodiments. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

[0045] See also Figure 1 and Figure 2 The present invention provides an electrical control system for a welding workstation, comprising:

[0046] Execution and control core module, the execution and control core module is connected to the human-computer interaction module, the human-computer interaction module is connected to the automatic operation module, the manual operation module, the maintenance interface module, the parameter setting module, the alarm query module, the I / O monitoring module and the model selection module;

[0047] The execution and control core module uses a robot as the welding action actuator to accurately control the welding process and uses a controller to control the robot;

[0048] The human-computer interaction module is used for human-computer interaction.

[0049] Specifically, the execution and control core module includes a safety fence 1, a welding wire barrel 2, a protective gas cylinder 3, a wire feeder 4, a welding robot 5, a gun cleaner 6, a PLC control cabinet 7, a robot control cabinet 8, a welding power supply 9, a safety light curtain 11, a head and tail rack positioner 12, a tooling chuck 13 and a head and tail rack positioner active end 14, and the human-computer interaction module includes a touch screen 10.

[0050] Specifically, the operation process of the automatic operation module includes the following:

[0051] The operator logs in with the corresponding account, enters the automatic operation interface, selects the product model of this production, and enters the welding pipe length. At this point, the product model corresponds to the robot program, and the system is ready for operation.

[0052] After the welding workstation is started, the robot works according to the preset program, and the production quantity counting module automatically accumulates the completed quantity, starting from the start to the end of welding. If a pause is required during operation;

[0053] When production is stopped or the walking axis needs to be moved to the end, press and hold the walking axis reset button, and the walking axis will automatically return to the end and stop. If the robot needs to return to the origin, press and hold the robot reset button. Wait until the red indicator light turns green and the robot will perform the return to origin operation.

[0054] It's important to note that operators can select the product model based on their needs, and the system will automatically associate the corresponding robot program. This means the welding workstation can flexibly handle the production of different product types without requiring extensive manual reprogramming or debugging, greatly increasing production diversity and flexibility, making it suitable for high-variety, low-volume production.

[0055] The robot operates according to pre-set procedures, reducing the need for manual intervention and the impact of human factors on welding quality, while also improving production efficiency. Compared to frequent manual operation, the robot can complete welding tasks with more stable speed and accuracy, and can achieve long-term continuous operation, thereby improving overall production capacity.

[0056] If you need to pause during operation, you can easily operate the pause function. This is extremely practical when dealing with temporary problems such as sudden equipment failures and material replenishment. It can not only avoid unnecessary waste of resources, but also ensure the controllability of the production process, and quickly resume production after the problem is resolved.

[0057] Specifically, the operation process of the manual operation module includes the following:

[0058] Modify the walking axis moving speed value, change the jog moving speed and automatic moving speed, and open the shielding safety door during maintenance and debugging. At this time, the safety door and grating trigger will not stop the robot operation.

[0059] It's important to note that the travel axis speed value can be modified, allowing you to adjust both the inching and automatic movement speeds based on actual needs. During equipment commissioning, technicians can precisely control the travel axis speed to more closely observe the robot's motion and welding results. This helps accurately adjust the robot's position and posture, improving commissioning accuracy and efficiency. During maintenance, technicians can also move the travel axis at the appropriate speed for inspection, repair, and maintenance.

[0060] During maintenance and commissioning, the shielded safety door can be opened to prevent the robot from being stopped by the door or light barrier triggering. This feature provides technicians with greater operating space and convenience. They can directly enter the work area while the robot is running to perform related operations, eliminating the need to frequently open and close the safety door. This saves time and improves maintenance and commissioning efficiency. It also allows technicians to observe the actual operation of the robot in real time, allowing them to quickly identify and resolve problems.

[0061] The manual operation module adjusts the travel axis speed and the safety door shielding function, which can reduce the operating time wasted due to the frequent opening and closing of the safety door and speed restrictions. It optimizes the maintenance and debugging operation process, enables technicians to complete their work more efficiently, reduces equipment downtime, and allows the equipment to resume normal production as soon as possible, thereby improving overall production efficiency.

[0062] Specifically, the operation process of the maintenance interface module includes the following:

[0063] After logging in, enter the maintenance interface and perform maintenance work such as pausing the robot, calibrating the servo zero point, shielding the servo limit, shielding the safety door, forcibly opening the servo brake, and controlling the tail top valve and gun cleaning station valve. Finally, exit the maintenance interface.

[0064] Specifically, the operation process of the parameter setting module includes the following:

[0065] Set the inner length of the flange pipe fitting. After entering the corresponding length value, the robot automatically performs laser scanning welding based on this parameter to provide accurate position information for welding.

[0066] Set the number of hooked workpieces on the workbench and the number of hooks on the workpieces, set the gun cleaning operation cycle, and set the oil injection time and gun cleaning time;

[0067] Save after completing the parameter settings.

[0068] It's important to note that by setting the inner length of the flange fitting, the robot automatically performs laser scanning welding based on this parameter, providing accurate positional information for welding. This ensures precise welding position, resulting in a tighter and more uniform connection between the weld seam and the fitting, reducing welding deviations and defects, thereby improving welding quality and enhancing product stability and reliability.

[0069] Setting the gun cleaning cycle, oil injection time, and gun cleaning time automates auxiliary welding operations. Regular gun cleaning keeps the welding gun clean and performing well, reduces welding problems caused by slag clogging or gun tip contamination, and improves welding stability and continuity. Proper oil injection time settings effectively protect the welding gun, extend its service life, and reduce equipment maintenance costs. Setting these parameters helps optimize the entire production process, reduce manual intervention, and improve production automation and efficiency.

[0070] After completing parameter settings, they are saved, facilitating the management and traceability of production data. These saved parameters can be used as part of the production record for subsequent quality analysis, process improvement, and product traceability. If product quality issues arise, the original parameter settings can be reviewed to analyze the possible causes and implement timely improvement measures. This also provides data support for the standardization and regularization of the production process, helping to improve the company's production management capabilities.

[0071] Specifically, the operation process of the alarm query module includes the following:

[0072] Real-time monitoring of all components and operating links of the welding workstation. When an abnormal situation occurs, the corresponding sensor will immediately capture it and generate corresponding alarm information;

[0073] The alarm information will be displayed on the alarm query interface of the touch screen 10, and the alarm information will be classified and sorted according to the alarm level, time or type of alarm;

[0074] Click on a specific alarm information entry to view more detailed alarm information. After viewing and handling the alarm problem, confirm the alarm and store all alarm information to form a historical alarm record.

[0075] It's important to note that by monitoring the various components and operational aspects of the welding workstation in real time, abnormalities can be detected immediately. If a problem occurs, the corresponding sensor immediately generates an alarm message, allowing operators to quickly detect equipment failures, preventing further escalation and minimizing the impact on production.

[0076] After reviewing and addressing the alarm issue, a confirmation operation is performed. This process ensures that every alarm is handled and confirmed promptly to avoid omissions. At the same time, all alarm information is stored as a historical alarm record, which helps operators and technicians refer to previous failure situations during subsequent equipment maintenance and optimization, summarize lessons learned, and prevent similar problems from recurring in advance.

[0077] As part of production data, historical alarm records provide a crucial basis for equipment maintenance, production management, and quality control. By analyzing this data, companies can understand equipment operating conditions and failure modes, identify potential problems and weaknesses, and provide data support for regular equipment maintenance, upgrades, and production process optimization, thereby improving equipment reliability and production efficiency while reducing production costs.

[0078] Specifically, the operation process of the I / O monitoring module includes the following:

[0079] Scan each input port in real time to obtain input signals from various sensors and switch devices in the welding workstation, analyze the scanned input signals, convert them into digital signals or logical states that the system can understand, and display the current status of the input signals;

[0080] Receive output control instructions from the welding workstation control system, convert the received control instructions into corresponding electrical signals or other physical signals, and send them to the corresponding actuators through the output port, and monitor the execution of the actuators after the output signals are sent;

[0081] Monitor and analyze input and output signals to detect abnormal conditions or faults in a timely manner. Once an abnormality is detected, the I / O monitoring module will immediately issue an alarm signal and display the corresponding alarm information on the touch screen to inform the operator of the type and location of the fault;

[0082] Real-time recording of input and output signal status changes, control instruction sending status, and abnormal event occurrence time and type data.

[0083] It should be noted that real-time scanning of each input port captures input signals from various sensors and switchgear within the welding workstation, providing comprehensive visibility into the workstation's operating status. This data captures equipment operating parameters, workpiece position information, and the on / off status of various switches, providing the system with a wealth of operational data. The scanned input signals are analyzed, converted, and displayed, providing the operator with a visual overview of the real-time status of each component of the workstation. This clear display of digital signals or logical states helps operators quickly determine whether the equipment is operating properly and identify potential issues. The system receives control commands output by the control system, converts them into corresponding physical signals, and transmits them to the actuators, while simultaneously monitoring their execution, forming a complete control loop. This enables the system to not only issue commands but also provide timely information on their execution, ensuring that the equipment is operating as expected and improving control accuracy and reliability.

[0084] By monitoring and analyzing input and output signals, abnormal conditions or faults can be detected promptly. Whether it is signal loss or error, or abnormal operation of the actuator, they can be quickly detected to prevent further development of the fault and reduce the impact on production.

[0085] Specifically, the operation process of the model selection module includes the following:

[0086] A list of available pipe fitting models is displayed on the touch screen 10. The desired pipe fitting model is selected from the list. When a pipe fitting model is selected, various parameters corresponding to the model are automatically associated.

[0087] The associated parameters will be displayed on the interface. Check the detailed information of these parameters to confirm whether the selected model and set parameters are correct;

[0088] The selected model and set parameters are stored, and the next operation steps are prompted.

[0089] It's important to note that displaying a list of available pipe fitting models on the touchscreen provides operators with a clear and intuitive selection interface, allowing them to quickly find the desired model and reducing search and selection time. When a pipe fitting model is selected, the corresponding parameters are automatically associated and displayed on the interface. This avoids errors that can occur when operators manually enter parameters, improves the accuracy and efficiency of parameter settings, and ensures consistency and compatibility between the selected model and the parameters.

[0090] Operators can view detailed information on associated parameters, which helps them fully understand the specific parameter settings of the selected model. This allows them to carefully confirm whether the selected model and set parameters are correct, and promptly discover and correct possible errors or unreasonableness, ensuring the accuracy and reliability of parameters during the production process and reducing production problems caused by parameter errors.

[0091] The electrical control system for a welding workstation provided by the present invention has been described in detail above. Specific embodiments have been used herein to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is intended only to facilitate understanding of the method and core concepts of the present invention. It should be noted that those skilled in the art will readily appreciate that various improvements and modifications may be made to the present invention without departing from the principles of the present invention, and such improvements and modifications are also within the scope of protection of the claims.

Claims

1. An electrical control system for a welding workstation, characterized in that: include: An execution and control core module, wherein the execution and control core module is connected to a human-computer interaction module, and the human-computer interaction module is connected to an automatic operation module, a manual operation module, a maintenance interface module, a parameter setting module, an alarm query module, an I / O monitoring module, and a model selection module; The execution and control core module uses a robot as the welding action actuator to accurately control the welding process and uses a controller to control the robot; The human-computer interaction module is used for human-computer interaction.

2. The electrical control system of a welding workstation according to claim 1, characterized in that: The execution and control core module includes a safety fence (1), a welding wire barrel (2), a protective gas cylinder (3), a wire feeder (4), a welding robot (5), a gun cleaner (6), a PLC control cabinet (7), a robot control cabinet (8), a welding power supply (9), a safety light curtain (11), a head and tail rack positioner (12), a tooling chuck (13) and a head and tail rack positioner active end (14), and the human-computer interaction module includes a touch screen (10).

3. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the automatic operation module includes the following: The operator logs in with the corresponding account, enters the automatic operation interface, selects the product model of this production, and enters the welding pipe length. At this point, the product model corresponds to the robot program, and the system is ready for operation. After the welding workstation is started, the robot works according to the preset program, and the production quantity counting module automatically accumulates the completed quantity, starting from the start to the end of welding. If a pause is required during operation; When production is stopped or the walking axis needs to be moved to the end, press and hold the walking axis reset button, and the walking axis will automatically return to the end and stop. If the robot needs to return to the origin, press and hold the robot reset button. Wait until the red indicator light turns green and the robot will perform the return to origin operation.

4. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the manual operation module includes the following: Modify the walking axis moving speed value, change the jog moving speed and automatic moving speed, and open the shielding safety door during maintenance and debugging. At this time, the safety door and grating trigger will not stop the robot operation.

5. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the maintenance interface module includes the following: After logging in, enter the maintenance interface and perform maintenance work such as pausing the robot, calibrating the servo zero point, shielding the servo limit, shielding the safety door, forcibly opening the servo brake, and controlling the tail top valve and gun cleaning station valve. Finally, exit the maintenance interface.

6. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the parameter setting module includes the following: Set the inner length of the flange pipe fitting. After entering the corresponding length value, the robot automatically performs laser scanning welding based on this parameter to provide accurate position information for welding. Set the number of hooked workpieces on the workbench and the number of hooks on the workpieces, set the gun cleaning operation cycle, and set the oil injection time and gun cleaning time; Save after completing the parameter settings.

7. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the alarm query module includes the following: Real-time monitoring of all components and operating links of the welding workstation. When an abnormal situation occurs, the corresponding sensor will immediately capture it and generate corresponding alarm information; The alarm information will be displayed on the alarm query interface of the touch screen (10), and the alarm information will be classified and sorted according to the alarm level, time or type of alarm; Click on a specific alarm information entry to view more detailed alarm information. After viewing and handling the alarm problem, confirm the alarm and store all alarm information to form a historical alarm record.

8. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the I / O monitoring module includes the following: Scan each input port in real time to obtain input signals from various sensors and switch devices in the welding workstation, analyze the scanned input signals, convert them into digital signals or logical states that the system can understand, and display the current status of the input signals; Receive output control instructions from the welding workstation control system, convert the received control instructions into corresponding electrical signals or other physical signals, and send them to the corresponding actuators through the output port, and monitor the execution of the actuators after the output signals are sent; Monitor and analyze input and output signals to detect abnormal conditions or faults in a timely manner. Once an abnormality is detected, the I / O monitoring module will immediately issue an alarm signal and display the corresponding alarm information on the touch screen to inform the operator of the type and location of the fault; Real-time recording of input and output signal status changes, control instruction sending status, and abnormal event occurrence time and type data.

9. The electrical control system of a welding workstation according to claim 1, characterized in that: The operation process of the model selection module includes the following: A list of available pipe fitting models is displayed on the touch screen (10), and the desired pipe fitting model is selected from the list. When a pipe fitting model is selected, various parameters corresponding to the model are automatically associated; The associated parameters will be displayed on the interface. Check the detailed information of these parameters to confirm whether the selected model and set parameters are correct; The selected model and set parameters are stored, and the next operation steps are prompted.

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