Welding man-hour processing system and method

Abstract

The invention provides a welding man-hour processing system and method, and relates to the technical field of computers or software. The system comprises a man-hour processing node server, a first node server, a second node server, a third node server, a fourth node server and a fifth node server which form a distributed network, for a target welder, the man-hour processing node server is used for broadcasting a man-hour calculation request; the first node server is used for broadcasting the skill level, the second node server is used for broadcasting the welding duration, the third node server is used for broadcasting the welding wire consumption, the fourth node server is used for broadcasting the welding seam theoretical volume of each preset welding type, and the fifth node server is used for broadcasting the welding qualification rate of each preset welding type; the man-hour processing node server is also used for calculating the man-hour calculation result of the target welder. According to the system, the safety and the accuracy of the man-hour calculation result are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of computer or software, and in particular to a welding work time processing system and method. BACKGROUND

[0002] In equipment manufacturing enterprises, a large number of equipment and components need to be welded, so that safe and accurate calculation of welding work time not only helps to stimulate the work enthusiasm of welders, but also helps to realize the cost reduction and benefit increase management of enterprises.

[0003] At present, most equipment manufacturing enterprises mainly rely on servers to record welding work time data. However, the server usually only records the working time and the number of welded equipment, and does not fully consider the key factors affecting the actual workload in the welding process, resulting in a large deviation between the work time calculation result and the real workload, and it is difficult to objectively reflect the real workload of the welder. In addition, since the welding work time data is stored in the server, there is a risk of data loss and tampering, which further affects the security and accuracy of the work time calculation result. SUMMARY

[0004] The present application provides a welding work time processing system and method, which improves the security and accuracy of the work time calculation result.

[0005] The first aspect of the present application provides a welding work time processing system, which comprises: a work time processing node server, a first node server, a second node server, a third node server, a fourth node server and a fifth node server constituting a distributed network;

[0006] The work time processing node server is configured to broadcast a work time calculation request of a target welder in the distributed network;

[0007] The first node server is configured to broadcast the skill level of the target welder in the distributed network;

[0008] The second node server is configured to broadcast the welding time of the target welder in the distributed network;

[0009] The third node server is configured to broadcast the welding wire consumption of the target welder in the distributed network;

[0010] The fourth node server is configured to broadcast the weld seam theoretical volume of the target welder in each preset welding type in the distributed network;

[0011] The fifth node server is configured to broadcast the welding qualification rate of the target welder in each preset welding type in the distributed network;

[0012] The man-hour processing node server is also used for obtaining a man-hour calculation result of the target welder according to the skill level, the welding time length, the welding wire consumption, and the welding seam theoretical volume and the welding qualified rate of each preset welding type.

[0013] In a possible design, the man-hour processing node server is specifically used for:

[0014] obtaining a skill level weight of the target welder according to the skill level; wherein the skill level weight is positively correlated with the skill level;

[0015] obtaining a first man-hour calculation result of the target welder according to the skill level weight, the welding time length and the welding wire consumption, and obtaining a second man-hour calculation result of the target welder according to the skill level weight, the welding time length, and the welding seam theoretical volume, the welding qualified rate and the preset welding type weight of each preset welding type;

[0016] when the first man-hour calculation result is greater than the second man-hour calculation result, determining the second man-hour calculation result as the man-hour calculation result of the target welder;

[0017] when the first man-hour calculation result is less than or equal to the second man-hour calculation result, determining an average value of the first man-hour calculation result and the second man-hour calculation result as the man-hour calculation result of the target welder.

[0018] In a possible design, the first man-hour calculation result is calculated according to the following formula:

[0019]

[0020] wherein J represents the skill level weight, M represents the welding wire consumption, T represents the welding time length, represents the total weight of the welding wire consumption of all welders in a calculation period, and the calculation period represents a period corresponding to the man-hour calculation result, and the target welder is any one of the all welders;

[0021] The second man-hour calculation result is calculated according to the following formula:

[0022]

[0023] wherein represents the welding seam theoretical volume of the xth preset welding type, represents the welding qualified rate of the xth preset welding type, represents the preset welding type weight of the xth preset welding type, represents the total welding seam theoretical volume of the xth preset welding type of all welders in the calculation period.

[0024] In a possible design, the plurality of preset welding types include flat welding, horizontal welding, vertical welding, and overhead welding.

[0025] The preset welding type weights of the flat welding, the horizontal welding, the vertical welding, and the overhead welding are sequentially increased.

[0026] In a possible design, the man-hour processing node server is further configured to:

[0027] obtain a welding wire loss coefficient of the target welder according to the welding wire consumption and / or a theoretical volume of a weld seam of each preset welding type;

[0028] trigger an abnormality warning when the welding wire loss coefficient is outside a preset coefficient interval; the abnormality warning is used to indicate that the welding wire loss of the target welder is abnormal.

[0029] In a possible design, the system further includes a camera.

[0030] The camera is configured to capture a work video of the target welder.

[0031] The second node server is in communication connection with the camera.

[0032] The second node server is specifically configured to obtain the welding time according to the work video.

[0033] In a possible design, the second node server is specifically configured to:

[0034] obtain a total welding torch ignition time of the target welder according to the work video;

[0035] obtain the welding time according to the total welding torch ignition time.

[0036] In a possible design, the system further includes a sampling scale.

[0037] The sampling scale is configured to detect a weighed weight of welding wire of the target welder.

[0038] The third node server is in communication connection with the sampling scale.

[0039] The third node server is specifically configured to obtain the welding wire consumption according to the weighed weight of welding wire.

[0040] In a possible design, the system further includes a flaw detection device.

[0041] The flaw detection device is configured to detect a qualified weld seam quantity and an unqualified weld seam quantity of the target welder.

[0042] The fifth node server is in communication connection with the flaw detection device.

[0043] The fifth node server is specifically configured to obtain a welding qualified rate according to the qualified weld seam quantity and the unqualified weld seam quantity.

[0044] The second aspect of the present application provides a welding man-hour processing method, the method is used for a man-hour processing node server, the man-hour processing node server is located in a distributed network, the distributed network is located in the welding man-hour processing system of any one of the first aspect, the distributed network further includes a first node server, a second node server, a third node server, a fourth node server and a fifth node server, and the method comprises:

[0045] Broadcasting a man-hour calculation request of a target welder in the distributed network;

[0046] From the distributed network, obtaining the skill level of the target welder broadcast by the first node server, the welding time of the target welder broadcast by the second node server, the welding wire consumption of the target welder broadcast by the third node server, the weld theoretical volume of the target welder in each preset welding type broadcast by the fourth node server, and the welding pass rate of the target welder in each preset welding type broadcast by the fifth node server;

[0047] According to the skill level, the welding time, the welding wire consumption, and the weld theoretical volume and the welding pass rate of each preset welding type, the man-hour calculation result of the target welder is obtained.

[0048] The welding man-hour processing system and method provided by the present application, the method comprises: a man-hour processing node server, a first node server, a second node server, a third node server, a fourth node server and a fifth node server constituting a distributed network; for a target welder, the man-hour processing node server is used for broadcasting a man-hour calculation request; the first node server is used for broadcasting a skill level, the second node server is used for broadcasting a welding time, the third node server is used for broadcasting a welding wire consumption, the fourth node server is used for broadcasting a weld theoretical volume of each preset welding type, and the fifth node server is used for broadcasting a welding pass rate of each preset welding type; the man-hour processing node server is further used for calculating a man-hour calculation result of the target welder. The following technical effects are achieved: the skill level of the welder, the welding time, the welding wire consumption, and the weld theoretical volume and the welding pass rate of each preset welding type are comprehensively considered, the accuracy of the man-hour calculation result is calculated; the key factors are obtained through the node servers in the distributed network, the security of the man-hour calculation result is calculated; after the man-hour node server broadcasts the man-hour calculation request, the key factors broadcast by other node servers in the distributed network are obtained, and the man-hour of the welder is calculated based on this, the automatic calculation of the man-hour calculation result is realized. BRIEF DESCRIPTION OF DRAWINGS

[0049] In order to more clearly illustrate the technical solutions in the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor.

[0050] Figure 1 Structure diagram of the welding man-hour processing system provided by the embodiment of the present application Figure 1 ;

[0051] Figure 2 Structure diagram of the welding man-hour processing system provided by the embodiment of the present application Figure 2 ;

[0052] Figure 3 Flowchart of the welding man-hour processing method provided by the embodiment of the present application.

[0053] Reference signs:

[0054] 100-distributed network; 110-man-hour processing node server; 121-first node server; 122-second node server; 123-third node server; 124-fourth node server; 125-fifth node server; 130-camera; 140-data acquisition scale; 150-flaw detection equipment. DETAILED DESCRIPTION

[0055] The exemplary embodiments will be described in detail herein with reference to the accompanying drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application. Instead, they are merely examples of apparatuses and methods consistent with some aspects of the present application as detailed in the appended claims.

[0056] In the present application, the terms "first", "second", and the like are used to distinguish between similar or identical items or elements having substantially the same function and action. Those skilled in the art can understand that the terms "first", "second", and the like do not limit the quantity and execution order, and the terms "first", "second", and the like do not necessarily mean different. It should be noted that the words "exemplary" or "for example" in the present application are used to represent an example, illustration, or description. Any embodiment or design scheme described as "exemplary" or "for example" in the present application should not be interpreted as more preferred or more advantageous than other embodiments or design schemes. Rather, the words "exemplary" or "for example" are used to present the relevant concept in a specific manner. In the present application, "at least one" means one or more, and "multiple" means two or more.

[0057] It should be noted that the "at" in the present application can be the moment when a certain condition occurs, or a period of time after a certain condition occurs, which is not limited in the present application. In addition, the welding time processing system provided in the present application is only an example, and the welding time processing system can also include more or less content. The user information (including but not limited to user equipment information and user personal information, etc.) and data (including but not limited to data for analysis, stored data and displayed data, etc.) involved in one or more embodiments of the present application are all information and data authorized by the user or authorized by all parties, and the collection, use and processing of related data need to comply with relevant laws, regulations and standards, and provide corresponding operation portal for user to choose authorization or refusal.

[0058] In order to clearly understand the technical solutions of the present application, the prior art solutions are first introduced in detail.

[0059] In equipment manufacturing enterprises, a large number of equipment and components need to be welded, so safe and accurate calculation of welding time not only helps to stimulate the work enthusiasm of welders, but also helps to realize the management of cost reduction and efficiency improvement of enterprises.

[0060] At present, most equipment manufacturing enterprises mainly rely on servers to record welding time data. For example, the working time of welders and the number of welded equipment are stored in a centralized database with tables, rows and columns.

[0061] This results in that the server fails to fully consider the key factors affecting the actual workload in the welding process, such as the welding ability level of the welder, the time, number and type of welds welded by the welder on the equipment to be welded, the number of welding wires consumed by the welder, and the qualified rate of welding by the welder. The lack of these key factors leads to a large deviation between the time calculation result and the real workload, and it is difficult to objectively reflect the real workload of the welder.

[0062] In addition, the centralized database is easy to manage and has strong scalability, but lacks transparency, security and integrity. Since the welding time data is stored centrally in the server, database administrators or other personnel can read, write, update or delete these data, which poses risks of data loss and tampering, further affecting the security and accuracy of the time calculation result.

[0063] Therefore, in view of the above technical problems, it is found in the research that in order to solve the problem, the skill level, welding time, welding wire consumption, and the theoretical volume of welds of each preset welding type and the welding qualified rate are considered, so as to realize the accuracy of the time calculation result; at the same time, by storing these key factors in a distributed network, the security of the time calculation result is realized.

[0064] Based on the above creative findings, the technical scheme of the present application is proposed. The technical scheme of the present application will be described in detail below with specific examples. The following specific examples can be combined with each other, and the same or similar concepts or processes may not be described again in some examples. The embodiments of the present application will be described below with reference to the accompanying drawings.

[0065] Figure 1 The structure of the welding man-hour processing system provided by the embodiments of the present application is shown in Figure 1 . As shown in the figure, the system includes a man-hour processing node server 110, a first node server 121, a second node server 122, a third node server 123, a fourth node server 124 and a fifth node server 125 which constitute a distributed network 100. Figure 1 Specifically, the topology between the man-hour processing node server 110 and the first node server 121, the second node server 122, the third node server 123, the fourth node server 124 and the fifth node server 125 can be a star topology as shown in the figure, that is, the man-hour processing node server 110 is the center node, and the other node servers are directly connected to it; or other feasible topologies, such as ring topology, mesh topology, tree topology or hybrid topology, etc.

[0066] Figure 2 The man-hour processing node server 110 is used to broadcast the target welder's man-hour calculation request in the distributed network 100.

[0067] Specifically, the man-hour processing node server 110 can broadcast the man-hour calculation request regularly according to the preset strategy, for example, it can broadcast once a day or once a month to calculate the daily man-hour or monthly man-hour of the target welder. The man-hour processing node server 110 can also broadcast the man-hour calculation request irregularly according to user demand, for example, the database administrator requests the man-hour processing node server 110 to initiate the man-hour calculation process of the target welder, and when receiving the request of the database administrator, the man-hour processing node server 110 broadcasts the man-hour calculation request once. It should be noted that the man-hour processing node server 110 supports broadcasting the man-hour calculation request of multiple welders at the same time, and the target welder is any one of these welders, and the welding man-hour processing methods of these welders are the same as each other, which will not be described in detail in the embodiments of the present application.

[0068] The first node server 121 is used to broadcast the skill level of the target welder in the distributed network 100.

[0069] The second node server 122 is used to broadcast the welding time of the target welder in the distributed network 100.

[0070] The third node server 123 is used to broadcast the welding position of the target welder in the distributed network 100.​

[0071] The third node server 123 is configured to broadcast the welding wire consumption of the target welder in the distributed network 100.

[0072] The fourth node server 124 is configured to broadcast the theoretical weld volume of the target welder for each preset welding type in the distributed network 100.

[0073] The fifth node server 125 is configured to broadcast the welding pass rate of the target welder for each preset welding type in the distributed network 100.

[0074] Specifically, the skill level, welding duration, welding wire consumption, and the theoretical weld volume and welding pass rate for each preset welding type are responses of the first node server 121, the second node server 122, the third node server 123, the fourth node server 124, and the fifth node server 125 to the work hour processing node server 110 after receiving the work hour calculation request. To ensure the security of the request and response broadcast in the distributed network 100, a multi-level security protection system needs to be built. For example, data encryption such as symmetric encryption or asymmetric encryption is used for the request and response; integrity verification such as data signature or hash chain is used for the request and response; two-way identity authentication and access control such as two-way authentication of certificates or fine-grained permission control are used for the request and response.

[0075] The first node server 121 can be a human resource server of an equipment manufacturing enterprise or a skill authentication server of a vocational skill appraisal center. The first node server 121 stores the skill level authentication information of the welder, i.e., the skill level, which is used to represent the welding ability level of the welder, such as training records, test results, and vocational qualification certificates.

[0076] The second node server 122 can be a work hour statistics server of an equipment manufacturing enterprise, or a server equipped with a manufacturing execution system (MES), etc. The second node server 122 stores an actual total working time of a welder in a welding task, i.e., a welding time, for representing a time length of welding a weld on a device to be welded. The welding time can be obtained through automation recording, for example, a programmable logic controller (PLC) of the welding device records the welding time according to a start working time and an end working time of the welding device; it can also be obtained through data analysis, for example, a third-party server analyzes a video of the welder's operation captured by a camera, or analyzes a check-in time and a check-out time of the welder recorded by a work station terminal, to obtain the welding time; or it can be obtained through manual input, for example, a field manager manually inputs the welding time into the second node server 122.

[0077] The third node server 123 can be a material management server of an equipment manufacturing enterprise, or a server equipped with an enterprise resource planning system (ERP), etc. The third node server 123 stores a consumption amount of welding material such as welding wire, i.e., a welding wire consumption amount, for representing a quantity of welding wire consumed by the welder. The welding wire consumption amount can be obtained through automatic weighing, for example, a sensor is installed on a welding wire rack to monitor a weight difference before and after the welding wire is used in real time; it can also be obtained through data analysis, for example, the welding wire consumption amount is calculated according to a theoretical volume of a weld, a material density of the welding wire, and a utilization rate of the welding wire, wherein the unit of the welding wire consumption amount can be a weight unit or a volume unit.

[0078] The fourth node server 124 can be a welding process database service of an equipment manufacturing enterprise, or a server equipped with computer-aided design (CAD) or computer-aided manufacturing (CAM), etc. The fourth node server 124 stores a calculation formula or model of a theoretical volume of a weld of different preset welding types, and calculates a theoretical volume of a weld of each preset welding type welded by the welder according to the calculation formula or model, for representing a quantity and type of the weld welded by the welder on the device to be welded. The theoretical volume of the weld of each preset welding type welded by the welder can be obtained through formula calculation, for example, a volume is calculated according to preset welding types such as flat welding, horizontal welding, vertical welding, overhead welding, butt welding, and fillet welding, and a base material thickness and a weld size, by using an empirical formula; or it can be obtained through model calculation, for example, a model of a weld joint is established by using CAD software, and the volume is directly measured.

[0079] The fifth node server 125 can be a quality detection server of an equipment manufacturing enterprise, or a server equipped with a quality management system (QMS), etc. The fifth node server 125 stores the welding qualification rate of different preset welding types, which is used to represent the qualification rate of the welder welding. The welding qualification rate of the welder in each preset welding type can be obtained by non-destructive testing, for example, by detecting the weld defects through X-ray or ultrasonic wave, etc., and automatically generating a detection report; it can also be obtained by sampling statistics, for example, by sampling the welds by batch, recording the number of qualified welds and the number of unqualified welds, and calculating the welding qualification rate.

[0080] It should be noted that the first node server 121, the second node server 122, the third node server 123, the fourth node server 124 and the fifth node server 125 can be independent physical servers, or virtual instances divided by virtualization technology on one or more physical servers. The implementation of each node server can be the same or different, and the embodiments of the present application do not limit this.

[0081] The man-hour processing node server 110 is also configured to obtain the man-hour calculation result of the target welder according to the skill level, the welding time length, the welding wire consumption, and the weld theoretical volume and the welding qualification rate of each preset welding type.

[0082] Specifically, the man-hour processing node server 110 is the core calculation node in the distributed network 100, which is responsible for integrating the above-mentioned multi-source data to obtain the man-hour calculation result of the target welder.

[0083] During the man-hour calculation process, the skill level, the welding time length, the welding wire consumption, and the weld theoretical volume and the welding qualification rate of each preset welding type can be preprocessed by numerical mapping, standardization processing or unit conversion algorithm, and the man-hour calculation result of the target welder can be obtained according to the preprocessed numerical value through a preset algorithm model.

[0084] In one possible design, the skill level, the welding time length, the welding wire consumption, the weld theoretical volume and the welding qualification rate of each preset welding type, and the man-hour calculation result of the target welder are stored in the blockchain, and the characteristics of the blockchain that cannot be tampered with are used to ensure the credibility of the data source. At the same time, a preset smart contract is used to synchronize the man-hour calculation result to the salary management system after the data is verified.

[0085] The embodiment of the application provides a welding work hour processing system, the system comprises: a work hour processing node server, a first node server, a second node server, a third node server, a fourth node server and a fifth node server which constitute a distributed network; for a target welder, the work hour processing node server is used for broadcasting a work hour calculation request; the first node server is used for broadcasting a skill level, the second node server is used for broadcasting a welding time length, the third node server is used for broadcasting a welding wire consumption, the fourth node server is used for broadcasting a welding seam theoretical volume of each preset welding type, and the fifth node server is used for broadcasting a welding qualified rate of each preset welding type; and the work hour processing node server is further used for calculating a work hour calculation result of the target welder. The following technical effects are achieved: the skill level, the welding time length, the welding wire consumption, the welding seam theoretical volume of each preset welding type and the welding qualified rate are comprehensively considered as key factors, so that the accuracy of the work hour calculation result is calculated; the key factors are obtained through the node servers in the distributed network, so that the security of the work hour calculation result is calculated; after the work hour node server broadcasts the work hour calculation request, the key factors broadcasted by the other node servers in the distributed network are obtained, and the work hour of the welder is calculated based on the key factors, so that the automation of the work hour calculation result is achieved.

[0086] In a possible design, the work hour processing node server 110 is specifically used for:

[0087] According to the skill level, a skill level weight of the target welder is obtained; wherein the skill level weight is positively correlated with the skill level.

[0088] Specifically, the skill level can be determined according to the level indicated in the certificate issued by a relevant institution. For example, the skill level is divided into five levels, i.e., level one to level five. If a welder holds multiple certificates, the highest level is taken as the skill level of the welder. The skill level is one of the key factors for calculating the work hour of the welder, and the first node server 121 is responsible for dynamically maintaining and updating the skill level of the welder.

[0089] The work hour processing node server 110 maps the skill level of the target welder broadcasted by the first node server 121 into a skill level weight. Let the skill level weight be represented as J, J is a constant, and the value of J can be set according to the enterprise management requirement. Generally, the skill level weight is positively correlated with the skill level. For example, the skill level weight is set in the interval [1, 1.4]. When the skill level is level one, J=1.0; when the skill level is level two, J=1.1; when the skill level is level three, J=1.2; when the skill level is level four, J=1.3; and when the skill level is level five, J=1.4.

[0090] The first work hour calculation result of the target welder is obtained according to the skill level weight, the welding time length and the welding wire consumption, and the second work hour calculation result of the target welder is obtained according to the skill level weight, the welding time length, the welding seam theoretical volume of each preset welding type, the welding qualified rate and the preset welding type weight;

[0091] In a possible design, the first work hour calculation result is calculated according to the following formula:

[0092]

[0093] wherein, J refers to the skill level weight, M refers to the welding wire consumption, T refers to the welding time length, refers to the total weight of the welding wire consumption of all welders in a calculation period, the calculation period refers to a period corresponding to the work hour calculation result, and the target welder is any one of the all welders;

[0094] The second work hour calculation result is calculated according to the following formula:

[0095]

[0096] wherein, refers to the welding seam theoretical volume of the xth preset welding type, refers to the welding qualified rate of the xth preset welding type, refers to the preset welding type weight of the xth preset welding type, refers to the welding seam theoretical total volume of all welders in the calculation period in the xth preset welding type.

[0097] When the first work hour calculation result is greater than the second work hour calculation result, the second work hour calculation result is determined as the work hour calculation result of the target welder; when the first work hour calculation result is less than or equal to the second work hour calculation result, the average value of the first work hour calculation result and the second work hour calculation result is determined as the work hour calculation result of the target welder.

[0098] Specifically, when the first work hour calculation result is greater than the second work hour calculation result , it indicates that the welding qualified rate is too low and is out of an acceptable range, and then the work hour calculation result of the target welder is taken; is less than or equal to the second work hour calculation result , it indicates that the welding qualified rate is within the acceptable range, and then the work hour calculation result of the target welder is taken.

[0099] In a possible design, the plurality of preset welding types include flat welding, horizontal welding, vertical welding and overhead welding;

[0100] The preset welding type weights of flat welding, horizontal welding, vertical welding and overhead welding are sequentially increased.

[0101] Specifically, the preset welding types are distinguished according to the spatial positions of the joints of the equipment to be welded, and according to the different spatial positions, the preset welding types include flat welding, horizontal welding, vertical welding and overhead welding, and the welding difficulties of the preset welding types are different.

[0102] The work hour processing node server 110 maps the preset welding types to preset welding type weights. The preset welding type weight of flat welding is set as , the preset welding type weight of horizontal welding is set as , the preset welding type weight of vertical welding is set as , and the preset welding type weight of overhead welding is set as . Because the welding positions of the welds are different, the welding difficulties are also different, in which the flat welding is the easiest, the horizontal welding is the second, the vertical welding is the third, and the overhead welding is the most difficult. For example, the preset welding type weight is set in the interval [1, 1.3], , , , .

[0103] The technical effect of the embodiment of the present application is that the work hour calculation result of the target welder is calculated according to the skill level, the welding time length, the welding wire consumption, and the weld theoretical volume and the welding qualified rate of each preset welding type through the preset calculation formula, thereby improving the accuracy of the work hour calculation result calculation; the work hour calculation result of the target welder is obtained through the first work hour calculation result and the second work hour calculation result, thereby avoiding the extreme of a single result.

[0104] In a possible design, the work hour processing node server 110 is further configured to:

[0105] obtain a welding wire loss coefficient of the target welder according to the welding wire consumption and / or the weld theoretical volume of each preset welding type;

[0106] trigger an abnormality early warning when the welding wire loss coefficient is located outside a preset coefficient interval; wherein the abnormality early warning is used to indicate that the welding wire loss of the target welder is abnormal.

[0107] Specifically, in order to prevent the welder from intentionally consuming the welding wire and the welding wire weighing error and other problems, the welding wire loss abnormality early warning of the target welder is performed according to the welding wire consumption and / or the weld theoretical volume of each preset welding type.

[0108] For example, the welding wire loss coefficient is calculated according to the welding wire consumption and the weld theoretical volume of each preset welding type. An error E is introduced as the welding wire loss coefficient. The calculation formula of E is:

[0109]

[0110] wherein, E refers to the welding wire density. Set the preset coefficient interval is greater than or equal to 8%. When E < 8%, it is considered that no intentional consumption and weighing error of welding wire occurs, and no abnormal warning is triggered; when E ≥ 8%, it is considered that intentional consumption and weighing error of welding wire occurs, and abnormal warning is triggered, so as to facilitate relevant personnel to analyze the abnormal reason and carry out abnormal treatment.

[0111] For example, the welding wire loss coefficient is calculated according to the welding wire consumption and the theoretical volume of the weld of each preset welding type. The material utilization rate is introduced as the welding wire loss coefficient. The calculation formula of E is:

[0112]

[0113] Set the preset coefficient interval as the industry benchmark value ± 10%, then when < industry benchmark value - 10%, or, > industry benchmark value + 10%, abnormal warning is triggered.

[0114] For example, the welding wire loss coefficient is calculated according to the welding wire consumption. The deviation degree is introduced as the welding wire loss coefficient. The calculation formula of E is:

[0115]

[0116] wherein, E refers to the average welding wire consumption of welders with the same skill level. Set the preset coefficient interval as less than or equal to 20%. Then abnormal warning is triggered.

[0117] For example, the welding wire loss coefficient is calculated according to the theoretical volume of the weld of each preset welding type. The calculation formula of E is:

[0118]

[0119] wherein, E refers to the target welder's theoretical total volume of the weld, , E refers to the average theoretical total volume of the weld of welders with the same skill level. Set the preset coefficient interval as less than or equal to 20%. Then abnormal warning is triggered.

[0120] The technical effect of the embodiment of the present application is: judging whether the welding wire loss is abnormal by the welding wire loss coefficient, thereby avoiding the problem of welders deliberately consuming welding wire and incorrect welding wire weighing.

[0121] Figure 2 Schematic diagram of the structure of the welding time processing system provided in the embodiment of the present application Figure 2 .like Figure 1 As shown, the welding time processing system provided by the embodiment of the present application is Figure 3 The welding time processing system provided in the embodiment is further refined.

[0122] In one possible design, the welding time processing system provided in the embodiment of the present application further includes a camera 130;

[0123] Camera 130, used to capture the working video of the target welder;

[0124] The second node server 122 is in communication with the camera 130;

[0125] The second node server 122 is specifically used to obtain welding time according to the working video.

[0126] Specifically, the second node server 122 can obtain the welding duration based on image processing technology. For example, the welding gun position can be located through motion detection, color threshold segmentation, or edge detection, and the welding duration can be obtained from this. For another example, the contour of the molten pool or weld can be extracted through morphological operations, and the welding duration can be obtained from this. The second node server 122 can also obtain the welding duration based on machine learning technology. For example, a machine learning model can be trained using manually annotated frame-level labels to indicate the welding status, where the welding status refers to whether welding is in progress or not. Subsequently, the trained machine learning model can be used to extract the welding duration from the work video.

[0127] It should be noted that the camera 130 supports simultaneously capturing the working videos of multiple welders. The target welder is any one of these welders. The methods for determining the welding time of these welders are the same and will not be elaborated in detail in the embodiments of the present application.

[0128] In one possible design, the second node server 122 is specifically configured to:

[0129] According to the working video, the total duration of the target welder's welding torch spraying is obtained;

[0130] The welding time is obtained based on the total time of the welding gun spraying fire.

[0131] Specifically, the second node server 122 defines the welding time length as a time length for which the target welder welds the to-be-welded equipment through the welding torch, and the welding time length is positively correlated with, or even equal to, the total welding torch flame spouting time length. Then, the second node server 122 identifies, through image processing technology, a total number of times of spouting of the welding torch flame from the working video and a time of spouting of the welding torch flame for the i th time and the total welding torch flame spouting time length is Then, the total welding torch flame spouting time length is multiplied by a preset correction coefficient to obtain the welding time length.

[0132] The technical effect of the embodiment of the present application is that the total welding torch flame spouting time length is quantified through the camera, the calculation accuracy of the welding time length is improved, and the calculation accuracy of the work hour calculation result is further improved.

[0133] In a possible design, the welding work hour processing system further includes a sampling scale 140.

[0134] The sampling scale 140 is configured to detect a welding wire weighing weight of the target welder.

[0135] The third node server 123 is in communication connection with the sampling scale 140.

[0136] The third node server 123 is specifically configured to obtain a welding wire consumption amount according to the welding wire weighing weight.

[0137] Specifically, the target welder periodically takes welding wires and weighs the welding wires on the sampling scale 140. Further, the target welder takes the welding wires when starting work every day and returns the welding wires when finishing work every day, and the welding wires are weighed on the sampling scale 140 when the welding wires are taken and returned. The third node server 123 can calculate the welding wire consumption amount according to the welding wire weighing weight weighed each time.

[0138] The technical effect of the embodiment of the present application is that the welding wires are weighed through the sampling scale, the calculation accuracy of the welding wire weighing weight is improved, and the calculation accuracy of the work hour calculation result is further improved.

[0139] In a possible design, the welding work hour processing system further includes a flaw detection device 150.

[0140] The flaw detection device 150 is configured to detect a welding seam qualified number and a welding seam unqualified number of the target welder.

[0141] The fifth node server 125 is in communication connection with the flaw detection device 150.

[0142] The fifth node server 125 is specifically configured to obtain a welding seam qualified rate according to the welding seam qualified number and the welding seam unqualified number.

[0143] Specifically, the flaw detection equipment 150 can include a magnetic particle testing (MT) equipment and an ultrasonic testing (UT) equipment, wherein the magnetic particle testing equipment is used to inspect cracks on the surface of the weld, and the ultrasonic testing equipment is used to inspect bubbles and cracks inside the weld. If both the above two inspection results are qualified, the weld is considered qualified; otherwise, the weld is considered unqualified. By inspecting each weld one by one to see if it is qualified, the qualified number and the unqualified number of the welds of the target welder can be obtained; it should be noted that the welds that do not need to be detected are considered qualified by default. The welding qualification rate can be calculated by the fifth node server 125 according to the qualified number and the unqualified number of the welds.

[0144] The technical effect of the embodiment of the present application is that the welding qualification rate is calculated with higher accuracy by inspecting the welds by the flaw detection equipment, thereby improving the accuracy of the calculation result of the working hour calculation.

[0145] Figure 3 A flowchart of a welding working hour processing method provided by the embodiment of the present application is shown. The embodiment of the present application also provides a welding working hour processing method, as shown in Figure 1 The method is used for a working hour processing node server, the working hour processing node server is located in a distributed network, the distributed network is located in the welding working hour processing system as in the above-mentioned embodiment, and the distributed network further includes a first node server, a second node server, a third node server, a fourth node server and a fifth node server. The method includes the following steps.

[0146] S301, broadcasting a working hour calculation request of a target welder in a distributed network;

[0147] S302, obtaining, from the distributed network, a skill level of the target welder broadcast by the first node server, a welding time of the target welder broadcast by the second node server, a welding wire consumption of the target welder broadcast by the third node server, a theoretical volume of a weld of each preset welding type of the target welder broadcast by the fourth node server, and a welding qualification rate of each preset welding type of the target welder broadcast by the fifth node server;

[0148] S303, obtaining a working hour calculation result of the target welder according to the skill level, the welding time, the welding wire consumption, and the theoretical volume of the weld and the welding qualification rate of each preset welding type.

[0149] The welding working hour processing method provided by the embodiment of the present application is used for the system embodiment as shown in Figure 1 The technical scheme of the system embodiment, the implementation principle and the technical effect are similar to the system embodiment as shown in Figure 1 The embodiment of the present application will not be described again.

[0150] In a possible design, S303, according to the skill level, the welding time length, the welding wire consumption, and the welding seam theoretical volume and the welding qualified rate of each preset welding type, the work hour calculation result of the target welder is obtained, including:

[0151] According to the skill level, the skill level weight of the target welder is obtained; wherein the skill level weight is positively correlated with the skill level;

[0152] According to the skill level weight, the welding time length and the welding wire consumption, the first work hour calculation result of the target welder is obtained, and according to the skill level weight, the welding time length, and the welding seam theoretical volume, the welding qualified rate and the preset welding type weight of each preset welding type, the second work hour calculation result of the target welder is obtained;

[0153] When the first work hour calculation result is greater than the second work hour calculation result, the second work hour calculation result is determined as the work hour calculation result of the target welder; when the first work hour calculation result is less than or equal to the second work hour calculation result, the average value of the first work hour calculation result and the second work hour calculation result is determined as the work hour calculation result of the target welder.

[0154] In a possible design, the first work hour calculation result The calculation formula is:

[0155]

[0156] Wherein, J refers to the skill level weight, M refers to the welding wire consumption, T refers to the welding time length, refers to the total weight of the welding wire consumption of all welders in the calculation period, and the calculation period refers to the period corresponding to the work hour calculation result, and the target welder is any one of all welders;

[0157] The calculation formula of the second work hour calculation result is:

[0158]

[0159] Wherein, refers to the welding seam theoretical volume of the xth preset welding type, refers to the welding qualified rate of the xth preset welding type, refers to the preset welding type weight of the xth preset welding type, refers to the total welding seam theoretical volume of all welders in the calculation period in the xth preset welding type.

[0160] In a possible design, the plurality of preset welding types include flat welding, horizontal welding, vertical welding and overhead welding;

[0161] The preset welding type weights of flat welding, horizontal welding, vertical welding and overhead welding increase in sequence.

[0162] In one possible design, after obtaining the target welder's work hour calculation result based on the skill level, welding time, wire consumption, and the theoretical weld volume and welding qualification rate of each preset welding type in S303, the method further includes:

[0163] Obtaining a wire loss coefficient of a target welder based on wire consumption and / or a theoretical weld volume of each preset welding type;

[0164] When the wire loss coefficient is outside the preset coefficient range, an abnormal warning is triggered; wherein the abnormal warning is used to indicate that the wire loss of the target welder is abnormal.

[0165] The welding time processing method provided in the embodiment of the present application is used for Figure 2 and Figure 1 The technical solution of the system embodiment shown in the figure has the same implementation principle and technical effect as ​ The system embodiments shown are similar and will not be described in detail in the embodiments of this application.

[0166] So far, the technical solution of the present application has been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the scope of protection of the present application is obviously not limited to these specific embodiments. The above embodiments are only used to illustrate the technical solution of the present application, rather than to limit it. Although the present application has been described in detail with reference to the aforementioned embodiments, ordinary technicians in this field should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some or all of the technical features therein. However, these modifications or replacements do not cause the essence of the corresponding technical solution to deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A welding time processing system, characterized in that: The system includes: a work time processing node server, a first node server, a second node server, a third node server, a fourth node server and a fifth node server constituting a distributed network; The work time processing node server is used to broadcast the work time calculation request of the target welder in the distributed network; The first node server is configured to broadcast the skill level of the target welder in the distributed network; The second node server is configured to broadcast the welding time of the target welder in the distributed network; The third node server is configured to broadcast the welding wire consumption of the target welder in the distributed network; The fourth node server is configured to broadcast the target welder's theoretical weld volume for each preset welding type in the distributed network; The fifth node server is configured to broadcast the welding qualification rate of the target welder for each of the preset welding types in the distributed network; The work hour processing node server is also used to obtain the work hour calculation result of the target welder based on the skill level, the welding time, the welding wire consumption, and the theoretical weld volume and welding qualification rate of each preset welding type.

2. The welding time processing system according to claim 1, characterized in that: The work time processing node server is specifically used to: According to the skill level, a skill level weight of the target welder is obtained; wherein the skill level weight is positively correlated with the skill level; Obtaining a first work-hour calculation result for the target welder based on the skill level weight, the welding time, and the welding wire consumption, and obtaining a second work-hour calculation result for the target welder based on the skill level weight, the welding time, and the theoretical weld volume, welding pass rate, and preset welding type weight of each preset welding type; When the first work-hour calculation result is greater than the second work-hour calculation result, determining the second work-hour calculation result as the work-hour calculation result of the target welder; When the first work-hour calculation result is less than or equal to the second work-hour calculation result, an average value of the first work-hour calculation result and the second work-hour calculation result is determined as the work-hour calculation result of the target welder.

3. The welding time processing system according to claim 2, characterized in that: The first working hours calculation result The calculation formula is: Wherein, J refers to the skill level weight, M refers to the wire consumption, T refers to the welding time, The target welder is any one of the welders in the calculation period. The second working hours calculation result The calculation formula is: Among them, the Refers to the theoretical volume of the weld of the xth preset welding type, Refers to the welding qualification rate of the xth preset welding type, Refers to the preset welding type weight of the xth preset welding type, It refers to the theoretical total volume of welds of the xth preset welding type by all welders within the calculation period.

4. The welding time processing system according to claim 3, characterized in that: The plurality of preset welding types include flat welding, horizontal welding, vertical welding and overhead welding; The preset welding type weights of the flat welding, the horizontal welding, the vertical welding and the overhead welding are increased in sequence.

5. The welding time processing system according to claim 1, characterized in that: The work time processing node server is also used for: Obtaining a welding wire loss coefficient of the target welder according to the welding wire consumption and / or the weld theoretical volume of each of the preset welding types; When the wire loss coefficient is outside the preset coefficient range, an abnormal warning is triggered; wherein the abnormal warning is used to indicate that the wire loss of the target welder is abnormal.

6. The welding time processing system according to any one of claims 1 to 5, characterized in that: The system also includes a camera; The camera is used to capture the working video of the target welder; The second node server is communicatively connected to the camera; The second node server is specifically used to obtain the welding time according to the working video.

7. The welding time processing system according to claim 6, characterized in that: The second node server is specifically used to: According to the working video, the total duration of the target welder's welding torch spraying is obtained; The welding time is obtained according to the total time of the welding gun spraying fire.

8. The welding time processing system according to any one of claims 1 to 5, characterized in that: The system also includes a data acquisition scale; The digital scale is used to detect the welding wire weight of the target welder; The third node server is in communication with the data acquisition scale; The third node server is specifically used to obtain the welding wire consumption according to the weighed weight of the welding wire.

9. The welding time processing system according to any one of claims 1 to 5, characterized in that: The system also includes flaw detection equipment; The flaw detection equipment is used to detect the number of qualified welds and the number of unqualified welds of the target welder; The fifth node server is in communication with the flaw detection equipment; The fifth node server is specifically used to obtain the welding qualification rate according to the number of qualified welds and the number of unqualified welds.

10. A method for processing welding time, characterized in that: The method is used for a work time processing node server, the work time processing node server is located in a distributed network, the distributed network is located in the welding work time processing system according to any one of claims 1 to 9, the distributed network further includes a first node server, a second node server, a third node server, a fourth node server and a fifth node server, and the method includes: broadcasting a target welder's work time calculation request in the distributed network; Obtaining, from the distributed network, the skill level of the target welder broadcasted by the first node server, the welding time of the target welder broadcasted by the second node server, the wire consumption of the target welder broadcasted by the third node server, the theoretical weld volume of the target welder for each preset welding type broadcasted by the fourth node server, and the welding qualification rate of the target welder for each preset welding type broadcasted by the fifth node server; The working hours calculation result of the target welder is obtained according to the skill level, the welding time, the welding wire consumption, and the theoretical weld volume and welding qualification rate of each preset welding type.

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