Welding wire production energy management method capable of improving efficiency

Abstract

The invention relates to the technical field of welding wire production energy management, and discloses a welding wire production energy management method capable of improving efficiency, and the management method comprises the following steps: S1, technology optimization and technology upgrading, S2, intelligent production and process control, S3, material and energy cycle management, S4, personnel training and standardized execution, and S5, quality closed loop and continuous improvement. When the welding wire is produced, laser welding and double-wire welding are used for reducing subsequent welding wire use, the deposition rate is increased, unit welding line energy consumption is reduced, the welding period is shortened, and when the welding wire is produced, redundant energy waste and rework are avoided according to the diameter and material thickness of the produced welding wire, matched current, voltage and speed, and the production efficiency is improved. Therefore, the production efficiency is improved, the consumption of production energy is reduced, when the welding wire raw materials are purchased, high-quality suppliers are screened, the welding wire quality standard and the acceptance flow are determined, and then stock management is conducted on the raw materials.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding wire production energy management, in particular to a welding wire production energy management method for improving efficiency. BACKGROUND

[0002] Welding wire is a metal wire welding material used as filler metal or as a conductive metal. In gas welding and tungsten inert gas welding, welding wire is used as filler metal. In submerged arc welding, electroslag welding and other gas tungsten arc welding, welding wire is both filler metal and conductive electrode. The surface of the welding wire is not coated with an anti-oxidizing flux. During the welding wire production process, the welding wire production parameters are adjusted according to the type of the welding wire, resulting in long production time, reduced production efficiency and energy consumption. Therefore, it is difficult to complete the current large workload of welding wire production engineering with poor welding wire quality and welding quality, which will inevitably affect the welding wire production process. The specific aspects are as follows:

[0003] (1) During the welding wire production process, the welding wire production parameters are adjusted according to the type of the welding wire, resulting in long production time, reduced production efficiency and energy consumption; (2) During the welding wire production process, a large amount of heat and electricity is wasted due to mass production of welding wire, thereby increasing the production cost of welding wire and reducing the energy utilization rate of welding wire production; (3) The subsequent use of welding wire cannot be checked, which makes it difficult to update the welding wire production method and equipment, reducing the update rate of the production method. SUMMARY

[0004] The present application aims to provide a welding wire production energy management method for improving efficiency to solve the problems of current welding wire production energy management as mentioned in the background, including (1) adjusting welding wire production parameters according to the type of welding wire during the welding wire production process, resulting in long production time, reduced production efficiency and energy consumption; (2) a large amount of heat and electricity is wasted during the welding wire production process due to mass production of welding wire, thereby increasing the production cost of welding wire and reducing the energy utilization rate of welding wire production; (3) the subsequent use of welding wire cannot be checked, which makes it difficult to update the welding wire production method and equipment, reducing the update rate of the production method.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical solution: a welding wire production energy management method for improving efficiency, the management method comprising the following steps:

[0006] S1, process optimization and technology upgrading

[0007] S1.1, adopt efficient welding process, ① introduce laser welding, ② introduce double wire welding, S1.2, apply narrow gap welding technology, S1.3, parameter precise control, ① determine the wire diameter, ② adjust the current voltage, ③ adjust the wire production speed;

[0008] S2, intelligent production and process control

[0009] S2.1, deploy MES system to realize fine management, ① system automatic production scheduling and monitoring equipment state, ② real-time tracking of welding wire consumption data, ③ dynamic adjustment of production plan, S2.2, application of robot collaborative work, ① adopt welding robot;

[0010] S3, material and energy cycle management

[0011] S3.1, welding wire whole life cycle control, ① procurement link, ② inventory management, S3.2, energy recovery and utilization, ① electric energy recovery device, ② waste heat recovery device;

[0012] S4, personnel training and standardized execution

[0013] S4.1, implement standardized operation, ① equipment debugging, ② parameter equipment, ③ welding, ④ quality inspection, S4.2, skill enhancement training, ① carry out vertical welding basic module time limit training, ② carry out horizontal welding basic module time limit training, S4.3, simulate multi-process cooperation, ① multiple scenes, ② exchange workers;

[0014] S5, quality closed loop and continuous improvement

[0015] S5.1, establish quality traceability mechanism, ① associate welding wire batch, ② welding quality data, S5.2, quickly locate the source of the problem, ① material defects, ② parameter abnormalities, S5.3, dynamically optimize energy efficiency model, regularly, ① welding wire consumption, ② energy consumption data, S5.4, update, ① iterative process parameters, ② update equipment configuration.

[0016] Preferably, the formula for calculating the deposition rate in the welding process is deposition rate = deposited metal mass / welding time, unit kg / h and g / min.

[0017] Preferably, the total consumption of welding wire m is determined by the welding seam cross-sectional area A, the welding seam length L, the deposited metal density p and the loss coefficient K_s, and the welding wire consumption calculation formula is m = A * L * p / (1-K_s), A is the welding seam cross-sectional area, unit cm 2 , determined by the groove form, p is the density of deposited metal, unit g / cm 3 , the carbon steel is usually 7.85 g / cm 3K_s is the comprehensive loss coefficient of the welding wire, including spatter, burn-off and electrode tip residue, which is generally 0.15–0.30.

[0018] Preferably, the parameters need to be adjusted according to the process type when performing twin-wire welding. When twin wires are connected in parallel, such as Twin Arc, the two wires form a fusion pool and the total current is superimposed. The A value needs to be calculated based on the actual weld width. When twin wires are connected in series, the current does not flow through the base material, the weld depth is shallower, and the A value needs to be reduced by 10%-20%.

[0019] Preferably, the MES mean square error calculation formula is MES=∑(Xx) 2 / n, where X is the actual observed value of the i-th data point, x is the predicted value of the i-th data point, and n is the total number of data samples.

[0020] Preferably, the torque-driving force conversion formula of the welding robot is F=r / T·η, where T is the output torque of the motor in N·m, r is the wheel radius (m), when the diameter is 0.2m, r=0.1m, and η is the transmission efficiency, which is usually taken as 0.85~0.95.

[0021] Preferably, the energy consumption formula for single-point welding of the welding robot is Q = I 2 ×R×t, where I is the welding current in A, R is the resistance in Ω, and t is the time in s.

[0022] Preferably, the energy recovery efficiency η of the energy recovery device is Erecovery / Eoutput x 100%, where η is the recovery efficiency in % , Erecovery is the recovered energy value in J and kWh, and Eoutput is the total input energy value in J and kWh.

[0023] Preferably, the formula for calculating the amount of electricity recovered by the energy recovery device is Erecovery = Q * U * t, where Q is the recovery current (A), U is the voltage (V), and t is the recovery time (s).

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. This invention reduces the use of subsequent welding wires by using laser welding and twin-wire welding during the production of welding wires, thereby increasing the deposition rate, reducing the energy consumption per unit weld, and shortening the welding cycle. Furthermore, during the production of welding wires, the current, voltage, and speed are matched according to the diameter and material thickness of the welding wires to avoid unnecessary energy waste and rework, thereby improving production efficiency and reducing production energy consumption.

[0026] 2. This invention improves the recycling and reuse of excess heat and electricity by selecting high-quality suppliers, clarifying welding wire quality standards and acceptance procedures during the procurement of welding wire raw materials, managing raw material inventory by classifying and storing them and strictly implementing "first-in, first-out" (FIFO) and conducting regular inventory checks to prevent stockpiling, and by using an energy recovery device to recover excess electricity generated during the welding wire production process and then feeding it back into the production equipment. Furthermore, a waste heat recovery device is used to recover excess heat and then reuse it for subsequent and preceding steps. This reduces the production cost of welding wire and improves the energy utilization rate during the welding wire production process.

[0027] 3. This invention establishes a quality traceability mechanism through the MES system, linking welding wire batches with welding quality data to quickly locate the source of problems, such as material defects and parameter anomalies. Then, based on the material defects and parameter anomalies, emergency adjustments and optimizations are made to the equipment. Furthermore, by utilizing the dynamic optimization energy efficiency model, welding wire consumption and energy consumption data are analyzed periodically, and process parameters and equipment configurations are iterated to facilitate the optimization of welding wire production and inspection, thereby improving and optimizing the subsequent production formula and quality of welding wire. Attached Figure Description

[0028] Fig. 1 This is a flowchart of the energy management process for welding wire production according to the present invention;

[0029] Fig. 2 This is a logic diagram of the work order scheduling engine of the MES system of the present invention;

[0030] Fig. 3 This is a logic diagram of the operation quality traceability module of the MES system of the present invention. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Example 1:

[0033] Please see Figs. 1-3 An energy management method for improving the efficiency of welding wire production, the method comprising the following steps:

[0034] S1. Process optimization and technology upgrade

[0035] S1.1 Employing efficient welding processes: ① Introducing laser welding, ② Introducing twin-wire welding; S1.2 Applying narrow-gap welding technology; S1.3 Precise parameter control: ① Determining the welding wire diameter, ② Adjusting the current and voltage, ③ Adjusting the welding wire production speed. During welding wire production, laser welding and twin-wire welding are used to reduce the use of subsequent welding wires, increase the deposition rate, reduce the energy consumption per unit weld, and shorten the welding cycle. Furthermore, during welding wire production, the current, voltage, and speed are matched according to the diameter of the welding wire and the material thickness to avoid unnecessary energy waste and rework, thereby improving production efficiency and reducing production energy consumption.

[0036] S2, Intelligent Production and Process Control

[0037] S2.1 Deploy a MES system to achieve refined management: ① The system automatically schedules production and monitors equipment status; ② It tracks welding wire consumption data in real time; ③ It dynamically adjusts production plans. S2.2 Apply robot collaborative operations: ① Welding robots are used to automatically schedule production and monitor equipment status during the welding wire production process, reducing downtime and tracking welding wire consumption data in real time. Then, the dynamic adjustment system uses IoT sensors to monitor the welding wire production quality, automatically warning parameter deviations. Subsequently, robots are used to operate the production and welding work, precisely controlling the welding trajectory through welding robots to reduce ineffective actions and energy consumption.

[0038] S3, Material and Energy Recycling Management

[0039] S3.1 Welding wire lifecycle management: ① Procurement, ② Inventory management; S3.2 Energy recovery and utilization: ① Electricity recovery device, ② Waste heat recovery device. When procuring welding wire raw materials, select high-quality suppliers, clarify welding wire quality standards and acceptance procedures, and then manage raw material inventory, classify and store them, strictly implement "first-in, first-out," and conduct regular inventory checks to prevent stockpiling. During the welding wire production process, the electricity recovery device recovers excess electricity generated during the process and reinvests it in the production equipment. The waste heat recovery device recovers excess heat and uses it for subsequent and preceding steps, thereby improving the recovery and reuse of excess heat and electricity, reducing welding wire production costs, and increasing energy utilization during the welding wire production process.

[0040] S4. Personnel Training and Standardization Implementation

[0041] S4.1 Implement standardized operations: ① Equipment debugging, ② Equipment parameter setting, ③ Welding, ④ Quality inspection. S4.2 Enhance skills training: ① Conduct timed training on basic vertical welding modules, ② Conduct timed training on basic flat welding modules. S4.3 Simulate multi-process collaboration: ① Multiple scenarios, ② Exchange of personnel. Before personnel are put into production and use, they undergo rigorous training. The production process of welding wire is "equipment debugging → parameter setting → welding → quality inspection" module. Set time standards for each step, and set a fixed time for each step. Then conduct timed training on basic flat / vertical welding modules to improve the first-pass yield rate and cultivate comprehensive operational capabilities by simulating multi-process collaboration scenarios.

[0042] S5, Quality Closed Loop and Continuous Improvement

[0043] S5.1 Establish a quality traceability mechanism, ① linking welding wire batches, ② welding quality data; S5.2 Quickly locate the source of problems, ① material defects, ② parameter anomalies; S5.3 Dynamically optimize the energy efficiency model, regularly, ① welding wire consumption, ② energy consumption data; S5.4 Update and upgrade, ① iterating process parameters, ② updating equipment configuration. By establishing a quality traceability mechanism through the MES system, linking welding wire batches and welding quality data, the source of problems, such as material defects and parameter anomalies, can be quickly located. Based on these issues, emergency adjustments and optimizations can be made to the equipment. Then, utilizing the dynamic optimization energy efficiency model, welding wire consumption and energy consumption data can be analyzed regularly, iterating process parameters and equipment configurations to facilitate the optimization of welding wire production and inspection, thereby improving and optimizing subsequent welding wire production formulas and quality.

[0044] In this embodiment: The formula for calculating the deposition rate during welding is: Deposition rate = Mass of cladding metal / Welding time, with units of kilograms per hour (kg / h) and grams per minute (g / min).

[0045] In this embodiment, the total wire consumption m is determined by the weld cross-sectional area A, weld length L, deposited metal density ρ, and loss coefficient K_s. The formula for calculating wire consumption is m = A * L * ρ / (1 - K_s), where A is the weld cross-sectional area in cm. 2 Determined by the bevel shape, ρ is the density of the deposited metal, in g / cm³. 3 Carbon steel is typically rated at 7.85 g / cm³. 3 K_s is the comprehensive loss coefficient of the welding wire, including spatter, burn-off and electrode tip residue, which is generally 0.15–0.30.

[0046] In this embodiment: When welding with two wires, the parameters need to be adjusted according to the process type. When two wires are connected in parallel, such as Twin Arc, the two wires melt together, and the total current is superimposed. The A value needs to be calculated according to the actual weld width. When two wires are connected in series, the current does not flow through the base material, the weld depth is shallower, and the A value needs to be reduced by 10%-20%.

[0047] In this embodiment: The formula for calculating the mean squared error of MES is MES=∑(Xx). 2 / n, where X is the actual observed value of the i-th data point, x is the predicted value of the i-th data point, and n is the total number of data samples.

[0048] In this embodiment: the torque-driving force conversion formula for the welding robot is F=r / T·η, where T is the output torque of the motor in N·m, r is the wheel radius (m), when the diameter is 0.2m, r=0.1m, and η is the transmission efficiency, which is usually taken as 0.85~0.95.

[0049] In this embodiment: the energy consumption formula for single-point welding of the welding robot is Q = I 2 ×R×t, where I is the welding current in A, R is the resistance in Ω, and t is the time in s.

[0050] In this embodiment: the energy recovery efficiency η of the energy recovery device is Erecovery / Eoutput x 100%, where η is the recovery efficiency in %, Erecovery is the recovered energy value in J and kWh, and Eoutput is the total input energy value in J and kWh.

[0051] In this embodiment: the formula for calculating the amount of electricity recovered by the energy recovery device is Erecovery = Q * U * t, where Q is the recovery current in A, U is the voltage in V, and t is the recovery time in s.

[0052] Example 2:

[0053] like Figs. 1-3 As shown, unlike Embodiment 1, this embodiment provides an energy management method for improving the efficiency of welding wire production. The management method includes the following steps:

[0054] S1. Process optimization and technology upgrade

[0055] S1.1. Adopt efficient welding processes, ① introduce laser welding, ② introduce twin-wire welding. S1.2. Apply narrow gap welding technology. When producing welding wire, laser welding and twin-wire welding are used to reduce the use of subsequent welding wires, improve the deposition rate, reduce the energy consumption per unit weld, and shorten the welding cycle.

[0056] S2, Intelligent Production and Process Control

[0057] S2.1 Deploy the MES system to achieve refined management: ① The system automatically schedules production and monitors equipment status; ② It tracks welding wire consumption data in real time; ③ It dynamically adjusts the production plan. S2.2 Apply robot collaborative operation: ① Welding robots are used to automatically schedule production and monitor equipment status during the welding wire production process, reducing downtime and tracking welding wire consumption data in real time. Then, the dynamic adjustment system uses IoT sensors to monitor the welding wire production quality and automatically warn of parameter deviations.

[0058] S3, Material and Energy Recycling Management

[0059] S3.1 Welding wire lifecycle management: ① Procurement process, ② Inventory management. When procuring welding wire raw materials, select high-quality suppliers, clarify welding wire quality standards and acceptance procedures, and then manage the inventory of raw materials, classify and store them and strictly implement "first in first out", and conduct regular inventory checks to prevent backlog.

[0060] S4. Personnel Training and Standardization Implementation

[0061] S4.1 Implement standardized operations: ① Equipment debugging, ② Equipment parameter setting, ③ Welding, ④ Quality inspection. S4.2 Enhance skills training: ① Conduct timed training on basic vertical welding modules, ② Conduct timed training on basic flat welding modules. S4.3 Simulate multi-process collaboration: ① Multiple scenarios, ② Staff exchange. Before staff are put into production and use, they undergo rigorous training. The welding wire production process is "equipment debugging → parameter setting → welding → quality inspection" modules. Set time standards for each step, with fixed equipment time for each step. Then conduct timed training on basic flat / vertical welding modules to improve the first-pass yield rate and cultivate comprehensive operational capabilities by simulating multi-process collaboration scenarios.

[0062] In summary, compared with Example 2, Example 1 can reduce the use of subsequent welding wires, increase the deposition rate, reduce the energy consumption per unit weld, and shorten the welding cycle by using laser welding and twin-wire welding during the production of welding wire. Furthermore, during the production of welding wire, the current, voltage, and speed are matched according to the diameter and material thickness of the welding wire to avoid unnecessary energy waste and rework, thereby improving production efficiency and reducing production energy consumption.

[0063] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0064] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for improving the energy management efficiency of welding wire production, characterized in that: Its management methods include the following steps: S1. Process optimization and technology upgrade S1.

1. Adopting efficient welding processes: ① Introducing laser welding, ② Introducing twin-wire welding; S1.

2. Applying narrow gap welding technology; S1.

3. Precise parameter control: ① Determining the welding wire diameter, ② Adjusting the current and voltage, ③ Adjusting the welding wire production speed. S2, Intelligent Production and Process Control S2.1 Deploy the MES system to achieve refined management: ① The system automatically schedules production and monitors equipment status; ② It tracks welding wire consumption data in real time; ③ It dynamically adjusts production plans. S2.2 Apply robot collaborative operations: ① Welding robots are adopted. S3, Material and Energy Recycling Management S3.1 Welding wire lifecycle management, ① Procurement, ② Inventory management; S3.2 Energy recovery and utilization, ① Electricity recovery device, ② Waste heat recovery device. S4. Personnel Training and Standardization Implementation S4.1 Implement standardized operations: ① Equipment debugging, ② Parameter equipment, ③ Welding, ④ Quality inspection; S4.2 Enhance skills training: ① Conduct timed training on basic vertical welding modules, ② Conduct timed training on basic flat welding modules; S4.3 Simulate multi-process collaboration: ① Multiple scenarios, ② Exchange of personnel. S5, Quality Closed Loop and Continuous Improvement S5.1 Establish a quality traceability mechanism, ① linking welding wire batches, ② welding quality data; S5.2 Quickly locate the source of problems, ① material defects, ② parameter anomalies; S5.3 Dynamically optimize the energy efficiency model, periodically, ① welding wire consumption, ② energy consumption data; S5.4 Update and replace, ① iterating process parameters, ② updating equipment configuration.

2. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The formula for calculating the deposition rate during the welding process is: Deposition rate = Mass of clad metal / Welding time, with units of kilograms per hour (kg / h) and grams per minute (g / min).

3. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The total welding wire consumption m is determined by the weld cross-sectional area A, weld length L, deposited metal density ρ, and loss coefficient K_s. The formula for calculating welding wire consumption is m = A * L * ρ / (1 - K_s), where A is the weld cross-sectional area in cm. 2 Determined by the bevel shape, ρ is the density of the deposited metal, in g / cm³. 3 Carbon steel is typically rated at 7.85 g / cm³. 3 K_s is the comprehensive loss coefficient of the welding wire, including spatter, burn-off and electrode tip residue, which is generally 0.15–0.

30.

4. The energy management method for improving the efficiency of welding wire production according to claim 3, characterized in that: When performing twin-wire welding, the parameters need to be adjusted according to the process type. For parallel twin-wire welding, such as Twin Arc, the two wires form a fusion pool, and the total current is superimposed. The A value needs to be calculated based on the actual weld width. For series twin-wire welding, the current does not flow through the base material, resulting in a shallower weld depth. The A value needs to be reduced by 10%-20%.

5. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The formula for calculating the mean square error of MES is MES=∑(Xx). 2 / n, where X is the actual observed value of the i-th data point, x is the predicted value of the i-th data point, and n is the total number of data samples.

6. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The torque-driving force conversion formula for the welding robot is F=r / T·η, where T is the output torque of the motor in N·m, r is the wheel radius (m), and when the diameter is 0.2m, r=0.1m, and η is the transmission efficiency, which is usually taken as 0.85~0.

95.

7. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The energy consumption formula for single-point welding of the welding robot is Q = I. 2 ×R×t, where I is the welding current in A, R is the resistance in Ω, and t is the time in s.

8. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The energy recovery efficiency of the energy recovery device is η = Erecovery / Eoutput x 100%, where η is the recovery efficiency in % , Erecovery is the recovered energy value in J and kWh, and Eoutput is the total input energy value in J and kWh.

9. The energy management method for improving the efficiency of welding wire production according to claim 1, characterized in that: The formula for calculating the amount of electricity recovered by the energy recovery device is Erecovery = Q * U * t, where Q is the recovery current (A), U is the voltage (V), and t is the recovery time (s).

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