Welding machine parameter acquisition device

Abstract

The invention discloses a welding machine parameter acquisition device, and relates to the technical field of welding machine detection, the welding machine parameter acquisition device comprises a parameter acquisition module and an acquisition management terminal; the parameter acquisition module is connected between the welding machine and a welding gun of the welding machine and is used for acquiring operation parameters of the welding machine; the acquisition management terminal comprises a main control module, a charging management module and a battery, the main control module and the charging management module are electrically connected with the parameter acquisition module, and the main control module is used for controlling the charging management module to supply power to the parameter acquisition module or charge the battery according to the operation parameters of the welding machine. The heat dissipation performance of the welding machine parameter acquisition device is enhanced, and the safety of the welding machine parameter acquisition device is guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding machine detection, in particular to a welding machine parameter acquisition device. BACKGROUND

[0002] Traditional welding operation site welding machine parameter monitoring relies on manual observation, and cannot view relevant parameters online, and the degree of automation and intelligence is low. In related technologies, automatic acquisition devices are used to monitor welding machine parameters. When the welding machine is welding in real time, the current value is large, and there is a serious heating situation. The automatic acquisition device uses an additional power supply to dissipate heat. However, the welding operation site environment is complex, and the additional power supply needs to increase an external independent power supply line, which increases the difficulty of work. Once human error occurs, it is easy to cause a major safety accident. SUMMARY

[0003] The present application aims to at least solve one of the technical problems in the prior art, and provides a welding machine parameter acquisition device, which aims to enhance the heat dissipation performance of the welding machine parameter acquisition device and ensure the safety of the welding machine parameter acquisition device.

[0004] The present application provides a welding machine parameter acquisition device, which comprises a parameter acquisition module and an acquisition management terminal. The parameter acquisition module is connected between the welding machine and the welding gun of the welding machine, and is used to acquire the operating parameters of the welding machine. The acquisition management terminal comprises a main control module, a charging management module and a battery. The main control module and the charging management module are electrically connected with the parameter acquisition module. The main control module is used to control the charging management module to supply power to the parameter acquisition module or charge the battery according to the operating parameters of the welding machine.

[0005] According to the technical scheme of the present application, the charging management module and the battery are arranged in the acquisition management terminal. Therefore, the main control module can control the charging management module to supply power to the parameter acquisition module or charge the battery according to the operating parameters of the welding machine. That is, the battery of the acquisition management terminal is directly charged by the welding machine, and the battery of the acquisition management terminal is used as a power supply, without using an additional power supply and without increasing an external independent power supply line. In addition, since the welding machine parameter acquisition device adopts a split design, wired and wireless communication can be used between the welding machine and the welding gun, which ensures the stability of data transmission, and also ensures stable connection when the welding machine and the welding gun are far apart. Since the acquisition management terminal with the battery is not directly connected to the welding machine circuit, the heat generated by the operation of the acquisition management terminal will not affect the operation of the welding machine, and vice versa, thereby enhancing the heat dissipation performance of the welding machine parameter acquisition device.

[0006] According to some embodiments of this application, the parameter acquisition module includes a parameter acquisition box and a current sensor connected to each other. The parameter acquisition box is used to acquire the voltage parameters of the welding machine, and the current sensor is used to acquire the current parameters of the welding machine.

[0007] According to some embodiments of this application, the parameter acquisition box includes a step-down module, which is connected to the charging management module and in parallel to the output circuit of the welding machine. When the main control module controls the charging management module to charge the battery according to the operating parameters of the welding machine, the step-down module is used to step down the output voltage of the welding machine so as to charge the battery through the charging management module.

[0008] According to some embodiments of this application, the current sensor is disposed in the positive or negative circuit between the parameter acquisition box and the welding torch; the main control module includes a current analysis unit, and the main control module is further used to process the data collected by the current sensor in different setting directions or different setting positions through the current analysis unit to obtain the current parameters of the welding machine.

[0009] According to some embodiments of this application, the parameter acquisition module is also connected to the welding machine via a welding machine control line to control the output current of the welding machine via the welding machine control line.

[0010] According to some embodiments of this application, the parameter acquisition module further includes a speed sensor, which is disposed on the welding torch and communicates with the main control module. The speed sensor is used to detect the welding speed of the welding torch, and the main control module is also used to adjust the operating parameters of the welding machine according to the welding speed of the welding torch.

[0011] According to some embodiments of this application, the main control module is communicatively connected to a management platform for monitoring the welding machine parameter acquisition device, so as to upload the operating parameters of the welding machine to the management platform and store them.

[0012] According to some embodiments of this application, the main control module includes a local storage unit, and the main control module is further configured to save the operating parameters of the welding machine to the local storage unit when the communication connection between the main control module and the management platform is disconnected.

[0013] According to some embodiments of this application, the parameter acquisition module is provided with a hot-swappable port, which is used for hot-swapping expansion devices, including environmental sensors, gas sensors, and expansion battery modules.

[0014] According to some embodiments of this application, the main control module is also used to trigger a safety prompt and issue an alarm when an abnormal situation is detected, based on the operating parameters of the welding machine.

[0015] Other features and advantages of this application will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the description, claims and drawings. Attached Figure Description

[0016] The accompanying drawings are used to provide a further understanding of the technical solutions of this application and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of this application and do not constitute a limitation on the technical solutions of this application.

[0017] The present application will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a schematic block diagram of the structure of a welding machine parameter acquisition device provided in one embodiment of this application; Figure 2 This is a schematic diagram of the structure of a parameter acquisition module provided in one embodiment of this application; Figure 3 This is a schematic diagram of the structure of a parameter acquisition module provided in one embodiment of this application; Figure 4 This is a schematic diagram of the structure of a welding machine parameter acquisition device provided in another embodiment of this application; Figure 5 This is a schematic diagram of the structure of a welding machine parameter acquisition device provided in another embodiment of this application. Detailed Implementation

[0018] This section will describe in detail the specific embodiments of this application. Preferred embodiments of this application are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of this application, but they should not be construed as limiting the scope of protection of this application.

[0019] In the description of this application, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0020] In the description of this application, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. If the terms "first" and "second" are used, they are merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly specifying the number of indicated technical features, or implicitly indicating the order of the indicated technical features. In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0021] The present application will be further described below with reference to the accompanying drawings.

[0022] like Figure 1 As shown, Figure 1 This is a schematic block diagram of a welding machine parameter acquisition device provided in one embodiment of the present application. The welding machine parameter acquisition device includes a parameter acquisition module and an acquisition management terminal. The parameter acquisition module is connected between the welding machine and the welding torch of the welding machine to collect the operating parameters of the welding machine; The data acquisition and management terminal includes a main control module, a charging management module, and a battery. Both the main control module and the charging management module are electrically connected to the parameter acquisition module. The main control module is used to control the charging management module to supply power to the parameter acquisition module or charge the battery according to the operating parameters of the welding machine.

[0023] For example, the parameter acquisition module is connected between the welding machine and its welding torch, that is, between the welding machine's output terminals and the welding torch cable. The module integrates a shunt or current transformer to directly measure the large current flowing through the entire circuit. Simultaneously, a high-impedance voltage sampling circuit is directly connected in parallel to the positive and negative output terminals to measure the arc voltage. It is important to note that the parameter acquisition module must be able to withstand the entire current and complex operating conditions of the main welding circuit; therefore, it possesses extremely high electrical isolation and heat dissipation capabilities.

[0024] refer to Figure 2 and Figure 3 , Figure 2 This is a schematic diagram of the structure of a parameter acquisition module provided in one embodiment of this application. Figure 3 This is a schematic diagram of the structure of a parameter acquisition module provided in one embodiment of this application. The wiring filter board, wiring terminals and internal circuits inside the parameter acquisition module are isolated. The outer shell of the parameter acquisition module is equipped with heat dissipation fins and a bottom air inlet. By utilizing the regional isolation design and the principle of generating natural wind by the air temperature difference, the heat inside the parameter acquisition module is discharged through the fins, realizing structural heat dissipation, avoiding additional heat dissipation equipment, and still maintaining high heat dissipation efficiency.

[0025] For example, the parameter acquisition module may not be directly connected in series in the high-voltage, high-current main circuit. Instead, it can perform non-invasive measurements through external sensors. For instance, a current sensor can be clamped onto the power cable of the welding torch to indirectly calculate the current value by sensing changes in the magnetic field around the cable, thus achieving complete electrical isolation. Voltage measurement can use an independent voltage probe, which can be directly connected to the output terminal of the welding machine or the connection point of the welding torch.

[0026] For example, in addition to electrical parameters, the parameter acquisition module will also connect to the welding machine main control board through a digital communication interface to read data from the internal controller of the welding machine, such as preset current and voltage, wire feeder status, error codes, etc.

[0027] For example, the operating parameters collected by the parameter acquisition module include multiple types of parameter data, such as electrical, physical, process, and equipment status parameters. Among them, electrical parameters include welding current, arc voltage, and power. Welding current directly reflects the heat input of the molten pool and can be acquired through a series shunt or a non-contact Hall effect sensor. Arc voltage determines the stability and shape of the arc and can be acquired through a high-impedance differential voltage probe connected in parallel to the positive and negative terminals of the welding machine output. Wire feed speed can be acquired through an encoder installed on the wire feeder. Shielding gas flow rate is acquired through an electronic flow meter installed in the gas line. The acquisition of all these parameters involves analog-to-digital signal conversion (ADC), digital signal decoding, and timestamp synchronization, and is finally packaged and transmitted to the acquisition management terminal for analysis and processing.

[0028] For example, the parameter acquisition module can also be embedded as a slave station within the central control system (acquisition management terminal). Here, the parameter acquisition module can acquire not only the welding machine's operating parameters but also data from the welding power supply. Alternatively, the parameter acquisition module can be deployed as a standalone gateway device at the network aggregation point in the workshop. It establishes connections with multiple welding machines in the area via wired or wireless means, forming a centralized data acquisition node responsible for aggregating, preprocessing, and uploading data from all connected devices to the acquisition management terminal, cloud platform, or factory-level MES system.

[0029] For example, the operating parameters of the welding machine collected by the parameter acquisition module can be analyzed to uncover the deep correlation between parameter settings and weld formation and defect incidence, thereby optimizing the process and achieving adaptive real-time adjustment of parameters through machine learning algorithms.

[0030] For example, the operating parameters of the welding machine collected by the parameter acquisition module can continuously monitor the working status, load rate and temperature changes of the welding machine. The parameter acquisition module can provide early warnings of faults such as wire feeding mechanism wear and main transformer aging.

[0031] For example, the welding machine parameter acquisition device includes a parameter acquisition module and an acquisition management terminal. The acquisition management terminal includes a main control module, a charging management module, and a battery. Both the main control module and the charging management module are electrically connected to the parameter acquisition module. Here, the connection between the charging management module and the parameter acquisition module includes a power transmission connection for transmitting electrical energy, and its voltage and current specifications match the working requirements of the parameter acquisition module. The charging management module obtains electrical energy from the battery, and after passing through its internal voltage regulation, filtering, and intelligent distribution circuits, outputs a stable DC voltage to power various chips, sensors, and communication modules within the parameter acquisition module. The connection between the main control module and the parameter acquisition module includes a bidirectional data and control connection, such as I2C, SPI, UART, etc., which enables the main control module to send commands and upload data to the parameter acquisition module through corresponding data lines. The main control module also receives welding machine operating parameters from the parameter acquisition module in real time through this channel.

[0032] For example, in a welding machine parameter acquisition device, the main control module is used to coordinate control and data processing. This includes being responsible for real-time communication with the parameter acquisition module, receiving and parsing raw sensor data from the front end, and performing preliminary verification, filtering, and timestamping on this data. It also includes managing the working status of the parameter acquisition module according to preset programs or instructions received from external sources, such as starting or stopping acquisition, changing the sampling frequency, switching acquisition channels, or triggering specific diagnostic processes. Furthermore, it includes continuously monitoring the overall energy consumption status of the system and issuing precise instructions to the charging management module based on this information to determine the energy flow, thereby achieving intelligent power distribution and maximizing the equipment's endurance. Finally, it includes uploading the processed key data to the cloud or local server via a network interface for subsequent monitoring and analysis.

[0033] For example, the charging management module is used for energy conversion and distribution, including connecting an external power adapter or other charging source and converting its voltage and current to specifications suitable for charging the internal battery and powering the system circuit; it also includes safely and quickly charging the lithium battery through algorithms, while monitoring the battery's health status and charge status in real time, and providing overcharge, over-discharge, overcurrent, and short-circuit protection; it also includes changing the power supply path according to instructions sent by the main control module, deciding whether to charge the battery or switch to the battery to power the system.

[0034] For example, the main control module acquires and analyzes the welding machine's operating parameters in real time from the parameter acquisition module via an internal communication bus. Then, the main control module has one or more preset logical judgment thresholds, such as a current threshold and a voltage threshold. When the welding current and voltage continuously exceed their respective thresholds and remain above them for a certain period, the main control module logically determines that the welding machine is in welding operation mode. When the current and voltage remain below the thresholds for a certain period, the welding machine is determined to be in idle or off state. Subsequently, once the main control module determines that the welding machine has entered the working state, it can send a command to the charging management module to enter the power supply mode. In this mode, the charging management module provides full power to the parameter acquisition module, ensuring that all its sensors and processors operate at full speed. If an external power supply is connected, it will simultaneously charge the battery. When the main control module determines that the welding machine has entered the idle state, it triggers a low-power energy-saving mode. At this time, the main control module can first command the parameter acquisition module itself to reduce the sampling rate or shut down some unnecessary sensors to reduce its power consumption, and simultaneously instruct the charging management module to adjust, thereby charging the battery.

[0035] In some embodiments of this application, the parameter acquisition device for welding machines includes a parameter acquisition box and a current sensor connected to each other. The parameter acquisition box is used to acquire the voltage parameters of the welding machine, and the current sensor is used to acquire the current parameters of the welding machine.

[0036] For example, the parameter acquisition module includes interconnected parameter acquisition boxes and current sensors. The parameter acquisition box is used to acquire the voltage parameters of the welding machine. The parameter acquisition box integrates multi-layered circuit boards, on which a central processing unit (CPU) or microcontroller (MCU) is arranged to execute control logic, perform preliminary data calculations, and coordinate the work of various sub-modules; an analog-to-digital converter (ADC) is used to realize voltage parameter acquisition; a signal conditioning circuit is located between the voltage input interface and the ADC. Since the voltage signal output by the welding machine may be accompanied by high voltage spikes, violent fluctuations, and strong electromagnetic noise, directly connecting it to the ADC will damage the chip or cause data distortion. Therefore, the signal conditioning circuit usually includes protection circuits, filtering circuits, and scaling and biasing circuits composed of operational amplifiers; multiple communication interface modules are used for data output and command input, such as RS-485, CAN bus, Ethernet, Wi-Fi, USB interface, etc.; and a power management module may also be included to provide DC operating voltage for all chips and circuits in the box.

[0037] Understandably, welding processes generate extremely strong electromagnetic interference, including high-frequency arc-starting noise, magnetic field interference from huge current changes, and drastic voltage fluctuations caused by arc instability. Ordinary multimeters or simple voltmeters cannot provide stable and accurate readings in this environment, and their internal circuits are easily interfered with or even damaged. The metal casing of the parameter acquisition box provides electromagnetic shielding, and its internal signal conditioning circuitry suppresses common-mode and differential-mode noise, thus allowing for the measurement of accurate voltage signals. Furthermore, welding quality control requires microsecond-level waveform capture capabilities. The high-speed, high-resolution ADC chip inside the parameter acquisition box can sample the voltage at a high response rate, accurately recording the transient details of the voltage. Ordinary voltage measurement equipment, with its low sampling rate and slow response, can only display a rough average or effective value, completely failing to meet the needs of process analysis.

[0038] In some embodiments of this application, the parameter acquisition device for a welding machine includes a step-down module. The step-down module is connected to the charging management module and in parallel to the output circuit of the welding machine. When the main control module controls the charging management module to charge the battery according to the operating parameters of the welding machine, the step-down module is used to step down the output voltage of the welding machine so that the battery can be charged through the charging management module.

[0039] For example, the parameter acquisition box includes a step-down module, which is connected to the charging management module and in parallel to the output circuit of the welding machine. The output circuit of the welding machine is the source of arc energy. In order to measure the voltage between any two points in the circuit, the input channel of the voltmeter or acquisition device is connected in parallel with these two points. The parallel connection ensures that the acquisition device presents extremely high input impedance, so that the current drawn from the circuit under test during measurement is extremely small, which will not cause any disturbance or load effect on the electrical characteristics of the welding main circuit and the welding process itself, thus ensuring the accuracy of the measurement and the integrity of the process.

[0040] For example, the step-down module includes an electrical isolation function to isolate the main circuit of the welding machine from the low-voltage logic ground of the acquisition box, thereby eliminating measurement errors caused by ground loops and the potential risk of high voltage intrusion, and ensuring the safety of the back-end electronic system and operators.

[0041] For example, the welding output voltage itself contains energy. The step-down module can not only divide the voltage for measurement, but also act as a switching power supply, continuously drawing a small portion of electrical energy from the welding machine's output circuit. After conversion, this energy powers the parameter acquisition box's own circuitry or the battery of the acquisition and management terminal. (Refer to...) Figure 4 , Figure 4 This is a schematic diagram of the structure of a welding machine parameter acquisition device provided in one embodiment of this application. The step-down module is directly connected to the charging management module to provide power to the charging management module.

[0042] For example, the module's input is directly connected in parallel to the welding machine's output. It first passes through a voltage divider network, which bears most of the voltage difference. Its power rating is large enough to dissipate the generated heat. Transient voltage suppression diodes or varistors connected in parallel with the voltage divider resistor are used to clamp unexpected voltage spikes. In addition, since there may be a large potential difference between the welding machine's working ground and the logic ground of the data acquisition system, a direct connection would lead to inaccurate measurements and equipment damage. Therefore, the step-down module uses an isolation amplifier or an isolated ADC. The isolation amplifier internally transmits the pre-attenuated signal to the secondary circuit through magnetic coupling or optical coupling, blocking the path of DC and harmful ground loops. At the same time, it can withstand thousands of volts of common-mode voltage, so that there is no direct electrical connection between the input side (welding machine side) and the output side (acquisition box logic side), only signal transmission, ensuring safety and anti-interference capabilities.

[0043] For example, the welding voltage output positive and negative terminals are connected in parallel to the step-down module in the acquisition box to convert the 40-80V DC voltage into a standard 12.6V battery charging voltage. This voltage is then connected to the acquisition and management terminal via a communication line. The 12.6V DC voltage enters the charging management module, which communicates with the main control module. The main control module determines the working status of the welding machine. When the welding machine is in standby mode, it automatically charges the lithium battery with 12.6V DC power. When the welding machine is working, it stops charging, switches to power supply mode, and protects the lithium battery.

[0044] For example, the welding machine parameter acquisition device can adopt a three-stage conversion topology: wide voltage regulation → DC / DC step-down → pulse charging management. The pre-amplifier circuit is compatible with a wide input voltage range of 40-80V; The intermediate stage reduces the voltage to a safe level of 12.6V; The final-stage charging management module controls the constant current / constant voltage charging of the lithium battery; When the welding machine is in standby mode for manual welding, the welding machine voltage is maintained at a constant value of 40-80V, and the welding machine current remains zero. When welding begins, the welding machine voltage drops to approximately 10-30V, while the welding machine current is not zero. The main control module determines the welding status based on the welding machine voltage and current parameters. The main control module communicates with the charging management module. When the welding machine is in standby mode, the standby voltage is used to charge the battery. When the welding machine is in working mode, the charging management module switches to battery power supply mode.

[0045] In some embodiments of the welding machine parameter acquisition device provided in this application, the current sensor is set in the positive or negative circuit between the parameter acquisition box and the welding torch; the main control module includes a current analysis unit, and the main control module is also used to process the data collected by the current sensor in different setting directions or different setting positions through the current analysis unit to obtain the current parameters of the welding machine.

[0046] For example, the current sensor must be connected in series in the complete main circuit through which the welding current flows in order to sense the entire current value. The current sensor can be set in the positive or negative circuit between the parameter acquisition box and the welding torch, or it can be set in the main circuit inside the welding machine, or installed on the side of the welding machine input power supply.

[0047] For example, the current analysis unit is an analysis unit within the main control module used for processing raw current signals, executing algorithms, and making intelligent judgments. At the hardware level, the current analysis unit can be a specific task carried out by a microprocessor and its peripheral dedicated circuitry within the main control module. Its high-resolution ADC is used to convert the analog voltage signal from the current sensor into a digital quantity at high speed and with high fidelity, while hardware filtering circuits or memory buffers are used to preprocess and temporarily store the high-speed data stream. At the software level, the current analysis unit can be a current analysis algorithm used to apply digital filtering to the raw digital signal to suppress high-frequency noise and run a calibration algorithm. It uses preset coefficients to convert the ADC reading into the true current value, while compensating for temperature drift and nonlinear errors.

[0048] For example, the main control module is also used to process data collected by current sensors in different installation directions or positions through the current analysis unit to obtain the welding machine's current parameters. In other words, as long as there is a current analysis unit, current sensors in any installation direction and position can collect the welding machine's current parameters. Regarding installation direction, current sensors are typically directional; the polarity of their output signal corresponds to the direction of current flow. If the installation direction is reversed, the polarity of the original signal voltage will also be reversed. The current analysis unit, based on software polarity judgment and reversal algorithms, monitors the DC bias of the signal or the transient current direction at startup. Once it detects that the signal polarity logic is opposite to the expectation, it automatically corrects it by multiplying the entire signal by -1 in the digital domain. Regarding installation position, different installation positions may introduce scaling factor error (i.e., the proportional error between the measured value and the true value) and phase error (the influence on AC or dynamic response measurement). For sensors installed in different positions in the welding main circuit, the current analysis unit can correct the original data through factory calibration and user calibration programs, thereby ensuring that the current value can be detected regardless of which sensor is used or in which equivalent series position it is installed.

[0049] In some embodiments of this application, the parameter acquisition device for welding machines is also connected to the welding machine via a welding machine control line to control the output current of the welding machine.

[0050] For example, the parameter acquisition box is also connected to the welding machine via a welding machine control line to control the output current of the welding machine. The welding machine control line is one or more dedicated communication cables connected between the parameter acquisition box and the internal control system of the welding machine, used to transmit digital commands and data, so that the parameter acquisition device can not only passively read data, but also actively intervene and optimize the welding process.

[0051] For example, the communication standard of the welding machine control line can be CAN bus, Profibus, EtherCAT, ModbusRTU or welding machine proprietary protocol, using a twisted pair structure and equipped with standard industrial connectors to enhance anti-interference capabilities and ensure the stability and reliability of command transmission in the harsh environment of the welding site.

[0052] For example, the welding machine control line transmission includes analog signals and digitized data frames, which include instruction information such as target current setpoints, target voltage setpoints, welding machine start / stop commands, wire feeder control commands, welding mode selection, waveform control parameters, and requests to read the welding machine's internal status and error codes.

[0053] For example, the process of the welding machine parameter acquisition device controlling the output current of the welding machine can be a closed-loop control process. By sensing the decision execution cycle, the output of the welding machine is dynamically adjusted to achieve the predetermined process target or to compensate for quality fluctuations caused by various disturbances in real time.

[0054] In some embodiments of this application, the parameter acquisition device for welding machines includes a speed sensor. The speed sensor is mounted on the welding torch and is connected in communication with the main control module. The speed sensor is used to detect the welding speed of the welding torch, and the main control module is also used to adjust the operating parameters of the welding machine according to the welding speed of the welding torch.

[0055] For example, the parameter acquisition module also includes a speed sensor, which is mounted on the welding torch and communicates with the main control module. The speed sensor is used to detect the moving speed of the welding torch relative to the workpiece, i.e., the welding speed. Welding speed is a key process parameter that determines the heat input and weld formation quality. Even if the current and voltage remain absolutely stable, fluctuations in the welding speed will cause significant changes in the heat absorbed per unit length of weld. Too high a speed will lead to insufficient penetration, narrow weld bead, and lack of fusion, while too low a speed will lead to overheating, burn-through, excessively wide weld bead, excessive weld reinforcement, grain coarsening, and deterioration of the heat-affected zone performance. Therefore, it is necessary to detect the welding speed of the welding torch through a speed sensor so that the main control module can adjust the operating parameters of the welding machine according to the welding speed of the welding torch.

[0056] For example, the main control module can adjust the welding current and welding voltage according to the welding speed of the welding torch. When the welding speed changes, the current and voltage are adjusted to compensate for the impact of the speed change in order to maintain a stable penetration depth and weld size. For example, when the welding torch moves to a workpiece bend or a complex contour section, the welding speed may be reduced to ensure tracking accuracy. At this time, if the welding current and voltage remain unchanged, the heat input will increase significantly because the welding torch stays on the weld seam per unit length for a longer time, which may easily lead to overheating, burn-through, or excessively wide weld in that area. When the welding speed is increased in a straight section, the heat input will decrease, which may lead to insufficient penetration depth and undercut. Therefore, when the main control module detects a decrease in welding speed, it will reduce the welding current accordingly according to a preset algorithm. When it detects an increase in welding speed, it will increase the welding current and voltage accordingly.

[0057] In some embodiments of this application, the welding machine parameter acquisition device is connected in communication with a management platform for monitoring the welding machine parameter acquisition device, so as to upload the operating parameters of the welding machine to the management platform and store them.

[0058] For example, a management platform for monitoring welding machine parameter acquisition devices can be used for data aggregation, visualization, analysis, storage, and control. The management platform can adopt a B / S (Browser / Server) or C / S (Client / Server) architecture, deployed on a local server or in the cloud, and communicate with all welding machine parameter acquisition devices in the field via wired or wireless networks. The management platform can display the key status of all online welding machines in a configurable manner in real time, and present the data visually at the workstation, production line, or workshop level. Furthermore, the management platform continuously stores the entire process history data of all welding machines. When a defect is found in a workpiece, the platform can quickly retrieve all parameter curves of that workpiece during welding based on the workpiece number, timestamp, or operator information, enabling quality traceability and root cause analysis. In addition, the management platform can perform statistical process control analysis on the accumulated data, calculate the CPK value of key parameters, and identify the drift trend of process parameters, thereby achieving predictive quality control and process window optimization.

[0059] In one embodiment, an edge computing module can be integrated into the acquisition and management terminal to perform local preprocessing and compression of welding process data (extracting key feature data through AI algorithms), and then transmit it to the management platform through a 4G communication module. This can significantly reduce data transmission volume, reduce bandwidth usage, and improve real-time performance and energy efficiency.

[0060] In one embodiment, reference Figure 5 , Figure 5This is a schematic diagram of the structure of a welding machine parameter acquisition device provided in another embodiment of this application. The acquisition management terminal is also connected to the smart welding cap and the temperature and humidity sensor, receives the data from the smart welding cap and the temperature and humidity sensor and uploads it to the management platform.

[0061] In some embodiments of the welding machine parameter acquisition device provided in this application, the main control module includes a local storage unit. The main control module is also used to save the operating parameters of the welding machine to the local storage unit when the communication connection between the main control module and the management platform is disconnected.

[0062] For example, the main control module includes a local storage unit. This unit is also used to save the welding machine's operating parameters to the local storage unit when the communication connection between the main control module and the management platform is lost. This ensures the integrity and continuity of welding process data recording, effectively addressing the complex network environment of industrial sites and providing data assurance for production quality traceability and equipment status monitoring. Because network connections are not stable and reliable in factory environments with strong electromagnetic interference, equipment movement, switch failures, or network congestion, once the welding production process starts, all data has irreplaceable value for subsequent quality analysis, process optimization, and responsibility determination. Data loss may disrupt the traceability chain, making it impossible to accurately analyze the root cause of quality problems, and even leading to significant commercial disputes or safety hazards.

[0063] For example, the local storage unit includes one or more non-volatile memory chips. Under normal operating conditions, when the communication connection between the main control module and the management platform remains unobstructed, the main control module will continuously upload the real-time collected and pre-processed welding machine operating parameters to the cloud or management platform via the network interface in a high-speed streaming manner. At this time, the local storage unit may only temporarily store the data of the most recent period in the form of a circular buffer. Once the network monitoring unit built into the main control module detects that the communication connection with the management platform is interrupted through heartbeat packet timeout or link detection, it will immediately trigger internal failover.

[0064] In some embodiments of the welding machine parameter acquisition device provided in this application, the parameter acquisition module is provided with a hot-swappable port, which is used for hot-swapping expansion devices, including environmental sensors, gas sensors, and expansion battery modules.

[0065] Understandably, setting up hot-swappable ports on the parameter acquisition module enables the welding machine parameter acquisition device to have modularity, flexibility, and scalability, thereby adapting to complex and ever-changing industrial application scenarios, while minimizing system downtime and improving availability and maintenance efficiency.

[0066] For example, the hot-swappable port is used for hot-swappable expansion devices, which include environmental sensors, gas sensors, and expansion battery modules. The environmental sensors are used to monitor the environmental conditions around the welding operation, as environmental parameters are important external variables affecting welding quality and stability. The environmental sensors include temperature, humidity, and atmospheric pressure sensors. The gas sensors are used to verify the delivery of shielding gas. The gas sensors can be installed near the gas path of the welding torch and can directly measure the instantaneous flow rate and cumulative consumption of the actual output gas. The expansion battery module is used to extend the independent working time of the parameter acquisition device when there is no external power supply.

[0067] In the welding machine parameter acquisition device provided in some embodiments of this application, the main control module is also used to trigger a safety prompt and issue an alarm when an abnormal situation is detected based on the operating parameters of the welding machine.

[0068] For example, the main control module is also used to trigger safety prompts and alarms when an abnormality is detected based on the welding machine's operating parameters, ensuring the safety and reliability of the welding operation. The main control module continuously compares and analyzes the data streams obtained from all data sources, such as the parameter acquisition box, current sensor, and speed sensor, with the upper and lower limits of process specification parameters and ideal waveform patterns pre-stored in the database. When an abnormality is detected and confirmed, the main control module triggers safety prompts and alarms, issuing an immediate warning through the connected audible and visual alarm.

[0069] In one embodiment, the data acquisition and management terminal is equipped with an NFC logo and a camera on the front, which can verify the user's information and display the corresponding process, facilitating adjustments, recording, and subsequent traceability.

[0070] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application.

[0071] In the several embodiments provided in this application, it should be understood that the disclosed systems, instruments, and methods can be implemented in other ways. For example, the instrument embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the shown or discussed mutual couplings, direct couplings, or communication connections may be through some interfaces; indirect couplings or communication connections between instruments or units may be electrical, mechanical, or other forms. Units described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, i.e., they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0072] It should also be understood that the various implementation methods provided in this application can be combined arbitrarily to achieve different technical effects.

Claims

1. A welding machine parameter acquisition device, characterized in that, include: A parameter acquisition module is connected between the welding machine and the welding torch of the welding machine to acquire the operating parameters of the welding machine. The data acquisition and management terminal includes a main control module, a charging management module, and a battery. Both the main control module and the charging management module are electrically connected to the parameter acquisition module. The main control module is used to control the charging management module to supply power to the parameter acquisition module or charge the battery according to the operating parameters of the welding machine.

2. The welding machine parameter acquisition device according to claim 1, characterized in that, The parameter acquisition module includes a parameter acquisition box and a current sensor connected to each other. The parameter acquisition box is used to acquire the voltage parameters of the welding machine, and the current sensor is used to acquire the current parameters of the welding machine.

3. The welding machine parameter acquisition device according to claim 2, characterized in that, The parameter acquisition box includes a step-down module, which is connected to the charging management module and in parallel to the output circuit of the welding machine. When the main control module controls the charging management module to charge the battery according to the operating parameters of the welding machine, the step-down module is used to step down the output voltage of the welding machine so that the battery can be charged through the charging management module.

4. The welding machine parameter acquisition device according to claim 2, characterized in that, The current sensor is disposed in the positive or negative circuit between the parameter acquisition box and the welding torch; the main control module includes a current analysis unit, which is also used to process the data collected by the current sensor in different settings or different positions through the current analysis unit to obtain the current parameters of the welding machine.

5. The welding machine parameter acquisition device according to claim 1, characterized in that, The parameter acquisition module is also connected to the welding machine via a welding machine control line to control the output current of the welding machine.

6. The welding machine parameter acquisition device according to claim 1, characterized in that, The parameter acquisition module also includes a speed sensor, which is mounted on the welding torch and communicates with the main control module. The speed sensor is used to detect the welding speed of the welding torch, and the main control module is also used to adjust the operating parameters of the welding machine according to the welding speed of the welding torch.

7. The welding machine parameter acquisition device according to claim 1, characterized in that, The main control module is communicatively connected to the management platform used to monitor the welding machine parameter acquisition device, so as to upload the operating parameters of the welding machine to the management platform and store them.

8. The welding machine parameter acquisition device according to claim 7, characterized in that, The main control module includes a local storage unit, and the main control module is also used to save the operating parameters of the welding machine to the local storage unit when the communication connection between the main control module and the management platform is disconnected.

9. The welding machine parameter acquisition device according to claim 1, characterized in that, The parameter acquisition module is equipped with a hot-swappable port, which is used for hot-swapping expansion devices, including environmental sensors, gas sensors, and expansion battery modules.

10. The welding machine parameter acquisition device according to claim 1, characterized in that, The main control module is also used to trigger a safety prompt and issue an alarm when an abnormal situation is detected, based on the operating parameters of the welding machine.

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