Welding counting mistake proofing system and method and computer readable storage medium

Abstract

The invention relates to the technical field of automobile design and manufacturing, and discloses a welding counting mistake proofing system and method and a computer readable storage medium, and the welding counting mistake proofing system comprises a welding counting mistake proofing device and at least one welding machine; the welding counting mistake proofing device comprises a control module, an electromagnetic valve control module and welding signal acquisition modules in one-to-one correspondence with the welding machines. Each welding signal acquisition module is respectively connected with the welding state output end of the corresponding welding machine and is used for acquiring a welding completion signal output by each welding machine after completing one welding process; the control module counts the received welding completion signals, and when the accumulated count reaches a preset number, the electromagnetic valve control module drives an electromagnetic valve arranged in a clamp gas circuit to be electrified and closed to conduct a compressed air channel, so that the clamp can normally act when receiving an external opening instruction; and intelligent mistake proofing and process interlocking control of welding operation are realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of automobile design and manufacturing technology, and particularly relates to a welding count mistake-proofing system and method and a computer readable storage medium. BACKGROUND

[0002] With the continuous development of the automobile manufacturing industry, as a key link in the production process of the body-in-white, the welding quality of the body-in-white directly affects the safety and reliability of the vehicle. Stud welding, as a common welding technology, is widely used in the connection of body parts, and plays an important role especially in positions requiring subsequent installation of other components. In order to ensure the welding quality, the integrity of the welding points after welding must be detected to confirm whether there are defects such as missing welding. At present, in the actual production process, the welding workshop generally adopts manual method for stud welding leak detection, that is, the quality inspection personnel checks the welding position one by one by visual inspection or simple tools to judge whether there is missing welding. However, manual detection depends on the experience level and attention concentration of the operator, and is prone to false detection or missed detection due to subjective factors, and the detection speed is slow, which is difficult to match the rhythm of the automatic production line, and restricts the improvement of the overall production efficiency and the quality control level. SUMMARY

[0003] Therefore, the embodiments of the present application provide a welding count mistake-proofing system and method and a computer readable storage medium, which can effectively solve the problems in the prior art that the manual method is used for stud welding leak detection, false detection or missed detection is prone to occur due to subjective factors, the detection speed is slow, it is difficult to match the rhythm of the automatic production line, and the overall production efficiency and the quality control level are restricted from being improved.

[0004] In a first aspect, the embodiments of the present application provide a welding count mistake-proofing system, comprising: a welding count mistake-proofing device and at least one welding machine; The welding count mistake-proofing device comprises a control module, an electromagnetic valve control module, and a welding signal acquisition module corresponding to each welding machine; The input end of each welding signal acquisition module is connected to the welding state output end of the corresponding welding machine, for acquiring the welding completion signal output by each welding machine after completing a welding process; The control module is electrically connected to each welding signal acquisition module and the electromagnetic valve control module, for counting the received welding completion signal, and when the cumulative count reaches a preset number, driving the electromagnetic valve in the clamp air path to be powered and attracted by the electromagnetic valve control module, to turn on the compressed air passage, so that the clamp can normally act when receiving an external opening instruction.

[0005] In some embodiments, the welding count mistake-proofing device further comprises a reset control module; An input end of the reset control module is connected to a magnetic switch installed on a clamp cylinder, and an output end of the reset control module is connected to the control module; The reset control module is configured to, in response to a clamp opening to position signal sent by the magnetic switch, apply a reset level signal to the control module to trigger the control module to reset, so as to clear a current welding count value and restore to an initial running state.

[0006] In some embodiments, each of the welding machines has the same structure and includes a welding machine controller and a welding state output module connected electrically; The welding machine controller is configured to trigger the welding state output module to output a welding completion signal after one of the welding processes is completed.

[0007] In some embodiments, the welding count error-proof device further includes a plurality of count display modules equal in number to the welding machines, and each of the count display modules is electrically connected to the control module. The count display module is configured to display the number of times of completed welding of the corresponding welding machine.

[0008] In some embodiments, the control module is one of a processor, a programmable logic controller or a single-chip microcomputer.

[0009] In some embodiments, the control module is further configured to, after obtaining a current welding completion signal, sample again to confirm whether the current welding completion signal is in a valid state after a preset time interval, and if yes, determine that it is one valid welding event and perform counting.

[0010] In some embodiments, the welding count error-proof device further includes a first power supply module and a second power supply module. The first power supply module is configured to provide a working voltage for the control module. The second power supply module is configured to provide a driving voltage for the electromagnetic valve and the welding signal acquisition module, and the second power supply module is isolated from the first power supply module.

[0011] In some embodiments, the welding count error-proof device further includes a clamp state indication module electrically connected to the control module, and the clamp state indication module is configured to indicate an opening to position state of the clamp.

[0012] In a second aspect, the embodiments of the present application provide a welding count error-proof method, which includes: obtaining a welding completion signal; counting the welding completion signal; When the accumulated count reaches the preset number, the solenoid valve control module drives the solenoid valve in the clamp air circuit to be powered and attracted, the compressed air passage is turned on, so that the clamp can normally act when receiving an external opening instruction.

[0013] In a third aspect, the embodiments of the present application provide a computer readable storage medium storing a computer program, which, when executed on a processor, implements the steps of the welding count error-proofing method.

[0014] The embodiments of the present application have the following beneficial effects: The welding count error-proofing system of the present application, by setting a welding signal acquisition module corresponding to each welding machine, acquires the welding completion signal output after the welding machine completes welding in real time, and the control module accurately accumulates the welding count. Only when the welding count reaches the preset value, the solenoid valve control module drives the solenoid valve in the clamp air circuit to turn on the compressed air passage, so that the clamp can normally act when receiving an external opening instruction. This effectively ensures that each workpiece completes the specified number of welding operations before entering the next process in the work station or automated welding production process, avoids quality defects caused by incomplete welding, insufficient welding or process skipping, significantly improves the controllability and product consistency of the welding process, and realizes intelligent error-proofing and process interlocking control of welding operations. BRIEF DESCRIPTION OF DRAWINGS

[0015] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed in the embodiments. It should be understood that the following drawings only show some embodiments of the present application, and therefore should not be considered as limiting the scope. For those skilled in the art, other related drawings can also be obtained without creative labor.

[0016] Figure 1 The structure schematic diagram of the welding count error-proofing system of the embodiments of the present application is shown; Figure 2 The structure schematic diagram of the welding machine of the embodiments of the present application is shown; Figure 3 The structure schematic diagram of the welding count error-proofing device of the embodiments of the present application is shown; Figure 4 The circuit schematic diagram of the welding count error-proofing device of the embodiments of the present application is shown; Figure 5 The flowchart of the welding count error-proofing method of the embodiments of the present application is shown.

[0017] Main element symbol explanation: 10: welding machine; 101: welding machine controller; 102: welding state output module; 20: welding count error-proof device; 201: welding signal acquisition module; 202: control module; 203: electromagnetic valve control module; 204: reset control module; 205: count display module; 206: first power supply module; 207: second power supply module; 30: electromagnetic valve. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, not all the embodiments of the present application.

[0019] The components of the embodiments of the present application generally described and illustrated herein can be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present application.

[0020] Hereinafter, the terms "include", "have", and their conjugates used in various embodiments of the present application are only intended to denote a certain characteristic, number, step, operation, element, component, or combination thereof, and should not be construed as excluding the presence or addition of one or more other characteristics, numbers, steps, operations, elements, components, or combinations thereof. In addition, the terms "first", "second", "third", and the like are used only to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0021] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which various embodiments of the present application belong. The terms (such as those defined in commonly used dictionaries) will be interpreted as having a meaning that is the same as the contextual meaning in the relevant technical field and will not be interpreted as having an idealized or overly formal meaning, unless clearly defined in various embodiments of the present application.

[0022] Some embodiments of the present application will be described in detail below with reference to the accompanying drawings. The following embodiments and features in the embodiments can be combined with each other without conflict.

[0023] In view of the fact that the stud welding leak detection in the prior art is performed in an artificial manner, false detection or missed detection is prone to occur due to subjective factors, and the detection speed is slow, which is difficult to match the pace of the automatic production line, thereby restricting the improvement of the overall production efficiency and the quality control level. The welding count mistake proofing system provided by the embodiments of the present application, the welding count mistake proofing system, by setting a welding signal acquisition module 201 corresponding to the welding machine 10, acquires in real time a welding completion signal output after the welding machine 10 completes welding, and the control module 202 accurately accumulates the welding times, and only when the welding quantity reaches a preset value, the electromagnetic valve control module 203 is allowed to drive the electromagnetic valve 30 in the clamp air path to conduct the compressed air passage, so that the clamp can normally act when receiving an external opening instruction, effectively ensuring that each workpiece in the station or automatic welding production process can enter the next process only after completing the specified number of welding operations, avoiding quality defects caused by incomplete welding, less welding or process skipping, significantly improving the controllability of the welding process and product consistency, and realizing intelligent mistake proofing and process interlocking control of welding operation.

[0024] The welding count mistake proofing system will be described below in combination with some specific embodiments.

[0025] Figure 1 A structural schematic diagram of the welding count mistake proofing system of the embodiments of the present application is shown. Exemplarily, the welding count mistake proofing system includes a welding count mistake proofing device 20 and at least one welding machine 10, and the number of welding machines 10 can be set according to actual application conditions, and a single welding machine 10 or multiple welding machines 10 can be set. Exemplarily, the welding count mistake proofing system of the embodiments includes three welding machines 10, and each welding machine 10 has the same structure, as shown in Figure 2 The welding machine controller 101 is used to trigger the welding state output module 102 to output a welding completion signal after a welding process is completed.

[0026] Specifically, the welding machine controller 101 can be a digital stud welding power supply control board, for example, an embedded control system taking an STM32 series microcontroller as the core; the welding machine controller 101 can also be a programmable logic controller, for example, a Siemens PLC or a Mitsubishi PLC; and the welding controller can also be a special integrated circuit welding control chip. The welding controller has a built-in program logic, which can determine whether the current welding process is complete according to the internal timing and sensor feedback. Only when all steps are executed in sequence, the welding state output module 102 is triggered to act, thereby avoiding false judgment of incomplete welding or interrupting welding as complete.

[0027] The welding process can be set according to actual application, and the welding process is exemplarily a stud welding process, which includes welding machine 10 positioning, arc striking cleaning, main arc melting, stud falling and immersing into the molten pool, pressure maintaining and solidifying, and welding machine 10 lifting.

[0028] Specifically, in the welding machine 10 positioning stage, the welding machine 10 chuck clamps the stud and moves to a predetermined position above the workpiece. In the arc striking cleaning stage, the welding machine 10 is powered on, and the stud is lifted to a preset height away from the workpiece. At the moment when the stud leaves the workpiece, the welding machine 10 generates a guide arc, which lasts for a very short time. This arc is weak and mainly serves to clean and preheat the surface of the welding area, blow away contaminants and oxide layers, and prepare for formal welding. In the main arc melting stage, the welding machine controller 101 switches to the main welding current, and the current increases sharply. The powerful main arc burns stably, rapidly and uniformly melts the stud end and the workpiece surface, and forms a molten pool. In the stud falling and immersing into the molten pool stage, the main arc current is cut off, the welding machine 10 electromagnetic coil is powered off, and the stud is driven by the spring or pneumatic pressure to move downward at high speed and immerse into the molten pool. This action extrudes part of the liquid metal in the molten pool to form a weld toe, and at the same time, expels air and impurities. In the pressure maintaining and solidifying stage, the stud is pressed on the workpiece, and the pressure lasts for a period of time to allow the molten metal to complete solidification and crystallization under pressure, forming a dense welding joint. In the welding machine 10 lifting stage, the welding machine controller 101 controls the welding machine 10 to lift up, completing the entire welding process.

[0029] The system takes the welding machine 10 control core as the signal source, and performs closed-loop judgment based on the preset complete process flow logic. Only when all steps are executed in sequence, the welding machine controller 101 triggers the welding state output module 102 to output the welding completion signal, thereby ensuring that the signal directly reflects the logical integrity of the welding process, rather than relying on the indirect inference of current, voltage and other physical parameters, fundamentally avoiding the situation that a false weld or interrupted welding is misjudged as completed, achieving 100% counting accuracy without missing or wrong counting.

[0030] The welding state output module 102 is an interface unit of the welding machine controller 101 for outputting the welding completion state, which receives instructions from the welding controller and converts the instructions into electrical signals recognized by the welding signal acquisition module 201.

[0031] As an example, the welding state output module 102 can be a relay contact output module, the controller drives a direct current relay, the normally open contact of which is used as an output terminal, which is closed after the welding is completed to enable the welding signal acquisition module 201 to acquire the signal; the welding state output module 102 can also be a switching tube, which uses a triode or a MOS tube to form a contactless switch to achieve high-speed on-off response; the welding state output module 102 can also be an optocoupler, which has electrical isolation capability and strong anti-interference capability, and is suitable for a welding shop with a complex electromagnetic environment; further, the welding state output module 102 can also be a communication interface, which sends a welding completion event frame in the form of a digital message through an industrial bus. As an example, the embodiment adopts a relay contact output mode, each welding machine 10 is equipped with a set of independent dry contact output terminals, and the contact of the corresponding channel is closed for about 200 milliseconds after each welding process is completed, thereby forming a 24V direct current pulse signal to enable the welding signal acquisition module 201 to identify.

[0032] The welding state output module 102 adopts a relay dry contact output mode to output a 24V direct current pulse signal lasting for about 200 milliseconds, which is generated by a hardware circuit and has strong anti-interference capability, and is not affected by factors such as the electromagnetic environment on site, cable wiring, welding parameter fluctuations, etc., thereby significantly improving the stability and reliability of the system; at the same time, the relay scheme has a simple structure, low cost, and is easy to deploy and maintain.

[0033] The welding count error-proof device 20 includes a control module 202, a solenoid valve control module 203, and a welding signal acquisition module 201 corresponding to each welding machine 10, the control module 202 can be set according to actual application conditions, and the control module 202 can be any one of a processor, a programmable logic controller, or a single-chip microcomputer. As an example, the controller is a single-chip microcomputer, which has the characteristics of high integration, low power consumption, and strong real-time performance, can respond to external interrupt inputs at the microsecond level, accurately capture pulse-type welding completion signals from each welding machine 10, and its program can be flexibly configured to set count rules and output timing according to different welding machine 10 types, process cycles, or production line tempos, support multi-channel independent management, and ensure that each welding machine 10 signal corresponds one-to-one and does not interfere with each other.

[0034] Compared with a PLC or a general-purpose processor, the single-chip microcomputer scheme has a simple peripheral circuit, low cost, and compact size, and is particularly suitable for deployment in small-sized error-proof devices in industrial sites, significantly reduces the development difficulty, manufacturing cost, and maintenance complexity of the overall device under the premise of ensuring system reliability, anti-interference capability, and long-term operation stability, and achieves a good balance between high performance and economy.

[0035] Exemplarily, three welding signal acquisition modules 201 are arranged, and the input end of each welding machine 10 signal acquisition module is connected to the welding state output end of the corresponding welding machine 10, that is, the welding machine 10 state output module, and each welding machine 10 signal acquisition module is used to acquire the welding completion signal output by each welding machine 10 after completing a welding process. According to actual application conditions, each welding machine 10 signal acquisition module can be arranged. Exemplarily, the welding machine 10 signal acquisition module is a relay, the relay coil is connected in series with the welding machine 10 state output module, when the contact of the welding machine 10 state output module is closed, a loop is formed, and the relay is attracted. The normally open contact of the relay is connected to a low-voltage direct-current circuit suitable for the controller to recognize. When the relay is attracted and the contact is closed, a high-level or low-level signal is sent to the I / O port of the single-chip microcomputer. The single-chip microcomputer program detects the rising edge or falling edge of the pulse signal and performs counting once.

[0036] By configuring an independent welding signal acquisition module 201 for each welding machine 10 and directly connecting the input end of the welding signal acquisition module 201 to the welding state output module 102 of the corresponding welding machine 10, the physical isolation and one-to-one acquisition of the signals of each welding machine 10 are realized. Since each channel is independently wired and processed, the system naturally has multi-gun isolation capability, does not need to rely on communication address coding, software polling or multiplexing identification mechanism, avoids signal confusion, crosstalk or identification delay problems, greatly simplifies the system integration complexity and signal processing logic. At the same time, the relay, as an intermediate isolation element, has electrical isolation and signal shaping functions, can effectively suppress adverse factors such as electromagnetic interference and contact jitter in the field, and improve signal stability and anti-interference capability.

[0037] The control module 202 is electrically connected with each welding signal acquisition module 201 and the electromagnetic valve control module 203, and is used to count the received welding completion signals. When the cumulative count reaches a preset number, the electromagnetic valve 30 arranged in the clamp air circuit is powered and attracted by the electromagnetic valve control module 203, the compressed air passage is turned on, and the clamp can normally act when receiving an external opening instruction.

[0038] It can be understood that the preset number can be set according to actual application conditions. For example, if the welding count error prevention system only has one welding machine 10, and the welding machine 10 needs to be welded three times, the preset number is set to three times; if the welding count error prevention system has three welding machines 10, and each welding machine 10 needs to be welded three times, the preset number is set to nine times.

[0039] The electromagnetic valve control module 203 can be any control module 202 such as a switch tube, a relay or an optical coupler. Exemplarily, the electromagnetic valve control module 203 is a relay. When the single-chip microcomputer monitors the pulse edges of the signals of each channel in real time through a program, the single-chip microcomputer accurately counts each effective welding action. When the cumulative welding number reaches a preset number, the single-chip microcomputer immediately outputs a high-level signal to drive the relay of the electromagnetic valve control module 203 to be attracted, the normally open contact of the relay is closed, the electromagnetic valve 30 connected in the clamp air circuit is powered on, and the compressed air passage is opened. At this time, if the operator presses the clamp opening button, the pneumatic circuit has a gas supply condition, and the clamp can normally perform the opening action to allow the workpiece to flow. Conversely, if the welding number does not reach the preset value, the single-chip microcomputer does not output a high-level signal, the relay remains in a power-off release state, the electromagnetic valve 30 is powered off, and the air circuit is in a cut-off state. Even if the employee presses the clamp opening button, the clamp cannot act because there is no compressed air supply, thereby forming an effective hardware cascade lock error-proofing mechanism.

[0040] Through the cooperation of the single-chip microcomputer logic judgment and the relay execution unit, the welding completion number is forcibly bound to the clamp unlocking condition, the process interlocking of welding enough to release is realized, the risk of leaking welding and less welding parts flowing into the next process is fundamentally eliminated, and the consistency of assembly quality and the controllability of the production process are improved.

[0041] Further, after the control module 202 acquires the current welding completion signal, the control module 202 is further configured to sample and confirm whether the current welding completion signal is in an effective state again after a preset time interval. If yes, the control module 202 determines that it is an effective welding event and performs counting.

[0042] Specifically, when the single-chip microcomputer detects that the level of a welding signal acquisition channel changes from high to low, that is, a falling edge interrupt is triggered or a state scanning program is entered. At this time, the single-chip microcomputer determines that there may be a welding completion signal input. In order to prevent false counting caused by contact jitter, electromagnetic pulse interference or transient noise, the single-chip microcomputer does not immediately count, but starts a preset time delay program, for example, a twenty-millisecond delay. During the delay, the signal is waited to be stable. After the delay ends, the level state of the channel is sampled and confirmed again. If the level read again is still low, it means that the signal is continuously effective, which is a complete welding completion pulse. The control module 202 determines that it is an effective welding event and performs a count-up operation.

[0043] By employing a delayed resampling mechanism to perform secondary verification of signal validity, short-term interference signals and false transitions are effectively filtered out. This ensures that only genuine and stable welding completion signals are counted, avoiding overcounting or miscounting caused by line noise or contact bounce, thus improving counting accuracy and anti-interference capabilities. Furthermore, this logic is executed autonomously by the microcontroller program without requiring additional hardware, making it simple to implement and responsive, further enhancing the system's reliability and robustness.

[0044] In one embodiment, based on the above embodiments, Figure 3 A schematic diagram of one structure of the welding counting error prevention device 20 is shown. Figure 4 It shows the relationship with Figure 3 The circuit diagram of the corresponding welding counting and error prevention device 20 is shown below. The microcontroller is U1, the welding signal acquisition modules 201 are relays KA1, KA2, and KA3, the solenoid valve 30 is S2, and the solenoid valve control module 203 is relay KA5. The microcontroller acquires the welding completion signal of the welding machine 10 through relays KA1, KA2, and KA3 and performs counting. When the cumulative count reaches a preset number, it controls relay KA5 to conduct, thereby energizing and engaging the solenoid valve 30.

[0045] Furthermore, the welding counting error prevention device 20 also includes a reset control module 204. The input terminal of the reset control module 204 is connected to a magnetic switch installed on the clamp cylinder, and the output terminal of the reset control module 204 is connected to the control module 202. The reset control module 204 is used to respond to the clamp opening signal issued by the magnetic switch, apply a reset level signal to the control module 202, trigger the control module 202 to reset, clear the current welding count value and restore it to the initial operating state. Exemplary, the reset control module 204 is an intermediate relay KA4, and the magnetic switch is S1. Understandably, when the welding quantity reaches the preset value and the air circuit is open, the operator presses the clamp open button. Compressed air drives the cylinder, and the clamp opens smoothly. When the clamp cylinder completes its action and opens to the correct position, the magnetic switch S1 mounted on the cylinder is triggered, outputting a clamp open-to-position signal. This signal undergoes level conversion and electrical isolation processing via the intermediate relay KA4. After the magnetic switch S1 is turned on, it drives the coil of the intermediate relay KA4 to energize, closing the normally open contact and pulling low the reset pin of the microcontroller U1, triggering a hardware reset of the microcontroller U1. The program restarts, and the internal counter is automatically reset to zero. Simultaneously, the relay KA5 is de-energized and released, cutting off the power supply to the solenoid valve 30 in the clamp's air circuit, restoring it to a de-energized and closed state, preparing for the next work cycle. This forms a complete closed-loop control process of welding counting, unlocking upon reaching the target value, and clamp opening to position reset.

[0046] The reset mechanism does not require manual intervention, avoids the counting superposition error caused by manual forgetting to clear, realizes the automatic clearing and restarting of the working cycle, ensures the independent welding process of each workpiece, and avoids interference. And it is realized by hardware cascade mode, the response is reliable and the time sequence is accurate, which effectively guarantees the independence of each production rhythm and the continuous effectiveness of the error-proof function, significantly improves the automation level and operation stability of the system.

[0047] Further, the welding count error-proof device 20 further comprises a plurality of counting display modules 205 equal in number to the welding machines 10, each of which is electrically connected to the control module 202, and is used to display the number of completed welds corresponding to the welding machine 10. Exemplarily, the number of counting display modules 205 is 3, including a digital tube DS1, a digital tube DS2 and a digital tube DS3, which correspond to three welding machines 10 respectively. When a welding machine 10 completes an effective welding event and is confirmed by the single-chip microcomputer, the single-chip microcomputer immediately updates the cumulative number of welding points corresponding to the channel and drives the corresponding digital tube to display the current value in real time. For example, when the first welding machine 10 completes the first effective welding, the digital tube DS1 displays "1"; as the subsequent weldings are completed in turn, the display value is incremented synchronously until the preset target value is reached. The display logic is controlled by the internal program of the single-chip microcomputer, supports dynamic refreshing, and ensures accurate information without delay.

[0048] After the clamp is opened to the position and triggers the reset signal, the reset control module 204 makes the reset pin of the single-chip microcomputer receive the reset level, the single-chip microcomputer restarts running, all counters are cleared, and at the same time, each digital tube synchronously returns to the initial state, all showing "0", indicating that the current workpiece welding task has ended, and the system enters the next working cycle. Not only realizes the independent display and centralized management of multi-channel welding data, but also enhances the friendliness of human-computer interaction through visual means, facilitates the on-site quick identification of welding progress and the discovery of missed welding abnormalities, and further improves the transparency and practicality of the error-proof system.

[0049] Further, the welding count error-proof device 20 further comprises a first power supply module 206 and a second power supply module 207.

[0050] The first power supply module 206 is used to provide working voltage for the control module 202, i.e. the single-chip microcomputer, for example, converting the external input power such as 24V DC or 220V AC into 5V DC voltage through a voltage stabilizing circuit to supply the single-chip microcomputer, ensuring the normal operation of the control system and the signal processing; the second power supply module 207 independently provides 24V DC voltage, which is specially used to drive high-power execution elements, such as the electromagnetic valve 30 and the relays KA1, KA2 and KA3 in the three welding signal acquisition modules 201. These devices all need large driving current to realize the coil attraction action, and the use of 24V power supply can effectively improve the response ability and working reliability.

[0051] The first power supply module 206 and the second power supply module 207 can be electrically isolated by an isolated power supply module or an independent transformer winding, avoiding the conduction of switch noise, inrush current or ground interference on the high-voltage side to the low-voltage control circuit, thereby preventing problems such as single-chip microcomputer false reset, program runaway or signal sampling error, and significantly enhancing the anti-interference ability and long-term operation stability of the system.

[0052] Further, the welding count error-proof device 20 also includes a cooling fan, and the 24V power supply is also extended to power the built-in cooling fan of the device. The cooling fan is used to forcibly ventilate and cool the inside of the control box during continuous operation of the equipment, preventing the accumulation of heat due to frequent operation of the relay from causing aging or performance degradation of components.

[0053] Further, the welding count error-proof device 20 is designed as a closed cuboid box, and the whole adopts a metal or high-strength engineering plastic shell with good sealing performance, excellent mechanical strength and protection performance, which can effectively resist the common metal dust, oil stains and electromagnetic interference in the welding shop. The box body is integrated with a dual-output power supply module, a single-chip microcomputer, a digital tube display unit, a terminal block, multiple intermediate relays, a cooling fan, internal connection wires, quick connectors, dustproof filter cotton and other key components, forming a complete, compact and functionally independent error-proof control system.

[0054] In terms of dust prevention, considering that there is a large amount of conductive metal dust in the welding environment, which may cause short circuits, poor contacts or component failures if entering the inside of the equipment, a fully enclosed structure is preferred as the device body, and high and low voltage partition wiring is realized in the electrical layout to further improve safety. To solve the problem of heat dissipation caused by the sealed structure, the box body is provided with air inlets and outlets at diagonal positions, covered with a honeycomb grid to ensure ventilation area and prevent large particles from entering. The air inlet is designed as a drawer-type clamping slot structure, which can conveniently insert and replace the dustproof filter cotton, ensuring that the external air is efficiently filtered before entering the box, removing dust particles and keeping the inside clean; the air outlet is installed with two groups of direct-current powerful cooling fans, forming a forced air duct circulation to quickly discharge the heat generated by internal electronic components during operation, avoiding overheating that causes component aging or unstable system operation, achieving the synergistic optimization of "efficient cooling" and "reliable dust prevention".

[0055] In the interface design, all external connections adopt standardized quick connectors, including three welding machine 10 signal inputs and one control output for driving the clamp air path electromagnetic valve 30, supporting plug and play, greatly shortening the on-site installation, debugging and replacement time, and improving the maintenance efficiency. The entire device has completed internal wiring, program burning and function testing before leaving the factory, realizing out-of-box use, and can be quickly deployed in various manual workstations, suitable for stud welding, spot welding, gluing and other process scenes that require counting and error prevention, with high universality and replicability.

[0056] The device integrates welding logic judgment, counting statistics, state display, interlocking control and reset mechanism through edge side intelligent control technology, realizes zero-error management and control of the production process, and promotes the production line to the fourth stage of information physical system. According to actual application measurement, this scheme can effectively prevent B-level quality defects caused by incomplete welding and insufficient welding, i.e. serious problems that may cause customer complaints and need to be repaired, avoid the chain risks of component damage, vehicle function failure, etc. caused thereby, and significantly improve product quality consistency. At the same time, annual rework hours, material waste and after-sales associated losses can be reduced by about 500,000 yuan, with outstanding cost reduction and efficiency improvement value. It is a low-carbon industrial solution integrating high reliability, ease of use, intelligence and economy.

[0057] In an embodiment, on the basis of the above-mentioned embodiments, the welding counting and error prevention device 20 further comprises a clamp state indication module, which is electrically connected with the control module 202. The clamp state indication module is used to indicate the clamp opening to position state. Exemplarily, the indication module can be composed of one or more high-brightness LED lamps, which intuitively and real-timely feedback to the operator whether the clamp has been successfully opened to position, improving the visualization level of human-machine interaction and operation safety.

[0058] In an embodiment, Figure 5 The flowchart of the welding counting and error prevention method of the embodiment of the present application is shown. The welding counting and error prevention method provided by the embodiment of the present application is applied to the welding counting and error prevention device 20 in any of the above-mentioned embodiments, and specifically comprises S101-S103: S101, acquiring a welding completion signal; S102, counting the welding completion signal; S103, when the cumulative count reaches a preset number, driving the electromagnetic valve 30 arranged in the clamp air path to be electrically attracted by the electromagnetic valve control module 203, so as to conduct the compressed air path, so that the clamp can normally act when receiving an external opening instruction.

[0059] It can be understood that the method of the embodiment corresponds to the welding count error prevention system of the above-mentioned embodiment, and the optional items in the above-mentioned embodiment are also applicable to the embodiment. The welding count error prevention method provided in the embodiment can realize the functions of the welding count error prevention system corresponding to the above-mentioned embodiment, and can achieve the same technical effects. To avoid repetition, it will not be described here.

[0060] The application further provides a computer readable storage medium for storing the computer program used in the terminal device. For example, the computer readable storage medium can include but is not limited to a U disk, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and various media that can store program codes.

[0061] In several embodiments provided in the application, it should be understood that the disclosed apparatus and method can also be implemented by other means. The apparatus embodiments described above are only schematic, for example, the flowcharts and block diagrams in the drawings show the possible implementation architectures, functions and operations of the apparatus, method and computer program product according to the embodiments of the application. In this regard, each block in the flowcharts or block diagrams can represent a module, a program segment or a part of code, which contains one or more executable instructions for implementing the specified logical functions. It should also be noted that, in alternative implementation manners, the functions noted in the blocks can also occur in different orders from those noted in the drawings. For example, two consecutive blocks can actually be executed substantially in parallel, and sometimes they can be executed in reverse order, depending on the functions involved. It should also be noted that each block in the structural diagram and / or flowchart, and the combination of blocks in the structural diagram and / or flowchart, can be implemented by a dedicated hardware-based system for executing the specified functions or actions, or can be implemented by a combination of dedicated hardware and computer instructions.

[0062] In addition, each functional module or unit in each embodiment of the application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0063] If the functions are implemented in the form of software function modules and sold or used as independent products, they can be stored in a computer readable storage medium. Based on this understanding, the technical solutions of the present application can be embodied in the form of a software product, which is stored in a storage medium and includes several instructions for causing a computer device (which can be a smart phone, a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present application.

[0064] The above merely provides a specific implementation of the present application, but the protection scope of the present application is not limited thereto, and any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be encompassed in the protection scope of the present application.

Claims

1. A weld count mistake proofing system characterized by, The welding count error-proof device comprises a control module, a solenoid valve control module, and a welding signal acquisition module corresponding to each welding machine. An input end of each welding signal acquisition module is connected to a welding state output end of the corresponding welding machine, and is used to acquire a welding completion signal output by each welding machine after a welding process is completed. The control module is electrically connected to each welding signal acquisition module and the solenoid valve control module, and is used to count the received welding completion signals. When the cumulative count reaches a preset number, the solenoid valve control module is used to drive an electromagnetic valve arranged in a clamp air path to be electrically attracted, to open a compressed air passage, so that the clamp can normally operate when receiving an external opening instruction. The welding count error-proof device further comprises a reset control module.

2. The weld count poka-yoke system of claim 1, wherein, An input end of the reset control module is connected to a magnetic switch arranged on a clamp cylinder, and an output end of the reset control module is connected to the control module. The reset control module is used to apply a reset level signal to the control module in response to a clamp opening to position signal sent by the magnetic switch, to trigger the control module to reset, to clear a current welding count value and restore to an initial operating state. Each welding machine has the same structure, and comprises a welding machine controller and a welding state output module connected in an electrical manner.

3. The weld count poka-yoke system of claim 1, wherein, The welding machine controller is used to trigger the welding state output module to output a welding completion signal after a welding process is completed. The welding count error-proof device further comprises a number of count display modules equal to the number of welding machines, and each count display module is electrically connected to the control module.

4. The weld count poka-yoke system of claim 1, wherein, The count display module is used to display the number of completed weldings of the corresponding welding machine. The control module is one of a processor, a programmable logic controller, or a single-chip microcomputer.

5. The weld count poka-yoke system of claim 1, wherein, The control module is further used to, after a current welding completion signal is acquired, sample and confirm whether the current welding completion signal is in a valid state again after a preset time interval, and if yes, determine that it is a valid welding event and perform counting.

6. The weld count poka-yoke system of claim 1, wherein, The welding count error-proof device further comprises a first power supply module and a second power supply module.

7. The weld count poka-yoke system of claim 1, wherein, The first power supply module is used to provide a working voltage for the control module. The second power supply module is used to provide a driving voltage for the solenoid valve and the welding signal acquisition module, and the second power supply module is isolated from the first power supply module. The welding count error-proof device further comprises a clamp state indication module electrically connected to the control module.

8. The weld count poka-yoke system of claim 2, wherein, The welding count error-proof method comprises the following steps.

9. A weld count mistake proofing method characterized by, Acquiring a welding completion signal. Counting the welding completion signal. When the cumulative count reaches a preset number, the solenoid valve control module is used to drive an electromagnetic valve arranged in a clamp air path to be electrically attracted, to open a compressed air passage, so that the clamp can normally operate when receiving an external opening instruction. ​ 10. A computer-readable storage medium, characterized in that, It stores a computer program which, when executed on a processor, implements the steps of the welding count mistake-proofing method according to claim 9.

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