Automatic release of welding tongs based on temperature determination of clamping zone

Abstract

The present application belongs to the technical field of electric welding equipment, and particularly relates to an automatic loosening electric welding tongs based on clamping area temperature judgment. The technical scheme is as follows: comprising a tong body, a clamping handle, a clamping jaw, and a clamping spring for providing clamping force, further comprising a temperature sensor, a control mechanism, and an electromagnetic drive assembly, the temperature sensor is arranged in the clamping jaw, the control mechanism and the electromagnetic drive assembly are installed on the clamping handle, and the temperature sensor, the control mechanism, and the electromagnetic drive assembly are electrically connected through wires; the control mechanism, based on the temperature signal collected by the temperature sensor, causes the clamping spring to lose the force acting on the clamping jaw through the electromagnetic drive assembly, and realizes automatic loosening of the welding rod. The present application realizes real-time collection of temperature signals in the clamping area of the electric welding tongs, and comprehensively judges in combination with a preset minimum fault duration, and only drives the loosening mechanism to act when it is confirmed that a dangerous welding rod adhesion fault occurs, so as to avoid false triggering while realizing reliable protection of welding safety.

Description

Technical Field

[0001] This invention belongs to the field of electric welding equipment technology, specifically relating to an automatic clamping welding clamp based on the temperature determination of the clamping zone. Background Technology

[0002] Manual arc welding is a widely used welding method in industrial manufacturing, equipment installation, and maintenance. It involves using welding clamps to hold a welding rod, creating an electric arc between the rod and the workpiece to weld it. In actual production and maintenance operations, welding tasks often need to be performed in environments with limited operating space, such as inside equipment, in pipe gaps, or within structural layers. These environments are typically confined and restrictive, placing higher demands on welding safety.

[0003] In welding scenarios with limited operating space, the welding electrode is prone to sticking to the workpiece during arc ignition or welding due to restricted welding posture, obstructed field of vision, and low welding current. Once the electrode sticks, a short circuit is formed, and the short-circuit current increases rapidly within a very short time, causing a sharp rise in temperature between the electrode and the clamping area. If the clamping relationship is not released in time, it may not only cause localized overheating of the electrode and clamp jaws, leading to burns or fires, but may also damage the welding equipment due to the short-circuit current surge.

[0004] In existing technologies, the handling of welding electrode adhesion problems mainly relies on manual intervention by operators, such as rapidly swinging the welding clamp to break the welding electrode, or manually loosening the clamp holding structure. However, in welding environments with limited operating space, operators have limited hand movement and often find it difficult to complete the above manual handling actions in a timely manner. This results in the continued presence of the dangerous state after welding electrode adhesion, significantly increasing safety hazards.

[0005] Furthermore, some existing welding clamps are susceptible to welding spatter, brief contact, or instantaneous current fluctuations, leading to false triggering or delayed response, making it difficult to provide reliable protection under complex welding conditions. Therefore, accurately determining the electrode adhesion status in welding environments with limited operating space and promptly releasing the clamping relationship without manual intervention has become a pressing technical problem in the field of manual arc welding.

[0006] Chinese Patent: An Automatic Data Acquisition System for Resistance Welding Grippers (CN111299787B), disclosed as follows: The purpose of this invention is to address the shortcomings of existing resistance welding gripper data acquisition devices, which only collect welding parameters and whose control devices cannot adaptively adjust to the state of the resistance welding gripper itself. This invention provides an automatic data acquisition system for resistance welding grippers, including a data detection unit and a data acquisition unit. The data detection unit includes a transformer temperature sensor, secondary voltage and current sensors, and a pressure sensor. The data acquisition unit includes a data acquisition module, a welding trigger module, a signal conversion module, a control module, a data storage module, and a data output module. The data acquisition module collects data when the collected parameters reach the threshold value of the welding trigger module. The transformer temperature sensor detects the transformer temperature, and the data acquisition unit outputs the transformer temperature. The secondary voltage and current sensors collect the voltage on the transformer side and the current of the electrode cap, respectively. The pressure sensor collects information reflecting the pressure between the two electrode caps during welding. Its disadvantages are as follows: 1. It mainly focuses on data acquisition and recording, outputting data signals. It cannot automatically loosen the gripper immediately when the welding rod sticks together, thus avoiding safety problems such as overheating of the welding rod and gripper jaws, fire, and burns caused by excessive short-circuit current. 2. No dedicated sensing and diagnostic logic has been established for the specific high-risk fault of "electrode adhesion," making it unable to adapt to normal temperature rise differences caused by different welding currents and electrode diameters, and thus unable to achieve adaptive adjustment. 3. During welding, the sensor signal may briefly exceed the preset threshold due to instantaneous high-temperature spatter, normal short-term contact between the electrode and the workpiece, etc., leading to system misjudgment. Summary of the Invention

[0007] This invention provides an automatic clamping welding clamp based on the temperature of the clamping area. By collecting temperature signals in real time in the clamping area of ​​the welding clamp and making a comprehensive judgment based on a preset minimum fault duration, the clamping mechanism is activated only when a dangerous electrode adhesion fault is confirmed. This avoids accidental triggering and provides reliable protection for welding safety.

[0008] The technical solution of the present invention is as follows:

[0009] An automatic welding electrode release clamp based on clamping zone temperature determination includes a clamp body, a clamping handle, clamping jaws, and a clamping spring for providing clamping force. It also includes a temperature sensor, a control mechanism, and an electromagnetic drive assembly. The temperature sensor is disposed in the clamping jaws, and the control mechanism and electromagnetic drive assembly are mounted on the clamping handle. The temperature sensor, control mechanism, and electromagnetic drive assembly are electrically connected by wires. Based on the temperature signal collected by the temperature sensor, the control mechanism uses the electromagnetic drive assembly to cause the clamping spring to lose its force on the clamping jaws, thereby automatically releasing the welding electrode.

[0010] Furthermore, in the aforementioned automatic clamping welding clamp based on clamping zone temperature determination, the clamp body and the clamping handle form a clamp-shaped structure, with the clamping jaws fixedly installed at the front end of the clamping handle; the clamp body has a screw hole in the middle, and the spring fixing sleeve has an external thread, with the spring fixing sleeve screwed into the screw hole and connected to the clamp body; the clamping handle has a through hole in the middle, with the lower end of the clamping spring placed inside the spring fixing sleeve and the upper end of the clamping spring placed in the through hole, and the upper end of the clamping spring being controlled by an electromagnetic drive assembly.

[0011] Furthermore, the automatic clamping welding clamp based on the temperature determination of the clamping area has an electromagnetic drive component including an electromagnetic coil and an electromagnet core. The electromagnetic coil is integrated in the clamping handle and located next to the through hole. The electromagnet core is controlled by the electromagnetic coil. After the electromagnet core protrudes from the electromagnetic coil, it is located above the through hole to hold the upper end of the clamping spring.

[0012] Furthermore, the automatic clamping welding clamp based on the temperature determination of the clamping area has a control mechanism including a controller and a power supply module, which are located at the tail of the clamping handle.

[0013] Furthermore, in the aforementioned automatic clamping welding clamp based on clamping zone temperature determination, the controller employs a microcontroller. The input terminal of the controller is connected to a signal amplification module and a filtering module. The output signal of the temperature sensor is amplified by the signal amplification module and filtered by the filtering module before being transmitted to the controller. The controller is equipped with a processor and a program storage unit. The program storage unit stores a control program for performing electrode adhesion determination. The control program includes a fault duration counter. The controller is equipped with a display screen and a parameter setting module.

[0014] Furthermore, in the automatic clamping welding clamp based on the temperature determination of the clamping area, the controller integrates a delay module. When the controller controls the electromagnetic coil to be powered on, the delay module starts timing. After the preset delay time is reached, the controller controls the electromagnetic coil to automatically power off.

[0015] Furthermore, in the automatic clamping welding clamp based on the temperature of the clamping area, the power supply module uses a rechargeable lithium battery and is used to supply power to the controller and the electromagnetic coil.

[0016] Furthermore, in the automatic clamping welding clamp based on the temperature of the clamping area, the temperature sensor is a high-temperature resistant thermocouple sensor, the probe end of which is fitted to the inner clamping surface of the clamping jaws, and the outer side is covered with an insulating high-temperature resistant protective layer.

[0017] Furthermore, the automatic clamping welding clamp based on the temperature of the clamping area has a lever on the spring fixing cylinder.

[0018] Furthermore, the implementation process of the control program for the automatic clamping welding clamp based on the temperature determination of the clamping area includes the following steps:

[0019] 1) Initialize parameter settings: Input welding parameters, i.e., welding current, through the display screen and parameter setting module. Electrode diameter Minimum Fault Duration And set the sampling period Electromagnetic coil de-energization delay time , keep the fault duration counter Reset to zero;

[0020] 2) Calculation of adaptive temperature threshold and sampling number threshold;

[0021] The adaptive temperature threshold is calculated according to formula (1). ;

[0022] (1)

[0023] In the formula, An adaptive temperature threshold, the value of which is based on the welding current. and electrode diameter Dynamically determined; The temperature reference threshold represents the temperature at which the reference current is applied. and reference diameter The fixed temperature value below, This is the current compensation coefficient, with units of ℃ / A; This is the diameter compensation coefficient, with units of ℃ / mm; The current setting corresponds to the electrode diameter, in amperes (A). This refers to the actual electrode diameter, in mm.

[0024] To avoid transient interference, a minimum fault duration is introduced. ; Calculate based on formula (2) Corresponding sampling number threshold ;

[0025] (2)

[0026] In the formula, Minimum fault duration;

[0027] 3) Signal acquisition and preprocessing;

[0028] The controller operates at a fixed cycle. The temperature signal is sampled, and the first ( At the sampling time, the effective temperature value obtained after processing the raw signal output by the temperature sensor through the signal amplification module and the filtering module is denoted as . (Unit: °C)

[0029] 4) Instantaneous fault detection and counter update;

[0030] Based on formula (1), the processed temperature sampling values With adaptive threshold Compare and generate the instantaneous fault flag at the current sampling time. ;

[0031] (3)

[0032] Based on transient fault flags Update the fault persistence counter That is, when When the value is "true", the fault persistence counter will continue. The cumulative number of failures, i.e. ;like If the value is "false", then the fault persistence counter is reset. And return to step 3) to continue monitoring; as shown in formula (4);

[0033] (4);

[0034] 5) Fault persistence determination;

[0035] When in continuous In the next sampling, the instantaneous fault flag Only if the fault duration remains true is it ultimately determined to be a real fault, and proceed to step 6); otherwise, the fault duration counter... Keep the current value unchanged and return to step 3) to continue monitoring; as shown in formula (5);

[0036] (5)

[0037] In the formula, The final fault determination result at time k is used, and its value is either 1 or 0.

[0038] 6) The controller immediately resets the fault duration counter. It also drives the electromagnetic actuator to automatically release the welding rod. Simultaneously, a timer is started to reach the preset time. Then, the electromagnetic coil was de-energized.

[0039] The beneficial effects of this invention are:

[0040] 1. Automatic clamp release without manual intervention: This invention detects the temperature at the clamping jaws in real time. When the welding rod sticks together and the temperature rises sharply and exceeds a preset threshold, the controller automatically drives the electromagnetic drive component to automatically release the welding clamp, avoiding the trouble of manual handling by the operator. It is especially suitable for welding operations in confined spaces and improves welding safety.

[0041] 2. The system is highly adaptable and applicable to a wide range of working conditions; the system can adapt to the operational needs of welding electrodes of different diameters, ensuring stable operation of the equipment under different welding conditions.

[0042] 3. Enhance anti-interference capability and effectively avoid false triggering; by introducing the minimum fault duration determination, the system effectively distinguishes between transient interference and real adhesion faults, eliminates false triggering, and ensures timely response while improving the system's anti-interference capability.

[0043] 4. High operational stability; the temperature sensor adopts a high-temperature resistant design and is covered with an insulating protective layer, and the electromagnetic coil is equipped with a heat insulation sleeve and heat dissipation groove, which can effectively adapt to the high-temperature environment during welding; the setting of the signal amplification and filtering module ensures accurate temperature signal transmission and avoids false triggering;

[0044] 5. Flexible operation and high practicality; the spring retaining cylinder is equipped with a lever for manual control of reset, adapting to different welding scenario requirements; the power supply module uses a rechargeable lithium battery to ensure stable power supply and improve the practicality of the equipment. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of an automatic clamping welding clamp based on the temperature of the clamping area.

[0046] Figure 2 This is a front sectional view of an automatic clamping welding clamp based on temperature determination in the clamping area;

[0047] Figure 3 This is a flowchart of the work process. Detailed Implementation

[0048] like Figure 1 , 2As shown, an automatic clamping welding clamp based on clamping zone temperature determination includes a clamp body 1, a clamping handle 14, a clamping jaw 2, a clamping spring 3 for providing clamping force, a temperature sensor 5, a control mechanism, and an electromagnetic drive assembly. The clamp body 1 and the clamping handle 14 form a clamp-like structure, and the clamping jaw 2 is fixedly installed at the front end of the clamping handle 14. A screw hole is provided in the middle of the clamp body 1, and a spring retaining sleeve 4 has external threads. The spring retaining sleeve 4 is screwed into the screw hole and connected to the clamp body 1. A through hole is provided in the middle of the clamping handle 14 for clamping... The lower end of the spring 3 is placed inside the spring fixing cylinder 4, and the upper end of the clamping spring 3 is placed in the through hole. The upper end of the clamping spring 3 is controlled by the electromagnetic drive assembly. The temperature sensor 5 is set in the clamping jaw 2. The control mechanism and the electromagnetic drive assembly are installed on the clamping handle 14. The temperature sensor 5, the control mechanism and the electromagnetic drive assembly are electrically connected by wires. Based on the temperature signal collected by the temperature sensor 5, the control mechanism uses the electromagnetic drive assembly to make the clamping spring 3 lose its force on the clamping jaw 2, thereby automatically releasing the welding rod 12.

[0049] The electromagnetic drive assembly includes an electromagnetic coil 7 and an electromagnet core 8. The electromagnetic coil 7 is integrated in the clamping handle 14 and located next to the through hole. The electromagnet core 8 is controlled by the electromagnetic coil 7. After the electromagnet core 8 protrudes from the electromagnetic coil 7, it is located above the through hole to hold the upper end of the clamping spring 3 and provide the clamping jaws 2 with the force to clamp the welding rod 12.

[0050] The control mechanism includes a controller 6 and a power supply module 11, which are located at the tail of the clamping handle 14.

[0051] The controller 6 employs a microcontroller. Its input terminals are connected to an operational amplifier (signal amplification module) and an RC filter circuit (filtering module). The output signal from the temperature sensor 5 is amplified by the operational amplifier, filtered by the RC filter circuit, and then transmitted to the controller 6. The controller 6 is equipped with a processor and a program storage unit. The program storage unit stores a control program for determining electrode adhesion, which includes parameter setting, signal processing, logic judgment, and output control functions. The control program includes a fault duration counter. The controller 6 is equipped with a display screen and a parameter setting module 13.

[0052] The controller 6 integrates a delay module with a preset delay time of 30-50 milliseconds. When the controller 6 controls the electromagnetic coil 7 to be powered on, the delay module starts timing. After the preset delay time is reached, the controller 6 controls the electromagnetic coil 7 to automatically power off.

[0053] The power supply module 11 uses a 12V rechargeable lithium battery and is used to supply power to the controller 6 and the electromagnetic coil 7.

[0054] The temperature sensor 5 is a K-type high-temperature resistant thermocouple sensor, with its detection end fitted to the inner clamping surface of the clamping jaw 2, and its outer side covered with an insulating high-temperature resistant protective layer 9.

[0055] A lever 15 is provided on the spring retaining cylinder 4.

[0056] The work process is as follows:

[0057] 1) Before welding, adjust the parameters of welding rod 12 ( , , , , The parameter setting module 13 inputs data to the controller 6 via the display screen; the controller automatically calculates the adaptive temperature threshold. Calculate the threshold number of samples Set the delay time to 50 milliseconds and the minimum fault time to 1.5 seconds; and ensure that the power supply module 11 is properly connected.

[0058] 2) Operators perform manual arc welding operations;

[0059] 3) When arc ignition fails or the welding electrode 12 sticks to the workpiece due to accidental reasons during the welding process, a short circuit current is generated, and the temperature at the connection between the welding electrode 12 and the clamping jaw 2 rises rapidly.

[0060] 4) Temperature sensor 5 collects temperature signals in real time, which are then processed by the signal amplification module and the filtering module and transmitted to controller 6;

[0061] 5) When controller 6 detects that the temperature signal exceeds the calculated adaptive temperature threshold If the duration exceeds the minimum fault duration of 1.5 seconds, it is determined that the welding rod is stuck together, and a power-on command is sent to the electromagnetic coil 7.

[0062] 6) When the electromagnetic coil 7 is energized, it generates a magnetic force, which pulls the electromagnet core 8 to move in the direction of the electromagnetic coil 7, causing the clamping spring 3 to lose its support and thus lose the pressure force on the clamping jaw 2. The clamping jaw 2 automatically releases the welding rod, and the short circuit circuit is broken.

[0063] 7) The delay module in the controller 6 starts timing synchronously. When the preset delay time of 50 milliseconds is reached, the controller 6 controls the electromagnetic coil 7 to cut off the power.

[0064] 8) First, rotate the spring fixing cylinder 4 downwards by lever 15 to manually push the electromagnet core 8 back to its original position. Then, reset the clamping spring 3 and tighten the spring fixing cylinder 4 by lever 15. The clamping spring 3 will then apply pressure to the clamping jaws 2 again, and the clamping jaws 2 will resume their clamping function. The operator can then re-clamp the welding rod 12 and continue working.

[0065] The above description is only a preferred embodiment of the present invention and is not intended to limit the ideas of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic clamping welding clamp based on clamping zone temperature determination, comprising a clamp body, a clamping handle, clamping jaws, and a clamping spring for providing clamping force, characterized in that, It also includes a temperature sensor, a control mechanism, and an electromagnetic drive assembly. The temperature sensor is set in the clamping jaws, and the control mechanism and electromagnetic drive assembly are mounted on the clamping handle. The temperature sensor, control mechanism, and electromagnetic drive assembly are electrically connected by wires. Based on the temperature signal collected by the temperature sensor, the control mechanism uses the electromagnetic drive assembly to make the clamping spring lose its force on the clamping jaws, thereby automatically releasing the welding rod. The clamp body and the clamping handle form a clamp-shaped structure, and the clamping jaws are fixedly installed at the front end of the clamping handle; the middle part of the clamp body is provided with a screw hole, and the spring fixing sleeve is provided with an external thread. The spring fixing sleeve is screwed into the screw hole and connected to the clamp body; the middle part of the clamping handle is provided with a through hole, the lower end of the clamping spring is placed in the spring fixing sleeve, and the upper end of the clamping spring is placed in the through hole. The upper end of the clamping spring is controlled by an electromagnetic drive component. The electromagnetic drive assembly includes an electromagnetic coil and an electromagnet core. The electromagnetic coil is integrated in the clamping handle and located next to the through hole. The electromagnet core is controlled by the electromagnetic coil. After the electromagnet core protrudes from the electromagnetic coil, it is located above the through hole to hold the upper end of the clamping spring. The control mechanism includes a controller and a power supply module, which are located at the tail of the clamping handle; The controller uses a microcontroller. The input terminal of the controller is connected to a signal amplification module and a filtering module. The output signal of the temperature sensor is amplified by the signal amplification module and filtered by the filtering module before being transmitted to the controller. The controller is equipped with a processor and a program storage unit. The program storage unit stores a control program for performing the determination of welding rod adhesion. The control program includes a fault duration counter. The controller is equipped with a display screen and a parameter setting module.

2. The automatic clamping welding clamp based on clamping zone temperature determination according to claim 1, characterized in that, The controller integrates a delay module. When the controller powers on the electromagnetic coil, the delay module starts timing. After the preset delay time is reached, the controller automatically powers off the electromagnetic coil.

3. The automatic clamping welding clamp based on clamping zone temperature determination according to claim 1, characterized in that, The power supply module uses a rechargeable lithium battery and is used to supply power to the controller and the electromagnetic coil.

4. The automatic clamping welding clamp based on clamping zone temperature determination according to claim 1, characterized in that, The temperature sensor is a high-temperature resistant thermocouple sensor, with its probe end fitted to the inner clamping surface of the clamping jaws, and its outer side covered with an insulating high-temperature resistant protective layer.

5. The automatic clamping welding clamp based on clamping zone temperature determination according to claim 1, characterized in that, A lever is provided on the spring retaining sleeve.

6. The automatic clamping welding clamp based on clamping zone temperature determination according to claim 1, characterized in that, The implementation process of the control program includes the following steps: 1) Initialize parameter settings: Input welding parameters, i.e., welding current, through the display screen and parameter setting module. Electrode diameter Minimum Fault Duration And set the sampling period Electromagnetic coil de-energization delay time , keep the fault duration counter Reset to zero; 2) Calculation of adaptive temperature threshold and sampling number threshold; The adaptive temperature threshold is calculated according to formula (1). ; （1） In the formula, An adaptive temperature threshold, the value of which is based on the welding current. and electrode diameter Dynamically determined; The temperature reference threshold represents the temperature at which the reference current is applied. and reference diameter The fixed temperature value below, This is the current compensation coefficient, with units of ℃ / A; This is the diameter compensation coefficient, with units of ℃ / mm; The current setting corresponds to the electrode diameter, in amperes (A). This refers to the actual electrode diameter, in mm. To avoid transient interference, a minimum fault duration is introduced. ; Calculate based on formula (2) Corresponding sampling number threshold ; （2） In the formula, Minimum fault duration; 3) Signal acquisition and preprocessing; The controller operates at a fixed cycle. The temperature signal is sampled, and the first ( At the sampling time, the effective temperature value obtained after processing the raw signal output by the temperature sensor through the signal amplification module and the filtering module is denoted as . (Unit: °C) 4) Instantaneous fault detection and counter update; Based on formula (1), the processed temperature sampling values With adaptive threshold Compare and generate the instantaneous fault flag at the current sampling time. ; （3） Based on transient fault flags Update the fault persistence counter That is, when When the value is "true", the fault persistence counter will continue. The cumulative number of failures, i.e. ;like If the value is "false", then the fault persistence counter is reset. And return to step 3) to continue monitoring; as shown in formula (4); （4）； 5) Fault persistence determination; When in continuous In the next sampling, the instantaneous fault flag Only if the fault duration remains true is it ultimately determined to be a real fault, and proceed to step 6); otherwise, the fault duration counter... Keep the current value unchanged and return to step 3) to continue monitoring; as shown in formula (5); （5） In the formula, The final fault determination result at the k-th sampling time, with a value of 1 or 0; 6) The controller immediately resets the fault duration counter. It also drives the electromagnetic actuator to automatically release the welding rod; at the same time, it starts the timer to reach the preset time. Then, the electromagnetic coil was de-energized.

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