Automatic welding equipment control system

Abstract

The invention discloses an automatic welding equipment control system which comprises an upper computer control module, a communication adaptation module, an interaction module and a real-time state monitoring module, and all the modules are electrically connected to form cooperative interaction. The upper computer control module is internally provided with a process database and a parameter editing unit, the process database and the parameter editing unit are responsible for welding process package compiling, parameter setting, data storage and equipment state monitoring, and the interaction module supports welding mode switching, parameter real-time adjustment, teaching operation and equipment state checking. The communication adaptation module realizes bidirectional data transmission between each module and an automatic welding equipment head as well as a power supply, the real-time state monitoring module acquires an equipment running state and welding parameters in real time and feeds back the equipment running state and the welding parameters to the upper computer control module and the interaction module, and each module is electrically connected to form closed-loop interaction. And full-process automatic connection of instruction issuing, parameter adjustment, state feedback and data storage is achieved, manual intervention links are greatly reduced, and the continuity and operation efficiency of welding operation are improved.

Description

Technical Field

[0001] This invention relates to the field of automatic welding equipment control, and in particular to an automatic welding equipment control system. Background Technology

[0002] Automatic welding equipment is increasingly widely used in oil and gas pipelines, chemical equipment, and machinery manufacturing. The control system, as the core of this equipment, directly determines the adaptability of the welding process, the accuracy of parameter control, and the stability of the welding process. Existing automatic welding equipment control systems suffer from the following shortcomings: First, poor process compatibility; most control systems only support a single welding mode or welding processes for a limited number of materials, making it difficult to meet the welding needs of multiple pipe specifications and materials. Second, insufficient flexibility in parameter control; lacking refined segmented parameter setting functions, it is impossible to perform differentiated parameter control for different welding positions (such as vertical welding and overhead welding). Third, poor ease of operation; the remote control has limited functions, parameter adjustment steps are cumbersome, and there is a lack of intuitive status feedback. Fourth, weak welding data traceability; it cannot effectively store welding process parameters and equipment operating status, which is detrimental to the traceability and control of welding quality. Fifth, insufficient communication stability; data transmission between the host computer, remote control, and actuator is easily interrupted, affecting the continuity of the welding process.

[0003] To address the aforementioned problems, an automatic welding equipment control system is proposed. Summary of the Invention

[0004] This invention overcomes the shortcomings of the prior art and provides an automatic welding equipment control system.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: an automatic welding equipment control system, comprising: a host computer control module, a communication adapter module, an interaction module, and a real-time status monitoring module, wherein the modules are electrically connected to form a collaborative interaction; The host computer control module has a built-in process database and parameter editing unit, which are responsible for welding process package compilation, parameter setting, data storage and equipment status monitoring. The interactive module provides a visual operation interface and multi-function buttons, supporting welding mode switching, real-time parameter adjustment, teaching operation, and equipment status viewing. The communication adapter module receives signals from the host computer control module and the interaction module, and transmits them to the automatic welding equipment head and power supply, thereby realizing bidirectional data transmission between each module and the automatic welding equipment head and power supply. The real-time status monitoring module collects the equipment operating status and welding parameters in real time and feeds them back to the host computer control module and the interaction module.

[0006] In a preferred embodiment of the present invention, the host computer control module supports four welding modes: PLASMA, GTAW, GMAW, and STT. It is compatible with rail-type, caliper-type, and rail-type gas metal arc welding heads, and is suitable for seven types of pipe materials: carbon steel, nickel-based alloy, titanium alloy, stainless steel, aluminum alloy, Monel alloy, and Hastelloy alloy.

[0007] In a preferred embodiment of the present invention, the host computer control module compiles a complete welding process package including engineering information, pipe material information, bevel information, and weld layer / weld bead information, sets welding parameters for the three stages of arc initiation, process control, and arc termination, and supports independent setting and copy-paste functions for parameters in 36 sector sections.

[0008] In a preferred embodiment of the present invention, each sector is adjustable in terms of oscillation speed, oscillation width, wire feed speed, inner and outer dwell time, welding current, and AVC arc length, and has the function of welding power supply step fine adjustment and head jogging parameter setting.

[0009] In a preferred embodiment of the present invention, the host computer control module divides users into four categories: administrators, process engineers, quality supervisors, and welders, and assigns corresponding permissions, supporting automatic storage of welding data and querying and exporting of historical data.

[0010] In a preferred embodiment of the present invention, the visualization interface displays equipment status, communication status, process type, welding mode information, and provides real-time feedback after parameter adjustment; The function keys support dual functions: they can be used as numeric inputs and combined with other operations to adjust parameters.

[0011] In a preferred embodiment of the present invention, the interaction module includes a mode switching unit, a head dynamics unit, and a real-time adjustment unit; The mode switching unit can switch between welding and test welding modes; The machine head dynamic unit includes adjusting the forward and reverse jogging or continuous movement of the machine head; The real-time adjustment unit includes parameters for adjusting the current, voltage, and wire feeding speed of the die head.

[0012] In a preferred embodiment of the present invention, the interactive module has a teaching function, supporting the setting and data saving of welding gun swing width at eight teaching points: 0°, 45°, 90°, 135°, 180°, 225°, 270°, and 315°. After completion, the teaching welding mode can be opened and the parameters synchronized.

[0013] In a preferred embodiment of the present invention, the communication adapter module adopts a wired and wireless compatible mode, the host computer and the head unit communicate via a wired control cable, the interaction module and the host computer adopt a wireless compatible mode, and the communication status is fed back in real time through the visual operation interface.

[0014] In a preferred embodiment of the present invention, the real-time status monitoring module monitors the status of wire feeding, pulse, motor operation, and emergency stop equipment in real time, and records the occurrence time and corresponding parameters when an abnormality occurs; Simultaneously, parameters such as peak current, base current, and welding voltage are collected and fed back bidirectionally.

[0015] This invention addresses the shortcomings of the prior art and has the following beneficial effects: (1) The host computer control module of this invention has a built-in process database and parameter editing unit, which is responsible for the compilation of welding process packages and parameter settings. The modules work together to form a complete control link, providing core support for process adaptation of multiple welding modes, multiple materials and multiple specifications of pipes. Through the flexible expansion capability of the process database and the flexible configuration function of the parameter editing unit, it can quickly adapt to the welding process requirements in different scenarios without reconstructing the core architecture of the control system. This solves the limitation of existing systems that only support a single or a few processes and materials, and greatly improves the adaptability to welding requirements of multiple specifications and multiple materials.

[0016] The parameter editing unit of the host computer control module and the real-time status monitoring module form a closed-loop control. The real-time status monitoring module collects welding process data and provides feedback. Based on this feedback, the host computer can set precise parameters through the parameter editing unit. At the same time, the interaction module supports real-time parameter adjustment. It provides hardware architecture and collaborative mechanism guarantee for differentiated parameter control for different welding positions (vertical welding, overhead welding, etc.), breaks the limitation of existing systems that lack fine segmented parameter settings, and can accurately adapt parameters for different stages and positions of the entire welding process, thereby improving the consistency of welding quality.

[0017] The interactive module provides a visual operation interface and multi-function buttons, supporting functions such as welding mode switching, real-time parameter adjustment, and equipment status viewing. At the same time, the real-time status monitoring module feeds back the equipment operating status and welding parameters to the interactive module, realizing the integration of operation and status feedback. The visual interface makes the changes in equipment status and parameters intuitively visible, and the multi-function buttons simplify the operation process, avoiding the problems of existing system remote controls having single functions, cumbersome parameter adjustment steps, and unintuitive status feedback, reducing operation complexity and improving operator efficiency.

[0018] The host computer control module is responsible for data storage, while the real-time status monitoring module collects the equipment operating status and welding parameters in real time and feeds them back to the host computer, forming a full-process data management mechanism of "parameter setting - process acquisition - data storage". It can completely store welding process parameters and equipment operating status, providing data support for welding quality traceability and control, filling the gap in the existing system's inability to effectively store key data, and helping to improve quality traceability and process optimization.

[0019] The communication adapter module is specifically responsible for bidirectional data transmission between the host computer control module, the interaction module, and the automatic welding equipment head and power supply. The electrical connections of each module form a closed-loop transmission link for collaborative interaction, ensuring efficient and stable transmission of commands and data feedback. This avoids the problem of easy interruption of data transmission between the host computer, remote control and actuator in the existing system, ensuring the continuity of the welding process and reducing work stoppages and quality defects caused by communication interruptions.

[0020] (2) The communication adapter module of this invention is compatible with both wired and wireless modes. The wired communication between the host computer and the machine head ensures accurate transmission of control commands. The wireless communication module is compatible with the host computer and adapts to flexible operating scenarios. The communication status is visualized and fed back in real time, avoiding work stoppage caused by communication interruption. It balances stability and layout flexibility.

[0021] Meanwhile, the host computer control module supports four welding modes: PLASMA, GTAW, GMAW, and STT. It is compatible with various types of welding heads, such as rail-type and caliper-type, and is suitable for seven types of pipe materials, including carbon steel, nickel-based alloys, and titanium alloys. It can meet the welding needs of multiple materials, processes, and equipment types without changing the core control system, thus reducing the equipment investment cost for cross-scenario operations.

[0022] The welding mode switching (welding / test welding), forward and reverse jogging / continuous movement of the welding head, and real-time adjustment of multiple parameters, combined with the welding gun swing width setting and teaching welding synchronization function at 8 teaching points, are adapted to the operational needs of different welding angles and weld types, and are especially suitable for precision welding under complex working conditions.

[0023] (3) The host computer of this invention compiles a complete process package containing information on engineering, pipe, bevel, and weld layer. It supports parameter settings for the three stages of arc initiation, process control, and arc termination. Key parameters such as swing speed, wire feeding speed, and welding current can be independently adjusted in 36 sectors. It also has copy and paste and step fine-tuning functions, which can optimize the weld quality in different areas and avoid welding defects caused by parameter uniformity.

[0024] The real-time status monitoring module collects core parameters such as peak current, base current, and welding voltage bidirectionally and feeds them back to the host computer and interactive module simultaneously to ensure that parameter adjustments take effect in real time. At the same time, it monitors the status of equipment such as wire feeding, motor operation, and emergency stop. When an anomaly occurs, it automatically records the time of occurrence and corresponding parameters, providing data support for quality traceability and fault diagnosis, and reducing the defect rate.

[0025] (4) The visual operation interface of this invention intuitively displays information such as equipment status, communication status, and process type. The multi-function button has both digital input and combination adjustment functions. With the wireless compatible interactive module, the operator can flexibly adjust the working position without having to bind the equipment at close range, thus improving the operating comfort and work safety.

[0026] The teaching function supports the saving and synchronization of parameters for 8 key angles. Functions such as head jogging adjustment and parameter step fine adjustment reduce the dependence on the operator's skill level, allowing novices to get started quickly and shortening the training cycle.

[0027] (5) The host computer of this invention divides users into four roles, such as administrators and process engineers, and assigns corresponding permissions to realize hierarchical control of operation permissions, avoids unauthorized personnel from modifying key process parameters, ensures the consistency of welding process, automatically stores welding data, supports historical query and export, and combines the parameter records of abnormal status to form a full-process data traceability chain of process setting-operation process-quality results, which facilitates quality supervisors to carry out compliance inspections and meets the quality control requirements of industrial production.

[0028] (6) The real-time status monitoring module of the present invention continuously monitors key states such as emergency stop, motor failure, and abnormal wire feeding. When an abnormality occurs, it quickly provides feedback and records relevant information, which facilitates timely shutdown and troubleshooting, and avoids equipment damage or the expansion of safety accidents. The collaborative feedback mechanism of each module of the system and the real-time monitoring of communication status ensure rapid response to emergency stop commands and abnormal signals, and improve the safety and reliability of equipment operation. Attached Figure Description

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a logic architecture diagram of the automatic welding equipment control system according to a preferred embodiment of the present invention; Figure 2 This is the process type selection interface of the automatic welding equipment control system according to a preferred embodiment of the present invention; Figure 3 This is the interface for obtaining the current process name in the automatic welding equipment control system of the preferred embodiment of the present invention; Figure 4 The preferred embodiment of the automatic welding equipment control system of the present invention inputs the required weld layer and weld interface; Figure 5 This is the welding parameter display interface of the automatic welding equipment control system according to a preferred embodiment of the present invention; Figure 6 This is the teaching mode display interface of the automatic welding equipment control system according to a preferred embodiment of the present invention; Figure 7 This is the user login interface of the automatic welding equipment control system according to a preferred embodiment of the present invention; Figure 8 This is the historical data query interface of the automatic welding equipment control system according to a preferred embodiment of the present invention. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0032] like Figures 1 to 8 As shown, an automatic welding equipment control system includes: a host computer control module, a communication adapter module, an interaction module, and a real-time status monitoring module. The modules are electrically connected to each other to form a collaborative interaction. The host computer control module has a built-in process database and parameter editing unit, which is responsible for welding process package compilation, parameter setting, data storage and equipment status monitoring; The interactive module provides a visual operation interface and multi-function buttons, supporting welding mode switching, real-time parameter adjustment, teaching operation, and equipment status viewing; The communication adapter module receives signals from the host computer control module and the interaction module, and transmits them to the automatic welding equipment head and power supply, realizing bidirectional data transmission between each module and the automatic welding equipment head and power supply. The real-time status monitoring module collects the equipment's operating status and welding parameters in real time and feeds them back to the host computer control module and interaction module.

[0033] The host computer control module supports four welding modes: PLASMA, GTAW, GMAW, and STT. It is compatible with rail-type, caliper-type, and rail-type gas metal arc welding heads, and is suitable for seven types of pipe materials: carbon steel, nickel-based alloy, titanium alloy, stainless steel, aluminum alloy, Monel alloy, and Hastelloy alloy.

[0034] The host computer control module compiles a complete welding process package that includes engineering information, pipe material information, bevel information, and weld layer / weld bead information. It sets welding parameters for the three stages of arc initiation, process control, and arc termination, and supports independent setting and copy-paste functions for parameters in 36 sectors.

[0035] Each sector allows adjustment of oscillation speed, oscillation width, wire feed speed, inner and outer dwell time, welding current, and AVC arc length, and features welding power supply step fine-tuning and head jogging parameter setting functions.

[0036] The host computer control module categorizes users into four types: administrators, process engineers, quality supervisors, and welders, and assigns corresponding permissions. It supports automatic storage of welding data and querying and exporting of historical data.

[0037] The visual interface displays equipment status, communication status, process type, and welding mode information, and provides real-time feedback after parameter adjustments; The function keys support dual functions: they can be used for numeric input and combined with other operations to adjust parameters.

[0038] The interaction module includes a mode switching unit, a head unit, and a real-time adjustment unit; The mode switching unit can switch between welding and test welding modes; The machine head dynamic unit includes adjusting the forward and reverse jogging or continuous movement of the machine head; The real-time adjustment unit includes parameters such as the adjustment current, voltage, and wire feeding speed of the die head.

[0039] The interactive module has a teaching function, supporting the setting and data saving of welding gun swing width at eight teaching points: 0°, 45°, 90°, 135°, 180°, 225°, 270°, and 315°. After completion, the teaching welding mode can be opened and the parameters synchronized.

[0040] The communication adapter module adopts a wired and wireless compatible mode. The host computer and the head unit communicate via a wired control cable, while the interaction module and the host computer adopt a wireless compatible mode. The communication status is fed back in real time through a visual operation interface.

[0041] The real-time status monitoring module monitors the status of wire feeding, pulse, motor operation, and emergency stop equipment in real time, and records the occurrence time and corresponding parameters when abnormalities occur. Simultaneously, parameters such as peak current, base current, and welding voltage are collected and fed back bidirectionally.

[0042] Example 1: Process Adaptation and Quality Control for Batch Welding of Multi-Material Oil and Gas Pipelines A certain oil and gas pipeline project requires the batch welding of carbon steel main pipes and stainless steel branch pipes, involving two modes: GTAW (argon arc welding) and GMAW (gas metal arc welding). It is required to ensure the continuity and parameter consistency of long-distance welding, while realizing full traceability of welding data.

[0043] 1. Process preparation stage: Process engineers log in through the visual interface of the interactive module (the host computer control module has been assigned exclusive permissions), call the basic parameters corresponding to carbon steel and stainless steel in the host computer's built-in process database, and compile a complete process package including project number, pipe specifications (Φ508×12mm), V-groove angle (60°), and 3 layers of weld.

[0044] For the 36 sectors of the pipe circumferential seam, differentiated parameters are set independently for vertical welding (90° sector) and overhead welding (270° sector): vertical welding area swing width 8mm, wire feeding speed 5m / min, overhead welding area swing width 6mm, wire feeding speed 4.5m / min. The parameters can be copied and pasted and the current step fine adjustment of ±0.1A can be completed through the multi-function button of the interactive module.

[0045] The host computer control module synchronously stores the process package data to the local database, and at the same time echoes the parameters back to the interactive module through the wireless link of the communication adapter module for administrator review and confirmation.

[0046] 2. Welding execution stage: After the review is approved, the host computer sends the process instructions and welding mode (GTAW root pass, GMAW fill / cover pass) to the automatic welding equipment head and power supply through the wired control cable of the communication adapter module; the interactive module's visual interface displays the status of "communication is normal" and "process is activated" in real time.

[0047] The welder selects the "welding" mode through the mode switching unit of the interactive module, presses the start button, and the welding head starts welding according to the preset path; the real-time status monitoring module starts data acquisition simultaneously, recording the peak current, base current, and welding voltage every 200ms, while monitoring the operating status of the wire feeding mechanism, motor speed, and emergency stop signal.

[0048] When welding reaches the overhead welding area, the monitoring module detects that the welding voltage drops from 28V to 25V (below the threshold of 26V). It immediately records the time of the anomaly (10:23:45), the corresponding sector (270°), and the parameters, and synchronously feeds them back to the host computer and the interactive module through a bidirectional transmission link. The interactive interface pops up a red "voltage anomaly" warning.

[0049] 3. Closed-loop control and data traceability stage: The welder fine-tunes the voltage parameter to 27V using the real-time adjustment unit of the interactive module. The instruction is wirelessly transmitted to the host computer via the communication adapter module. The host computer combines the real-time data fed back by the monitoring module, corrects the output instruction through the parameter editing unit, and then transmits it to the machine head power supply via the communication module. The voltage parameter correction is completed within 300ms, and the monitoring module reports that the voltage has recovered to a stable value of 27V.

[0050] After batch welding is completed, the host computer automatically stores complete data for each weld (including 36 sector parameter adjustment records and 2 abnormal warning data); quality supervisors can call historical data through the interactive module, and after wireless transmission through the communication module, they can view the data curves on the visualization interface, and export Excel format reports to complete quality traceability.

[0051] With the host computer's process planning and data storage capabilities as the core, the monitoring module's high-frequency data acquisition provides the basis for regulation, the communication module's "wired + wireless" dual-link ensures uninterrupted command and data transmission, and the interaction module realizes human-machine collaboration in "planning-operation-early warning-adjustment," ultimately achieving efficient and stable operation of welding multi-material, long-distance pipelines, with a welding qualification rate 15% higher than that of traditional systems.

[0052] Example 2: Teaching welding and precise fitting of complex bevels in chemical equipment A chemical pressure vessel manufacturing project requires welding a titanium alloy head to the cylinder circumferential seam. The bevel is a composite type (U-shaped at the root + V-shaped at the top). The weld involves eight key angles, including 0°, 45°, 135°, and 270°, requiring the welding torch to be precisely positioned to match the bevel shape.

[0053] 1. Teaching parameter acquisition stage The welder selects the "test welding" mode through the mode switching unit of the interactive module, starts the teaching function, operates the directional buttons of the machine head dynamic unit, controls the machine head to move forward and backward in jogs, and moves to 8 key angle positions in sequence: 0° (horizontal section of cylinder), 45° (transition section of end cap), 135° (top of end cap), etc.

[0054] When stopping at each teaching point, the welding torch swing width can be set via the multi-function button on the interactive module: 6mm at 0°, 8mm at 45°, and 7mm at 135°, completing the parameter settings for a total of 8 teaching points; the interactive module transmits the parameters to the host computer control module in real time via a wireless communication link.

[0055] 2. Path planning and parameter synchronization stage: After receiving the teaching data, the host computer automatically generates a continuous welding path adapted to the composite bevel, mapping the parameters of the 8 teaching points to the segmented parameters of 36 sectors to form a complete process package; at the same time, the path planning command is sent to the machine head actuator through the wired link of the communication adapter module, and the teaching parameters are echoed back to the interactive module through the wireless link for the welder to confirm.

[0056] After confirming that everything is correct, the host computer synchronizes the process package to the welding power source through the communication module, completing the parameter unification of the machine head, power source, and interaction module; the communication status is displayed on the visual interface as "wireless connection stable" and "wired command issued".

[0057] 3. Welding execution and dynamic correction phase: After switching to "welding" mode, the machine head runs along the planned path. The real-time status monitoring module continuously collects parameters such as motor running status, AVC arc length, and welding current, and feeds them back to the host computer and interaction module every 500ms. When the arc length fluctuation of the sector corresponding to the 135° teaching point exceeds ±0.2mm, the signal is immediately synchronized to the host computer.

[0058] The host computer, in conjunction with the monitoring data, automatically fine-tunes the swing width parameter of the sector (corrected from 7mm to 7.3mm) through the parameter editing unit. The command is transmitted to the welding head via the communication module to adjust the welding torch posture. The interactive module displays the corrected parameters in real time, and the welder confirms the adjustment effect through the visual interface.

[0059] Throughout the welding process, the monitoring module records data such as wire feeding status and pulse frequency. In case of abnormalities, it automatically triggers an emergency stop warning to ensure the low oxidation and high precision requirements of titanium alloy welding.

[0060] The interactive module's teaching function and the machine head's dynamic adjustment unit provide an operational basis for welding complex bevels. The path generation and parameter synchronization of the host computer achieve seamless connection between "teaching and welding". The closed-loop feedback between the monitoring module and the host computer ensures dynamic parameter correction, ultimately achieving precise welding of composite bevels with a weld formation qualification rate of 99.2%.

[0061] Example 3: Wireless Operation and Safety Protection for Irregular Workpieces in Mechanical Manufacturing A heavy machinery project requires welding irregular seams on the bed of a large machine tool. The workpiece is heavy and difficult to move. Operators need to observe the welding status from different positions, requiring the implementation of wireless remote operation and equipment safety early warning.

[0062] 1. Preoperative preparation and access control stage: Administrators set user permissions through the host computer control module: welders only have parameter adjustment and start permissions, while process engineers have process package modification permissions; at the same time, they call the GMAW welding parameters of carbon steel in the process database to compile process packages adapted to the bed welds, supporting switching between welding and trial welding modes.

[0063] The communication adapter module establishes a wireless connection, and the wireless link signal strength between the interaction module and the host computer is displayed as "-65dBm" (stable connection) on the visualization interface. The host computer sends process instructions to the machine head through a wired link, and the wireless link synchronizes the equipment status ("standby" or "power ready") to the interaction module.

[0064] 2. Wireless Operation and Status Monitoring Phase The welder carries the interactive module and moves around the workpiece to observe it. The welder controls the continuous forward and reverse movement of the weld head through the dynamic unit of the weld head to adjust the welding position. The welder fine-tunes the wire feeding speed (from 4.8m / min to 5.2m / min) through the real-time adjustment unit. The instructions are transmitted to the host computer via the wireless communication module. The host computer responds immediately and sends adjustment instructions to the weld head.

[0065] The real-time status monitoring module continuously monitors the motor's operating status and the emergency stop button's status, collecting parameters such as peak current and base current, and feeding them back to the host computer and the interaction module via a two-way link. When the operator accidentally presses the emergency stop button, the monitoring module immediately collects the emergency stop signal and transmits it synchronously to the host computer and the machine head via the communication module. The machine head stops within 300ms, the host computer records the emergency stop time and current parameters, and the interaction interface displays "Emergency stop triggered, equipment has stopped".

[0066] 3. Recovery Operation and Data Storage Phase After investigating the cause of the accidental activation, the welder cancels the emergency stop through the interactive module and issues a command to resume welding. The host computer, based on the equipment status feedback from the monitoring module ("emergency stop canceled" "parameters normal"), issues a start command through the communication module, and the welding head resumes welding.

[0067] After welding is completed, the host computer automatically stores the entire welding process data (including 3 parameter adjustment records and 1 emergency stop record), and supports historical data query and export; the quality supervisor can call the data through the interactive module to verify the parameter stability and equipment operating status of the welding process, and complete the quality control.

[0068] The wireless compatibility mode of the communication adapter module meets the needs of mobile operation, the multi-function buttons and visual interface of the interaction module simplify the remote operation process, the real-time safety monitoring and emergency stop response of the monitoring module ensure the safety of equipment and personnel, and the access control and data storage of the host computer realize process consistency and quality traceability, ultimately solving the problems of operational flexibility and safety in welding large workpieces.

[0069] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of these fall within the protection scope of the present invention.

Claims

1. An automatic welding equipment control system, characterized in that, include: The host computer control module, communication adapter module, interaction module, and real-time status monitoring module are electrically connected to form a collaborative interaction. The host computer control module has a built-in process database and parameter editing unit, which are responsible for welding process package compilation, parameter setting, data storage and equipment status monitoring. The interactive module provides a visual operation interface and multi-function buttons, supporting welding mode switching, real-time parameter adjustment, teaching operation, and equipment status viewing. The communication adapter module receives signals from the host computer control module and the interaction module, and transmits them to the automatic welding equipment head and power supply, thereby realizing bidirectional data transmission between each module and the automatic welding equipment head and power supply. The real-time status monitoring module collects the equipment operating status and welding parameters in real time and feeds them back to the host computer control module and the interaction module.

2. The automatic welding equipment control system according to claim 1, characterized in that: The host computer control module supports four welding modes: PLASMA, GTAW, GMAW, and STT. It is compatible with rail-type, caliper-type, and rail-type gas metal arc welding heads, and is suitable for seven types of pipe materials: carbon steel, nickel-based alloy, titanium alloy, stainless steel, aluminum alloy, Monel alloy, and Hastelloy alloy.

3. The automatic welding equipment control system according to claim 1, characterized in that: The host computer control module compiles a complete welding process package that includes engineering information, pipe material information, bevel information, and weld layer / weld bead information. It sets welding parameters for the three stages of arc initiation, process control, and arc termination, and supports independent setting and copy-paste functions for parameters in 36 sectors.

4. The automatic welding equipment control system according to claim 3, characterized in that: Each sector can adjust the oscillation speed, oscillation width, wire feed speed, inner and outer dwell time, welding current, and AVC arc length, and has the function of welding power supply step fine adjustment and head jogging parameter setting.

5. The automatic welding equipment control system according to claim 1, characterized in that: The host computer control module categorizes users into four types: administrators, process engineers, quality supervisors, and welders, and assigns corresponding permissions. It supports automatic storage of welding data and querying and exporting of historical data.

6. The automatic welding equipment control system according to claim 1, characterized in that: The visual interface displays equipment status, communication status, process type, and welding mode information, and provides real-time feedback after parameter adjustments. The function keys support dual functions: they can be used as numeric inputs and combined with other operations to adjust parameters.

7. The automatic welding equipment control system according to claim 1, characterized in that: The interaction module includes a mode switching unit, a head unit, and a real-time adjustment unit. The mode switching unit can switch between welding and test welding modes; The machine head dynamic unit includes adjusting the forward and reverse jogging or continuous movement of the machine head; The real-time adjustment unit includes parameters for adjusting the current, voltage, and wire feeding speed of the die head.

8. The automatic welding equipment control system according to claim 1, characterized in that: The interactive module has a teaching function, supporting the setting and data saving of welding gun swing width at eight teaching points: 0°, 45°, 90°, 135°, 180°, 225°, 270°, and 315°. After completion, the teaching welding mode can be opened and the parameters synchronized.

9. The automatic welding equipment control system according to claim 1, characterized in that: The communication adapter module adopts a wired and wireless compatible mode. The host computer and the head unit communicate via a wired control cable. The interaction module and the host computer adopt a wireless compatible mode. The communication status is fed back in real time through the visual operation interface.

10. The automatic welding equipment control system according to claim 1, characterized in that: The real-time status monitoring module monitors the status of wire feeding, pulse, motor operation, and emergency stop equipment in real time, and records the occurrence time and corresponding parameters when an abnormality occurs. Simultaneously, parameters such as peak current, base current, and welding voltage are collected and fed back bidirectionally.

Images