A multi-type terminal compatible welding machine human-computer interaction system

Abstract

The application provides a welding machine human-computer interaction system compatible with multiple types of terminals, which comprises a welding machine host station module and multiple interactive terminals in communication connection with the welding machine host station module; the multiple interactive terminals comprise a wireless terminal module, a wired welding cap interaction module, a mobile terminal module and an upper computer module; the welding machine host station module is used for processing operation instructions and storing welding parameters, and synchronously running data in real time to the connected interactive terminals; the wireless terminal module, the wired welding cap interaction module, the mobile terminal module and the upper computer module respond to the operation of the operator and send respective parameter adjustment instructions to the welding machine host station module. The application can realize multiple interaction modes based on different scenes by integrating multiple terminal modules, the operator can flexibly select according to the actual scene, and effectively solves the problems of single interaction mode and limited adaptive scene in traditional welding operation.

Description

Technical Field

[0001] This invention relates to the field of human-machine interaction technology for welding equipment, and in particular to a welding machine human-machine interaction system compatible with multiple types of terminals. Background Technology

[0002] Welding equipment, as an indispensable processing tool in modern industrial production, is widely used in various fields such as engineering machinery, shipbuilding, automotive industry, and aerospace. With the continuous development of welding automation and intelligent technologies, operators are also constantly increasing their requirements for the ease of interaction with welding machines and the versatility of their adaptability to different scenarios.

[0003] Currently, mainstream human-machine interaction solutions for welding machines can be divided into three categories: The first category is the physical panel solution integrated into the welding machine itself. Parameter adjustment and status viewing are completed through the display screen and physical buttons on the main unit. The limitation of this solution is that the operator must be close to the welding machine to operate it, which is extremely inconvenient for welding large workpieces or long-distance operation scenarios. The second category is the wireless remote control adjustment solution, which achieves remote operation by pairing a dedicated wireless remote control with the welding machine. This solves the problem of needing to be close to the welding machine to some extent, but the remote control needs to be carried separately, and most remote controls only support parameter adjustment without parameter saving or other functions. In addition, the screen size of the remote control is small and cannot clearly display the operating data of the welding machine. The third category is the wired remote control adjustment solution, which achieves operation through a wired handheld control box. Although this solution has a stable signal, the wired constraint restricts the operator's range of movement and has poor flexibility.

[0004] Analysis of existing technologies reveals that most welding machines currently support only one extended interaction mode, failing to flexibly switch interaction methods according to the needs of actual welding scenarios. For example, in welding large components in the field, operators need to adjust parameters remotely and also monitor parameters in real time using the welding helmet they wear during welding. If relying solely on a wireless remote control, the welding process requires stopping to remove the helmet and check the remote control parameters, severely impacting welding efficiency. If relying on a mobile phone for adjustment, the phone cannot be fixed near the operator during welding, making it inconvenient to access and posing a risk of equipment loss. Some technologies have attempted to add Bluetooth connectivity between the welding machine and a mobile app, but integration with existing welding equipment has not been achieved, and the welding helmet has not been integrated as an interaction node into the overall human-machine interaction system. Therefore, the problems of a single interaction mode and limited adaptability to various scenarios persist. Summary of the Invention

[0005] The purpose of this invention is to solve the problems in the prior art and propose a welding machine human-machine interaction system that is compatible with multiple types of terminals, which can solve the problems of single interaction mode and limited adaptability in the prior art.

[0006] To achieve the above objectives, this invention proposes a welding machine human-machine interaction system compatible with multiple types of terminals, including a welding machine main station module. The welding machine main station module uses a welding machine host as the main station. The welding machine host integrates a main control unit and a main communication unit. The main control unit processes operation commands and stores welding parameters, and synchronizes operating data in real time to connected interactive terminals through the main communication unit. A wireless terminal module is wirelessly connected to the welding machine main station module, used to send first parameter adjustment commands and synchronously display the operating data. The wireless terminal module is an independent wireless handheld device. A wired welding cap interaction module includes a protective welding cap. The protective welding cap is wired to the welding machine main station module. The protective welding cap includes a display screen and an input unit. The display screen is used to synchronously display the welding parameters, and the input unit is used to send a second parameter adjustment command. A mobile terminal module is connected to the welding machine main station module via a local area network (LAN) or wide area network (WAN) communication protocol. It is used to send a third parameter adjustment command and synchronously display the operating data, while also storing and managing data. A host computer module is connected to the welding machine main station module via a LAN or WAN communication protocol. It is used to send a fourth parameter adjustment command and synchronously display the operating data, monitor the welding process in real time, and store and analyze the collected data.

[0007] Preferably, the wired welding cap interaction module is connected to the welding machine master station module via a wired cable.

[0008] Preferably, the display screen is a micro liquid crystal display screen; the micro liquid crystal display screen is a transflective display screen.

[0009] Preferably, the protective welding cap has a built-in light sensor and a control unit; both the light sensor and the display screen are electrically connected to the control unit; the control unit is configured to control the display screen to turn off when the protective welding cap is in the open state, based on the detection signal from the light sensor; and to control the display screen to turn on when the protective welding cap is in the closed state.

[0010] Preferably, the input unit is an adjustment knob, which is used to generate a displacement electrical signal corresponding to the rotation angle; the welding machine master station module can receive the second parameter adjustment command according to the displacement electrical signal.

[0011] Preferably, the mobile terminal module is also used to establish a process database, which contains preset process recipes; the mobile terminal module is configured to respond to user selection commands and retrieve target process recipes from the process database.

[0012] Preferably, the main control unit includes a main control chip, which is configured to execute the operation instructions and store the welding parameters.

[0013] Preferably, the welding machine master station module supports simultaneous connection of multiple interactive terminals. Parameter adjustment instructions sent by any interactive terminal can be processed by the welding machine host and synchronized to all connected interactive terminals. When multiple interactive terminals send parameter adjustment instructions, the latest received parameter adjustment instruction is used as the target instruction, which overwrites the stored historical parameter adjustment instructions. The operating status of the welding machine master station module is then updated based on the target instruction.

[0014] Preferably, the wireless terminal module is connected to the welding machine main station module via WiFi communication technology, and the maximum communication distance of this connection is not less than 150 meters.

[0015] Preferably, the mobile terminal module can acquire the operating data uploaded by the welding machine master station module and export the operating data generated file to an external terminal; the mobile terminal module can match the collected equipment status data with a preset fault feature model, and when the matching degree exceeds a preset threshold, a prompt pop-up window will be generated on the interactive interface.

[0016] The beneficial effects of this invention are: 1) Multiple Interaction Modes Adapt to Various Scenarios: This invention integrates multiple modules, including a wireless terminal module and a wired welding helmet interaction module, enabling various interaction modes based on different scenarios. Operators can flexibly choose according to the actual scenario: Pre-set parameters can be adjusted remotely using the wireless terminal module before welding, without needing to move to the welding machine; during welding, parameters can be viewed and adjusted directly while wearing the protective welding helmet, without removing the helmet, improving operational efficiency; when it is necessary to save welding process parameters and analyze welding data, the mobile terminal module can be used, leveraging its storage and computing capabilities to expand the welding machine's functionality; remote detection can also be performed using the host computer module. These multiple interaction modes solve the problem that existing single interaction modes cannot adapt to different scenarios. 2) Real-time data synchronization across all terminals: This invention uses the welding machine host as the master station. All operation commands of interactive terminals are processed uniformly by the welding machine host, and the processing results are synchronized to all terminals, ensuring that the parameters displayed on any terminal are consistent with the welding machine host in real time, and avoiding operation errors caused by data asynchrony. 3) Interactive integrated design of welding helmet enhances user experience: This invention transforms the original ordinary welding helmet into an interactive terminal. Taking advantage of the fact that operators must wear welding helmets during welding, display and adjustment functions are integrated inside the protective welding helmet. Operators can observe parameter changes and adjust parameters at any time during welding without interrupting the work, thus improving the smoothness of welding operations. 4) Strong compatibility and low modification cost: This invention only requires adding a corresponding main communication unit to the original welding machine host, with minimal changes to the core control logic of the original welding machine; the protective welding cap can be modified based on the existing welding cap; the mobile terminal module can be adapted to most mainstream smartphones, without requiring operators to purchase additional special equipment, resulting in low modification cost and easy promotion and application.

[0017] The features and advantages of the present invention will be described in detail through embodiments and in conjunction with the accompanying drawings. Attached Figure Description

[0018] Figure 1 This is a system structure diagram provided in an embodiment of the present invention; Figure 2 This is a structural diagram of the wired soldering cap interaction module provided in an embodiment of the present invention; Figure 3 This is a flowchart of a time-based arbitration mechanism provided in an embodiment of the present invention; Figure 4 This is a state synchronization flowchart provided in an embodiment of the present invention.

[0019] The numbers in the diagram are: 100-Welding machine master station module; 110-Main control unit; 120-Main communication unit; 200-Wireless terminal module; 300-Wired welding cap interaction module; 310-Protective welding cap; 320-Display screen; 330-Input unit; 400-Mobile terminal module; 500-Host computer module. Detailed Implementation

[0020] See Figures 1 to 4This invention discloses a welding machine human-machine interaction system compatible with multiple types of terminals, comprising a welding machine master station module 100, which uses a welding machine host as the master station. The welding machine host integrates a main control unit 110 and a main communication unit 120. The main control unit 110 is used to process operation commands and store welding parameters, and synchronizes operating data with connected interactive terminals in real time through the main communication unit 120; a wireless terminal module 200, which is wirelessly connected to the welding machine master station module 100, and is used to send a first parameter adjustment command and synchronously display the operating data; the wireless terminal module 200 is an independent wireless handheld device; and a wired welding cap interaction module 300, which includes a protective welding cap 310. The protective welding cap 310 is wired to the welding machine master station module 100. The protective welding cap 310 includes a display screen 320 and an input unit 330. The display screen 320 synchronously displays the welding parameters, and the input unit 330 sends a second parameter adjustment command. The mobile terminal module 400 is connected to the welding machine master station module 100 via a local area network (LAN) or wide area network (WAN) communication protocol. It sends a third parameter adjustment command and synchronously displays the operating data, while also storing and managing data. The host computer module 500 is connected to the welding machine master station module 100 via a LAN or WAN communication protocol. It sends a fourth parameter adjustment command and synchronously displays the operating data, performs real-time monitoring during the welding process, and stores and analyzes the collected data.

[0021] In this embodiment, the independent wireless handheld device refers to a portable device with an independent power supply module, processing unit, and communication module, etc., and whose size and weight are suitable for operation by a person holding it with one or two hands, such as a remote control or control handle. The independent wireless handheld device is also equipped with a device display screen, which is a large screen that occupies the main area of ​​the front of the independent wireless handheld device, providing a wide field of view for information display. The independent wireless handheld device has knobs or buttons for adjusting current and voltage separately, saving parameters, and switching parameters. Rotating the knob or clicking the button sends the first parameter adjustment command. After the independent wireless handheld device is powered on, it can automatically pair and connect to the welding machine master station module 100, and can simultaneously display the current, voltage, and other parameters synchronized with the welding machine master station module 100 in real time.

[0022] In this embodiment, data transmission between the mobile terminal module 400 or the host computer module 500 and the welding machine master station module 100 is implemented based on a local area network (LAN) or wide area network (WAN) communication protocol. Specifically, the LAN communication protocol may include Ethernet, Wi-Fi, Bluetooth, etc.; the WAN communication protocol may include TCP / IP, 4G / 5G cellular network communication protocol, etc.

[0023] The wired welding cap interaction module 300 is connected to the welding machine master station module 100 via a wired cable.

[0024] In this embodiment, the wired cable is a communication carrier that transmits signals through a physical medium such as a metal conductor or optical fiber, including but not limited to industrial Ethernet cables, shielded twisted-pair cables, or optical fiber cables. This wired cable connection method provides a stable and interference-resistant wired communication link for the wired soldering cap interaction module 300.

[0025] The display screen 320 is a miniature liquid crystal display screen; the miniature liquid crystal display screen is a transflective display screen. The protective welding cap 310 has a built-in light sensor and a control unit; the light sensor and the display screen 320 are both electrically connected to the control unit; the control unit is configured to control the display screen 320 to turn off when the protective welding cap 310 is in the open state, based on the detection signal of the light sensor; and to control the display screen 320 to turn on when the protective welding cap 310 is in the closed state.

[0026] In this embodiment, the display screen 320 supports automatic brightness adjustment. The display screen 320 has a built-in sensor for real-time detection of ambient light intensity. When the ambient light is strong, the display screen 320 automatically increases its brightness to ensure that the operator can clearly see the data on the screen; when the ambient light is dim, the display screen 320 automatically decreases its brightness to avoid glare.

[0027] The input unit 330 is an adjustment knob, which is used to generate a displacement electrical signal corresponding to the rotation angle; the welding machine master station module 100 can receive the second parameter adjustment command according to the displacement electrical signal.

[0028] In this embodiment, the adjustment knob includes a knob cap and a knob connecting shaft, the knob cap being connected to an internal control circuit board via the knob connecting shaft. The main body of the adjustment knob can be cylindrical, polygonal, square, etc. The adjustment knob is configured to: switch between options such as welding current, arc voltage, and wire feed speed in response to the operator's pressing operation; and increase or decrease the value of the currently selected option in response to the operator's rotation operation.

[0029] The mobile terminal module 400 is also used to establish a process database, which contains preset process recipes; the mobile terminal module 400 is configured to respond to user selection commands and retrieve target process recipes from the process database.

[0030] The main control unit 110 includes a main control chip, which is configured to execute the operation instructions and store the welding parameters.

[0031] The welding machine master station module 100 supports simultaneous connection of multiple interactive terminals. Parameter adjustment instructions sent by any interactive terminal can be processed by the welding machine host and synchronized to all connected interactive terminals. When multiple interactive terminals send parameter adjustment instructions, the latest received parameter adjustment instruction is used as the target instruction. The target instruction is used to overwrite the stored historical parameter adjustment instructions, and the operating status of the welding machine master station module 100 is updated based on the target instruction.

[0032] The wireless terminal module 200 is connected to the welding machine master station module 100 via Wi-Fi communication technology, and the maximum communication distance of this connection is not less than 150 meters.

[0033] The mobile terminal module 400 can acquire the operating data uploaded by the welding machine master station module 100 and export the operating data generated file to an external terminal; the mobile terminal module 400 can match the collected equipment status data with a preset fault feature model, and when the matching degree exceeds a preset threshold, a prompt pop-up window will be generated on the interactive interface.

[0034] In this embodiment, the mobile terminal module 400 is specifically an application (APP) installed on a smartphone or tablet. During system operation, the APP is configured to perform high-frequency data acquisition tasks. Specifically, the timer or background service process within the APP is set to a 1-second sampling period, automatically reading the current operating parameters from the welding machine master station module 100 every 1 second. These operating parameters, after being parsed, are stored in the APP's local storage medium in the form of a time series, or displayed in real time on the APP's user interface in the form of a list.

[0035] In this embodiment, the host computer module 500 is specifically a computer communicatively connected to the welding machine master station module 100. This computer runs dedicated welding process monitoring software, which can acquire detailed operating data from the welding machine master station module 100 in real time, including welding current, voltage, wire feed speed, and working time. It can also precisely set and adjust the welding parameters. Furthermore, the computer can store historical data, facilitating in-depth process analysis and quality traceability for operators. In large-scale welding projects, operators can monitor the welding process and adjust parameters in real time from a monitoring room far from the welding site using this computer.

[0036] In actual use of this embodiment, operators can flexibly choose the interaction method according to the work scenario: In large ship hull welding operations, the welding machine master station module 100 is outside the work area. Before welding, the operator can use the independent wireless handheld device to adjust the parameters remotely without having to go back and forth. At the same time, real-time monitoring can be performed on the host computer module 500. During the welding process, the operator wears the protective welding helmet 310 and can view the current parameters at any time through the display screen 320 inside the protective welding helmet 310. When adjustments are needed, the operator can simply turn the adjustment knob without stopping the work and removing the protective welding helmet 310. After welding is completed, the parameter record of this operation can be exported through the mobile terminal module 400 for quality inspection and archiving.

[0037] Working principle: In this embodiment, the welding machine master station module 100 adopts a multi-terminal concurrent control architecture. The welding machine master station module 100, as the core control node, establishes communication connections with multiple control terminals, including the wireless terminal module 200, the wired welding cap interaction module 300, the mobile terminal module 400, and the host computer module 500. Each control terminal is configured to operate independently and can send parameter adjustment commands containing welding parameters to the welding machine master station module 100 at any time.

[0038] Specifically, when any control terminal detects an operator's action, it generates a corresponding parameter adjustment command. When multiple terminals send parameter adjustment commands simultaneously, to ensure timing accuracy, each control terminal obtains the current system time as a timestamp when generating the parameter adjustment command, and appends the timestamp to the parameter adjustment command. The parameter adjustment command carrying the timestamp is then sent to the welding machine master station module 100.

[0039] During operation, the welding machine master station module 100 monitors and receives parameter adjustment commands from various control terminals in real time. When the welding machine master station module 100 simultaneously receives multiple parameter adjustment commands from different control terminals within a preset time window, the following time-based arbitration mechanism is triggered: Step S1: The welding machine master station module 100 parses the parameter adjustment commands and extracts the timestamps carried in each parameter adjustment command; Step S2: The welding machine master station module 100 compares the values ​​of each timestamp and determines the parameter adjustment instruction with the largest timestamp value, i.e. the latest or newest generation time, as the target instruction. Step S3: The welding machine master station module 100 executes the target instruction to update the current welding parameters, while overwriting the other parameter adjustment instructions with earlier timestamps.

[0040] The duration of the preset time window can be set according to the latency characteristics of the communication network, such as 10 milliseconds, 20 milliseconds, or 50 milliseconds.

[0041] The welding machine master station module 100 also has a global status synchronization mechanism. As a global status manager, the welding machine master station module 100 establishes a two-way communication link with each control terminal. When the welding machine master station module 100 executes an instruction issued by any terminal, it will synchronize the updated system status to all online control terminals in real time to achieve synchronized display of multi-terminal interfaces.

[0042] During operation, when the welding machine master station module 100 receives a parameter adjustment command from a control terminal and completes the corresponding parameter adjustment, the following state synchronization process is triggered: Step T1: The welding machine master station module 100 acquires the latest system operating status data; Step T2: The welding machine master station module 100 encapsulates the system operation status data into a synchronization data packet and sends the synchronization data packet to all bound control terminals through a preset broadcast protocol or multicast protocol; Step T3: After receiving the synchronization data packet, each control terminal parses the system operation status data in it and refreshes its local display interface, so that multiple control terminals present consistent operation feedback.

[0043] Specifically, each control terminal is configured to monitor synchronization data packets from the welding machine master station module 100 in real time. Regardless of which control terminal the operator is currently operating, as long as the status of the welding machine master station module 100 changes, all control terminals can passively receive the latest synchronization data packets and automatically update their local display interfaces without requiring manual refresh by the operator.

[0044] The above embodiments are illustrative of the present invention and are not intended to limit the present invention. Any simple modifications to the present invention are within the scope of protection of the present invention.

Claims

1. A welding machine human-machine interaction system compatible with multiple types of terminals, characterized in that: The system includes a welding machine master station module, which uses the welding machine host as the master station. The welding machine host integrates a main control unit and a main communication unit. The main control unit processes operation commands and stores welding parameters, and synchronizes operating data in real time to a connected interactive terminal through the main communication unit. A wireless terminal module is wirelessly connected to the welding machine master station module and is used to send a first parameter adjustment command and synchronously display the operating data. The wireless terminal module is an independent wireless handheld device. A wired welding cap interaction module includes a protective welding cap, which is wiredly connected to the welding machine master station module. The protective welding cap includes a display screen and an input unit. The display screen synchronously displays the welding parameters, and the input unit sends a second parameter adjustment command. A mobile terminal module is connected to the welding machine master station module via a local area network (LAN) or wide area network (WAN) communication protocol and is used to send a third parameter adjustment command and synchronously display the operating data, while also performing data storage and process management. The host computer module is connected to the welding machine master station module via a local area network or wide area network communication protocol. It is used to send the fourth parameter adjustment command and display the running data synchronously, monitor the welding process in real time, and store and analyze the collected data.

2. The welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The wired welding cap interaction module is connected to the welding machine master station module via a wired cable.

3. The welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The display screen is a miniature liquid crystal display screen; the miniature liquid crystal display screen is a transflective display screen.

4. The welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The protective welding cap has a built-in light sensor and a control unit; the light sensor and the display screen are both electrically connected to the control unit; the control unit is configured to control the display screen to turn off when the protective welding cap is in the open state, based on the detection signal of the light sensor; and to control the display screen to turn on when the protective welding cap is in the closed state.

5. A welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The input unit is an adjustment knob, which is used to generate a displacement electrical signal corresponding to the rotation angle; the welding machine master station module can receive the second parameter adjustment command according to the displacement electrical signal.

6. The welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The mobile terminal module is also used to establish a process database, which contains preset process recipes; the mobile terminal module is configured to respond to user selection commands and retrieve target process recipes from the process database.

7. A welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The main control unit includes a main control chip, which is configured to execute the operation instructions and store the welding parameters.

8. A welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The welding machine master station module supports simultaneous connection of multiple interactive terminals. Parameter adjustment instructions sent by any interactive terminal are processed by the welding machine host and synchronized to all connected interactive terminals. When multiple interactive terminals send parameter adjustment instructions, the latest received parameter adjustment instruction is used as the target instruction. The target instruction is used to overwrite the stored historical parameter adjustment instructions, and the operating status of the welding machine master station module is updated based on the target instruction.

9. A welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The wireless terminal module is connected to the welding machine main station module via WiFi communication technology, and the maximum communication distance of this connection is not less than 150 meters.

10. A welding machine human-machine interaction system compatible with multiple types of terminals according to claim 1, characterized in that: The mobile terminal module can acquire the operating data uploaded by the welding machine master station module and export the operating data generated file to an external terminal; the mobile terminal module can match the collected equipment status data with a preset fault feature model, and when the matching degree exceeds a preset threshold, a prompt pop-up window will be generated on the interactive interface.

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