Dual intelligent gas saving control device for pipeline gas shielded welding process

Abstract

The utility model discloses a dual intelligent gas saving control device for a pipeline gas shielded welding process, which relates to the technical field of welding process energy conservation and comprises a current sensor, a power supply conversion module, a controller, a gas flow meter I, a flow regulation and control module I, a gas flow meter II, a flow regulation and control module II and a communication component. The gas flow meter I and the flow regulation and control module I are connected into a gas path of the welding gun gas pipe in series, the controller controls the opening degree of the flow regulation and control module I according to the type of shielding gas, welding current and the shielding gas flow detected by the gas flow meter I, and then the shielding gas flow of the welding gun gas pipe is automatically adjusted. The gas flow meter II and the flow regulation and control module II are connected in series into a pipeline inflation gas path, and the controller controls the opening degree of the flow regulation and control module II according to the type of shielding gas, the pipe diameter of the welding pipeline and the shielding gas flow detected by the gas flow meter II, so that the inflation flow leading to the pipeline is automatically adjusted; and dual intelligent gas saving of different kinds of gas shield welding under the pipeline welding procedure is achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of energy saving in welding process, and more specifically to a dual intelligent gas saving control device for pipeline gas protection welding process. Background Art

[0002] The gas shielded welding process is a welding technology that passes shielding gases such as argon and carbon dioxide around the arc welding during welding, isolates the air outside the welding area to prevent oxidation of the welding area, and uses high current to melt the welding material into a liquid on the welded substrate to form a molten pool, so that the welded metal and the welding material can achieve metallurgical bonding. The required flow rate of shielding gas is positively correlated with the welding current. When it comes to pipeline welding, there are usually two gas sources (from gas cylinders or pipeline gas), each of which is equipped with a manual regulating valve. One is to pass shielding gas into the pipeline in advance before welding to prevent oxidation of the welding area inside the pipeline, and the other is connected to the welding gun gas pipe to protect the welding area outside the pipeline. The two-way manual regulating valve is used for welding operators to adjust the gas shielding flow according to the pipe diameter, working conditions, etc.

[0003] There is a lot of waste of shielding gas in this welding process, mainly:

[0004] 1) The protective gas leading to the inside of the pipeline cannot automatically adjust the gas flow according to the pipe diameter, nor can it automatically start and stop according to welding needs. The continuous ventilation time is too long, resulting in a large amount of waste of protective gas.

[0005] 2) Although the other shielding gas leading to the welding gun gas pipe can be controlled by the welding gun handle switch, the gas flow cannot be automatically adjusted according to the actual welding current, resulting in waste of outer welding shielding gas. Utility Model Content

[0006] In order to overcome the defects existing in the above-mentioned prior art, the purpose of the utility model is to provide a dual intelligent gas saving control device for pipeline gas shielded welding process, so as to solve the problem of large amount of shielding gas waste existing in the above-mentioned prior art. During the pipeline inflation process, the utility model can not only realize the automatic start and stop of the shielding gas in the pipeline according to the welding needs, but also automatically adjust the inflation flow to the pipeline according to the size of the pipe diameter; during the welding process, the shielding gas flow of the welding gun air pipe can also be automatically adjusted according to the welding current size and the type of shielding gas, so as to realize the dual intelligent gas saving of different types of gas shielded welding in the pipeline welding process, and at the same time, it is equipped with a variety of communication modules to realize convenient communication interaction with third-party equipment or systems.

[0007] In order to achieve the above objectives, the technical solution adopted by the utility model is:

[0008] A dual intelligent gas saving control device for pipeline gas shielded welding process, comprising a control box, a current sensor, and a power conversion module, a controller, a gas flow meter I, a flow control module I, a gas flow meter II, a flow control module II and a communication component assembled in the control box;

[0009] The controller is electrically connected to the current sensor, power conversion module, gas flow meter I, flow control module I, gas flow meter II, flow control module II and communication component respectively, and the current sensor is connected to the welding cable to collect welding current;

[0010] The gas flow meter I and the flow control module I are connected in series to the gas path of the welding gun gas pipe, and the controller controls the opening of the flow control module I according to the type of shielding gas, welding current and shielding gas flow detected by the gas flow meter I;

[0011] The gas flow meter II and the flow control module II are connected in series to the pipeline charging gas path, and the controller controls the opening of the flow control module II according to the type of shielding gas, the diameter of the welding pipeline and the shielding gas flow detected by the gas flow meter II.

[0012] Preferably, the controller includes a processor module, a storage module, a communication module, an analog input module and an analog output module;

[0013] The processor module is electrically connected to the storage module, the analog input module and the analog output module respectively, the storage module is electrically connected to the communication module, the communication module is electrically connected to the communication component, the analog input module is electrically connected to the current sensor, the gas flow meter I and the gas flow meter II respectively, and the analog output module is electrically connected to the flow control module I and the flow control module II respectively.

[0014] Preferably, the communication component includes a LoRa module, a cellular module and a wifi module, and the LoRa module, the cellular module and the wifi module are all electrically connected to the communication module.

[0015] Preferably, the control box is provided with a touch screen, and the touch screen is electrically connected to the controller.

[0016] Preferably, a surge protector is also installed in the control box, and the surge protector is connected in parallel to an external power supply.

[0017] Preferably, a partition is provided in the control box, and the partition divides the interior of the control box into an upper chamber and a lower chamber. The power conversion module, controller and communication component are located in the upper chamber, and the gas flow meter I, flow control module I, gas flow meter II and flow control module II are located in the lower chamber.

[0018] Preferably, the current sensor is a handheld Hall current sensor; the gas flowmeter I and the gas flowmeter II are both miniature vortex flowmeters; the flow control module I and the flow control module II are both electromagnetic proportional valves.

[0019] Preferably, the inlet end of the gas path of the welding gun gas pipe is connected to the welding gas source I, and the outlet end is connected to the welding gun.

[0020] Preferably, the inlet end of the pipeline inflation gas circuit is connected to the welding gas source II, and the outlet end is connected to the inner side of the welding pipeline.

[0021] Preferably, the communication module has an RS232 / 485 interface, an Ethernet interface or a CAN interface.

[0022] Beneficial effects of the utility model:

[0023] The utility model provides a dual intelligent gas saving control device for a pipeline gas shielded welding process, wherein a gas flow meter I and a flow control module I are connected in series to the gas path of a welding gun gas pipe, and a controller controls the opening of the flow control module I according to the type of shielding gas, welding current and the shielding gas flow detected by the gas flow meter I, thereby automatically adjusting the shielding gas flow of the welding gun gas pipe; a gas flow meter II and a flow control module II are connected in series to the pipeline charging gas path, and the controller controls the opening of the flow control module II according to the type of shielding gas, the diameter of the welding pipeline and the shielding gas flow detected by the gas flow meter II, thereby automatically adjusting the charging flow to the pipeline, thereby realizing dual intelligent gas saving for different types of gas shielded welding in the pipeline welding process.

[0024] The dual intelligent gas saving control device for pipeline gas shielded welding process provided by the utility model is equipped with multiple communication modules to realize convenient communication interaction with third-party equipment or systems. In the pipeline gas shielded welding process, the device has a more obvious gas saving effect on the shielding gas, especially for the scene where gas protection is required in the pipeline, welding and pipeline assembly are frequently cross-operated, and the weld is short. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the dual intelligent air-saving control device of the utility model;

[0026] Figure 2 This is the internal schematic diagram of the dual intelligent air-saving control device of the utility model;

[0027] Figure 3 This is an external schematic diagram of the dual intelligent air-saving control device of the utility model;

[0028] Reference numerals:

[0029] 1. Control box; 2. Current sensor; 3. Power conversion module; 4. Controller; 5. Gas flow meter I; 6. Flow control module I; 7. Gas flow meter II; 8. Flow control module II; 9. LoRa module; 10. Cellular module; 11. Wi-Fi module; 12. Touch screen; 13. Surge protector; 14. Partition.

[0030] A, B, C, D, E, F, H, I, J, and K are interfaces. DETAILED DESCRIPTION

[0031] The concept, specific structure and technical effects of the present invention will be clearly and completely described below in combination with the embodiments and drawings to fully understand the purpose, features and effects of the present invention.

[0032] A dual intelligent gas saving control device for pipeline gas shielded welding process, such as Figure 1 , Figure 2 and Figure 3 As shown, it includes a control box 1, a current sensor 2, and a power conversion module 3, a controller 4, a gas flow meter I5, a flow control module I6, a gas flow meter II7, a flow control module II8 and a communication component assembled in the control box 1;

[0033] The controller 4 is electrically connected to the current sensor 2, the power conversion module 3, the gas flow meter I5, the flow control module I6, the gas flow meter II7, the flow control module II8 and the communication component respectively, and the current sensor 2 is connected to the welding cable to collect the welding current;

[0034] The gas flow meter Ⅰ5 and the flow control module Ⅰ6 are connected in series to the gas path of the welding gun gas pipe. The controller 4 controls the opening of the flow control module Ⅰ6 according to the type of shielding gas, welding current and shielding gas flow detected by the gas flow meter Ⅰ5.

[0035] The gas flow meter II7 and the flow control module II8 are connected in series to the pipeline charging gas circuit. The controller 4 controls the opening of the flow control module II8 according to the type of shielding gas, the diameter of the welding pipeline and the shielding gas flow detected by the gas flow meter II7.

[0036] like Figure 1 As shown, the inlet end of the welding gun gas pipe gas circuit is connected to the welding gas source I, and the outlet end is connected to the welding gun. The inlet end of the pipeline inflation gas circuit is connected to the welding gas source II, and the outlet end is connected to the inner side of the welding pipeline.

[0037] In this embodiment, the current sensor 2 is a handheld Hall current sensor, which can be conveniently inserted into the cable of the object to be measured through an operating handle to detect the current of the device. The output current is generally 4-20mA. Figure 1-Figure 3As shown, the current on the welding cable (+) is collected by a handheld Hall current sensor and then converted into a 4-20mA analog signal through interface (B), and then connected to the controller analog input module.

[0038] The power conversion module 3 is used to convert 220V AC power into 24V DC power to provide DC power for the components in the energy conservation control device. Figure 1-Figure 3 As shown, the device obtains power by connecting to an external power supply via a power interface (A), and supplies power to the controller 4, gas flow meter I5, flow control module I6, gas flow meter II7, flow control module II8 and communication components in the device through a power conversion module 3.

[0039] like Figure 1 As shown, the controller 4 includes a processor module, a storage module, a communication module, an analog input module and an analog output module; the processor module is electrically connected to the storage module, the analog input module and the analog output module respectively, the storage module is electrically connected to the communication module, the communication module is electrically connected to the communication component, the analog input module is electrically connected to the current sensor 2, the gas flow meter I5, and the gas flow meter II7 respectively, and the analog output module is electrically connected to the flow control module I6 and the flow control module II8 respectively.

[0040] In this embodiment, the controller is generally a PLC or other embedded controller, single-chip microcomputer, etc., and mainly includes a processor module, a storage module, a communication module, an analog input module and an analog output module. The analog input module supports the analog signal access of 4-20mA, 0-10V or ±5V of external devices. The analog output module provides 4-20mA, 0-10V or ±5V analog signal output for external devices. The communication module generally has an RS232 / 485 interface, an Ethernet interface, or a CAN interface, and is mainly used for communication connection with external devices.

[0041] In this embodiment, the gas flowmeter I5 and the gas flowmeter II7 are both micro vortex flowmeters for detecting gas media such as argon and carbon dioxide.

[0042] In this embodiment, the flow control module I6 and the flow control module II8 are both electromagnetic proportional valves, and are provided with different power supply currents or voltages by the control circuit to drive the electromagnetic coil to generate magnetic force, overcome the tension of the spring, control the opening of the throttle port, and control the flow rate of the fluid. A general proportional electromagnetic valve is mainly composed of a valve body, a spring, an electromagnetic coil, a sealing material, etc.

[0043] like Figure 1 and 2 As shown, the gas flow meter Ⅰ5 can be connected to the gas outlet of the welding gas source Ⅰ through the interface (C), and the 4-20mA flow signal is connected to the controller analog input module.

[0044] like Figure 1 and 2 As shown, the flow control module I6 receives the control signal (4-20mA) from the analog output module of the controller, adjusts the throttle opening of the proportional valve, and then connects to the air inlet of the welding gun air pipe through the interface (D).

[0045] like Figure 1 and 2 As shown, the gas flow meter II 7 can be connected to the gas outlet of the welding gas source II through the interface (E), and the 4-20mA flow signal is connected to the controller analog input module.

[0046] like Figure 1 and 2 As shown, the flow control module II 8 receives the control signal (4-20mA) from the analog output module of the controller, adjusts the throttle opening of the proportional valve, and then connects to the air inlet inside the pipe to be welded through the interface (F).

[0047] like Figure 1 and 2 As shown, the communication component includes a LoRa module 9, a cellular module 10 and a wifi module 11, and the LoRa module 9, the cellular module 10 and the wifi module 11 are all electrically connected to the communication module.

[0048] In this embodiment, the LoRa module 9 is a wireless communication module based on the LoRa technology, which uses an ultra-narrow bandwidth and a long spread spectrum sequence to achieve long-distance low-power communication between IoT devices. It mainly includes a LoRa chip, an antenna, and a power management circuit. Figure 1 and Figure 2 As shown, the LoRa module 9 is connected to the communication module of the controller through the RS485 interface, converted into a lora signal, and realizes wireless communication with external devices by installing an antenna.

[0049] In this embodiment, the cellular module 10 is a communication module that integrates standardized chips and other electronic components so that the device can access the mobile network according to different network standards (4G or 5G). Figure 1 and Figure 2 As shown, the cellular module 10 is connected to the communication module of the controller via RS485, converted into 4G / 5G signals, and realizes wireless communication with external devices by installing antennas.

[0050] In this embodiment, the wifi module 11 is an industrial-grade integrated 802.11 b / g / n communication module, which enables the device to quickly access the WIFI wireless network. Figure 1 and Figure 2As shown, the wifi module 11 is connected to the communication module of the controller via RS485, converted into a wifi signal, and realizes wireless communication with external devices by installing an antenna.

[0051] like Figure 1 and 3 As shown, a touch screen 12 is provided on the control box 1 , and the touch screen 12 is electrically connected to the controller 4 .

[0052] In this embodiment, the touch screen is an inductive liquid crystal display device that can receive input signals such as contacts. When the graphic button on the screen is touched, the tactile feedback system on the screen can communicate and interact with various external devices according to pre-programmed programs. The touch screen can be connected to the controller via an Ethernet or RS485 interface, and is mainly used to display parameters such as the current and gas flow of the welding machine, as well as the selection of parameters of different types of shielding gas and the setting of the adjustment coefficient.

[0053] like Figure 2 As shown, a surge protector 13 is also installed in the control box 1, and the surge protector 13 is connected in parallel to the external power supply.

[0054] A surge protector is an electronic device that provides safety protection for electronic equipment, instruments, etc. When a spike current or voltage suddenly occurs in an electrical circuit or communication line due to external interference, the surge protector can conduct and shunt the current in a very short time, thereby preventing the surge from damaging other devices in the circuit.

[0055] The surge protector is connected in parallel to an external power supply (usually AC 220VAC), and is mainly used to absorb and decompose voltage surges, limit overvoltage, and discharge surge currents caused by welding machine startup, etc., to protect the device.

[0056] A partition 14 is provided in the control box 1, which divides the interior of the control box 1 into an upper chamber and a lower chamber. The power conversion module 3, the controller 4 and the communication component are located in the upper chamber, and the gas flow meter I5, the flow control module I6, the gas flow meter II7 and the flow control module II8 are located in the lower chamber.

[0057] In order to better understand the present invention, the following is a complete description of the working principle of the present invention:

[0058] Before welding, first select the corresponding type of shielding gas (such as argon, carbon dioxide, mixed gas, etc.), the diameter of the pipe to be welded and other parameters on the touch screen 12; the dual intelligent gas-saving control device of the pipeline gas shielding welding process automatically adjusts the opening of the flow control module Ⅱ8 according to the diameter of the pipe to be welded and the type of shielding gas, fills the shielding gas into the inside of the pipe to be welded, and collects the shielding gas flow in real time through the gas flow meter Ⅱ7, and then adjusts the opening of the flow control module Ⅱ8 according to the real-time collected value.

[0059] After the inside of the pipeline is filled with shielding gas, start the welding machine and begin welding. At this time, the flow control module I6 is opened first, and the shielding gas is filled around the outside of the pipeline weld through the built-in gas pipe of the welding gun. The controller calculates the gas flow required for the corresponding welding according to the shielding gas type selected on the touch screen, the welding current collected by the current sensor, the shielding gas flow collected by the gas flow meter I5 and other parameters, and outputs an analog signal to the flow control module I6 to adjust the valve opening, thereby automatically adjusting the shielding gas flow.

[0060] After the welding of the pipe section is completed, when the gas saving control device detects that the welding current is 0, it delays for a few seconds and automatically closes the flow control module II8, stops filling the pipeline with protective gas, and realizes the pipeline protective gas saving.

[0061] At the same time, the device can communicate and interact with external devices through LoRa module 9, cellular module 10 and wifi module 11 in LoRa / wifi / 4G / 5G and other ways according to actual conditions.

[0062] The implementation methods of the present invention are described in detail above, but the present invention is not limited to the described embodiments. Those skilled in the art may make various equivalent modifications or substitutions without violating the spirit of the present invention, and these equivalents or substitutions are all included in the scope defined by the claims of the present invention.

Claims

1. A dual intelligent gas saving control device for pipeline gas shielded welding process, characterized in that: It comprises a control box (1), a current sensor (2), and a power conversion module (3), a controller (4), a gas flow meter I (5), a flow control module I (6), a gas flow meter II (7), a flow control module II (8) and a communication component, which are assembled in the control box (1); The controller (4) is electrically connected to the current sensor (2), the power conversion module (3), the gas flow meter I (5), the flow control module I (6), the gas flow meter II (7), the flow control module II (8) and the communication component respectively, and the current sensor (2) is connected to the welding cable to collect the welding current; The gas flow meter I (5) and the flow control module I (6) are connected in series to the gas path of the welding gun gas pipe, and the controller (4) controls the opening of the flow control module I (6) according to the type of shielding gas, welding current and shielding gas flow detected by the gas flow meter I (5); The gas flow meter II (7) and the flow control module II (8) are connected in series to the pipeline charging gas path, and the controller (4) controls the opening of the flow control module II (8) according to the type of shielding gas, the diameter of the welding pipeline and the shielding gas flow detected by the gas flow meter II (7).

2. The dual intelligent air-saving control device according to claim 1, characterized in that: The controller (4) comprises a processor module, a storage module, a communication module, an analog input module and an analog output module; The processor module is electrically connected to the storage module, the analog input module and the analog output module respectively; the storage module is electrically connected to the communication module; the communication module is electrically connected to the communication component; the analog input module is electrically connected to the current sensor (2), the gas flow meter I (5) and the gas flow meter II (7) respectively; and the analog output module is electrically connected to the flow control module I (6) and the flow control module II (8) respectively.

3. The dual intelligent air-saving control device according to claim 2, characterized in that: The communication component comprises a LoRa module (9), a cellular module (10) and a wifi module (11); the LoRa module (9), the cellular module (10) and the wifi module (11) are all electrically connected to the communication module.

4. The dual intelligent air-saving control device according to claim 1, characterized in that: The control box (1) is provided with a touch screen (12), and the touch screen (12) is electrically connected to the controller (4).

5. The dual intelligent air-saving control device according to claim 1, characterized in that: The control box (1) is also equipped with a surge protector (13), and the surge protector (13) is connected in parallel to an external power supply.

6. The dual intelligent air-saving control device according to claim 1, characterized in that: A partition (14) is provided in the control box (1), and the partition (14) divides the interior of the control box (1) into an upper chamber and a lower chamber. The power conversion module (3), the controller (4) and the communication component are located in the upper chamber, and the gas flow meter I (5), the flow control module I (6), the gas flow meter II (7), and the flow control module II (8) are located in the lower chamber.

7. The dual intelligent air-saving control device according to claim 1, characterized in that: The current sensor (2) is a handheld Hall current sensor; the gas flow meter I (5) and the gas flow meter II (7) are both miniature vortex flow meters; and the flow control module I (6) and the flow control module II (8) are both electromagnetic proportional valves.

8. The dual intelligent air-saving control device according to claim 1, characterized in that: The inlet end of the gas path of the welding gun gas pipe is connected to the welding gas source I, and the outlet end is connected to the welding gun.

9. The dual intelligent air-saving control device according to claim 1, characterized in that: The inlet end of the pipeline inflation gas circuit is connected to the welding gas source II, and the outlet end is connected to the inner side of the welding pipeline.

10. The dual intelligent air-saving control device according to claim 2, characterized in that: The communication module has an RS232 / 485 interface, an Ethernet interface or a CAN interface.

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