Welding wire monitoring system and welding wire conveying equipment

Abstract

The utility model discloses a welding wire monitoring system and welding wire conveying equipment, the welding wire monitoring system comprises a first welding wire assembly and a second welding wire assembly, welding wires are accommodated in the first welding wire assembly and the second welding wire assembly, and the welding wire monitoring system further comprises a detection device, the two detection ends of the detection device are arranged on the first welding wire assembly and the second welding wire assembly respectively, an alarm device is electrically connected between the two detection ends, when the welding wire consumption of the first welding wire assembly and / or the second welding wire assembly is insufficient, the alarm device gives an alarm and prompts, and the detection device is electrically connected to a digital display. And the digital display can digitalize the welding wire consumption detected by the detection device. According to the welding wire monitoring system, multi-pole welding wire conveying is achieved, in addition, the detection device can feed back the welding wire conditions in the first welding wire assembly and the second welding wire assembly to the digital displayer, an alarm can be given when the using amount of any welding wire assembly is insufficient, and therefore the purpose of monitoring the using amount of the welding wires in real time is achieved.

Description

Technical Field

[0001] This utility model belongs to the field of welding wire monitoring, and in particular relates to a welding wire monitoring system and welding wire conveying equipment. Background Technology

[0002] With the increasing digitalization of industrial welding, large steel structure welding is being carried out under long-span gantry structures. Welding materials are a crucial factor affecting welding quality and efficiency. Currently, due to the large span of the welding robot workstation, manual monitoring of welding material replacement is not timely, leading to wasted welding materials or arc interruptions, which greatly affects construction costs and weld quality control.

[0003] Therefore, it is urgent to design a welding wire monitoring system to achieve automated monitoring of welding wire delivery. Utility Model Content

[0004] To address the technical problem mentioned in the background art, where the large spatial span of the welding robot workstation leads to untimely manual monitoring of welding material replacement, resulting in wasted welding materials or welding arc interruption, a welding wire monitoring system and welding wire conveying equipment are provided to solve the aforementioned problems in the prior art.

[0005] To achieve the above objectives, the specific technical solution of this utility model for a welding wire monitoring system and a welding wire conveying device is as follows:

[0006] A welding wire monitoring system includes a first welding wire assembly and a second welding wire assembly, both of which contain welding wire. It also includes a detection device with two probes respectively located on the first and second welding wire assemblies. An alarm device is electrically connected between the two probes. When the amount of welding wire in the first and / or second welding wire assemblies is insufficient, the alarm device will issue an alarm and prompt. The detection device is electrically connected to a digital display, which digitizes the amount of welding wire measured by the detection device.

[0007] Furthermore, the detection device includes a metal sensor and a weighing module. The two sensing ends of the metal sensor are respectively located inside the first welding wire assembly and the second welding wire assembly. The two sensing ends of the weighing module are respectively located at the bottom of the first welding wire assembly and the second welding wire assembly. Both the metal sensor and the weighing module are connected to a digital display. The weighing module can monitor the weight of the first welding wire assembly and the second welding wire assembly.

[0008] Furthermore, the volume of the first welding wire assembly is larger than that of the second welding wire assembly.

[0009] Furthermore, the alarm device includes two audible and visual alarm lights, which are electrically connected to the weighing module and the metal sensor, respectively, to provide flashing alarms and prompts.

[0010] Furthermore, the alarm device also includes an instant stop switch, which is electrically connected to any of the audible and visual alarm lights. When the audible and visual alarm light flashes, the instant stop switch can disconnect the circuit containing the audible and visual alarm light.

[0011] Furthermore, the alarm device also includes an instant stop switch, which is electrically connected to two audible and visual alarm lights. When either audible or visual alarm light flashes, the instant stop switch can disconnect the circuit.

[0012] Furthermore, the welding wire monitoring system also includes two speed sensors, which are respectively installed at the wire exit ends of the first welding wire assembly and the second welding wire assembly, and are used to monitor the wire exit speed of the first welding wire assembly and the second welding wire assembly.

[0013] Furthermore, the speed sensor includes two sets of sensor rollers, which are spaced apart. The welding wire can extend between the two sets of sensor rollers and slide out of the first or second welding wire assembly relative to the sensor rollers. Each sensor roller assembly is provided with at least one sensor roller, which can detect the wire speed by its own rotational speed.

[0014] Furthermore, both sets of sensor rollers include several spaced-apart sensor rollers, and the two sets of sensor rollers are staggered.

[0015] A welding wire feeding device utilizes the aforementioned welding wire monitoring system.

[0016] The welding wire monitoring system of this utility model has the following advantages: the welding wire monitoring system sets up two welding wire integrations with different volumes to realize multi-pole welding wire feeding respectively. In addition, the detection device can feed back the welding wire status inside the first welding wire integration and the second welding wire integration to the digital display. Furthermore, an alarm will be triggered if the amount of welding wire in either welding wire integration is insufficient, thereby achieving the purpose of real-time monitoring of welding wire usage.

[0017] The welding wire feeding device of this utility model has the following advantages: the welding wire feeding device can monitor the amount of welding wire in real time, avoiding the waste of welding materials or welding arc interruption caused by untimely replacement of welding materials due to manual monitoring, which greatly affects the control of construction costs and weld quality. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the welding monitoring system of this utility model;

[0019] Figure 2 This is a circuit diagram of the welding monitoring system of this utility model;

[0020] Figure 3 for Figure 1 The structural diagram at point A in the diagram.

[0021] Explanation of markings in the diagram:

[0022] 1. First welding wire integration;

[0023] 2. Second welding wire integration; 21. Welding wire spool cover;

[0024] 3. Metal sensor; 31. Metal sensor sensing end;

[0025] 4. Digital display;

[0026] 5. Weighing module; 51. Weighing sensor; 52. Error corrector;

[0027] 6. Alarm device; 61. Audible and visual alarm light; 62. Instant stop switch;

[0028] 7. Speed ​​sensor; 71. Sensor roller assembly; 711. Sensor roller;

[0029] 8. Power supply; 9. Transformer. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0031] Those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of this invention and form different embodiments. For example, in the claims, any of the claimed embodiments can be used in any combination.

[0032] The following is a reference to the appendix. Figure 1 To be continued Figure 3 This invention describes the welding wire monitoring system and welding wire conveying equipment.

[0033] This utility model provides a welding wire monitoring system, which also includes a detection device. The two detection ends of the detection device are respectively set on the first welding wire integration 1 and the second welding wire integration 2. An alarm device is electrically connected between the two detection ends. When the welding wire quantity of the first welding wire integration 1 and / or the second welding wire integration 2 is insufficient, the alarm device 6 will issue an alarm and prompt. The detection device is electrically connected to a digital display 4, which can digitize the welding wire quantity measured by the detection device.

[0034] The welding wire monitoring system uses two welding wire integrations with different volumes to deliver multi-pole welding wires. In addition, the detection device can feed back the welding wire status inside the first welding wire integration 1 and the second welding wire integration 2 to the digital display 4. Furthermore, an alarm will be triggered if the amount of welding wire in either welding wire integration is insufficient, thereby achieving the purpose of real-time monitoring of welding wire usage.

[0035] Specifically, the detection device includes a metal sensor 3 and a weighing module 5. The two sensing ends 31 of the metal sensor 3 are respectively disposed inside the first welding wire integration 1 and the second welding wire integration 2. The two sensing ends of the weighing module 5 are respectively disposed at the bottom of the first welding wire integration 1 and the second welding wire integration 2. Both the metal sensor 3 and the weighing module 5 are connected to the digital display 4. The weighing module 5 can monitor the weight of the first welding wire integration 1 and the second welding wire integration 2.

[0036] Optionally, the volume of the first welding wire assembly 1 is larger than that of the second welding wire assembly 2. The first welding wire assembly 1 is configured as a welding wire hopper, the second welding wire assembly 2 is configured as a disc, and the disc welding wire assembly is provided with a welding wire disc cover 21 for providing protection for the welding wire.

[0037] Furthermore, the welding wire monitoring system also includes a weighing module 5. The two sensing ends of the weighing module 5 are respectively located at the bottom of the first welding wire integration 1 and the second welding wire integration 2, and the transmission end is connected to the digital display 4 to monitor the weight of the first welding wire integration 1 and the second welding wire integration 2.

[0038] In this embodiment, both sensing ends of the weighing module 5 and the metal sensor 3 are placed on the lower side of the welding wire spool cover 21 and the welding wire drum. When the welding wire decreases, both sensing ends of the weighing module 5 and the metal sensor 3 can move slightly to measure the remaining amount of welding wire.

[0039] Specifically, the weighing module 5 includes a weighing sensor 51 and an error corrector 52. The weighing sensor 51 is used to measure the weight of the first welding wire assembly 1 and the second welding wire assembly 2, and the error corrector 52 is used to correct measurement errors. In this embodiment, the error corrector 52 is configured as the aforementioned metal sensor 3 to avoid large measurement errors caused by excessive weight of the first welding wire assembly 1 or the second welding wire assembly 2. Furthermore, since the metal sensor 3 is more sensitive, it is connected in parallel with the weighing sensor 51 to compensate for the large error.

[0040] Furthermore, the welding wire monitoring system also includes an alarm device 6, which is installed inside the bracket and electrically connected to the digital display 4 for alarm and notification purposes.

[0041] Furthermore, the alarm device 6 includes two audible and visual alarm lights 61, which are electrically connected to the weighing module 5 and the metal sensor 3 respectively, for realizing flashing alarm and prompt.

[0042] Specifically, when the remaining amount of welding wire reaches the limit, the audible and visual alarm light 61 turns yellow, and at this time, the replenishment of welding wire is stopped; when the remaining amount of welding wire is lower than the minimum measurement value of the weighing module 5, the audible and visual alarm light 61 turns red, and at this time, the operator can disconnect the circuit and replenish the welding wire to the first welding wire integration 1 or the second welding wire integration 2.

[0043] In this embodiment, the alarm device 6 further includes an instant stop switch 62, which is electrically connected to any one of the audible and visual alarm lights 61. When the audible and visual alarm light 61 flashes, the instant stop switch 62 disconnects the circuit containing the audible and visual alarm light 61. In another embodiment, the alarm device 6 also includes an instant stop switch 62, which is electrically connected to two audible and visual alarm lights 61. When either audible and visual alarm light 61 flashes, the instant stop switch 62 disconnects the circuit. Specifically, when the welding material is exhausted, the instant stop switch 62 opens to disconnect the circuit. When the welding wire is replenished and the audible and visual alarm light 61 turns yellow, the instant stop switch 62 closes, achieving automatic reset.

[0044] Furthermore, the welding wire monitoring system also includes two speed sensors 7, which are respectively located at the wire exit ends of the first welding wire assembly 1 and the second welding wire assembly 2, and are used to monitor the wire exit speed of the first welding wire assembly 1 and the second welding wire assembly 2.

[0045] Furthermore, the speed sensor 7 includes two sets of sensor roller groups 71, which are spaced apart. The welding wire can extend between the two sets of sensor roller groups 71 and slide out of the first welding wire assembly 1 or the second welding wire assembly 2 relative to the sensor roller group 71. Each sensor roller group 71 is provided with at least one sensor roller 711, and the sensor roller 711 can detect the wire speed by its own rotation speed.

[0046] In some embodiments, the sensor roller 711 is configured as a linear velocity sensor roller, which is made of soft plastic, and the inlet and outlet diameters of the velocity sensor 7 are slightly larger than the diameter of the roller to maximize space utilization. In addition, the velocity sensor 7 measures the linear velocity by friction between the roller and the welding wire. The other rollers can be movable pulleys with the function of straightening the welding wire, or fixed pulleys that can be rotatably mounted on the housing of the velocity sensor 7. No specific limitation is made here.

[0047] Furthermore, both sets of sensor roller groups 71 include several spaced sensor rollers 711, and the two sets of sensor rollers 711 are staggered to ensure full contact between the rollers and the welding wire.

[0048] In this example, the digital display output is calculated using the following formula:

[0049] 1. Utilization rate = (Weight of welding material before welding - Weight of welding material after welding - Weight of welding wire spool or drum - Weight of welding wire spool or drum cover - Wire feeding indicator) / Designed welding material usage;

[0050] 2. Spatter rate = (Weight of welding material before welding - Weight of welding material after welding - Weight of welding wire spool or drum - Weight of welding wire spool or drum cover - Wire feeding for calibration - Utilization) / Weight of welding material before welding;

[0051] 3. Welding wire diameter uniformity = linear speed * wire feeding time * welding wire cross-sectional area * welding material density / designed welding material usage.

[0052] A welding wire feeding device utilizes the aforementioned welding wire monitoring system. This device can monitor the welding wire consumption in real time, avoiding the waste of welding materials or arc interruption caused by untimely replacement of welding materials due to manual monitoring, which greatly affects construction costs and weld quality control.

[0053] Furthermore, the aforementioned welding wire equipment also includes a power supply 8 and a transformer 9. The power supply 8 is configured to be 220V, and the transformer 9 is a rectifier transformer 9, which can convert the 220V power supply 8 voltage into a 24V input voltage, thereby powering the welding wire monitoring system.

[0054] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A welding wire monitoring system characterized by, The welding wire monitoring system comprises a first welding wire integration and a second welding wire integration, welding wires are contained in the first welding wire integration and the second welding wire integration, a detection device is arranged, two detection ends of the detection device are arranged in the first welding wire integration and the second welding wire integration, and an alarm device is electrically connected between the two detection ends. When the welding wire in the first welding wire integration and / or the second welding wire integration is insufficient, the alarm device will give an alarm and a prompt. The detection device is electrically connected to a digital display, and the digital display can digitalize the welding wire amount measured by the detection device.

2. The welding wire monitoring system of claim 1, wherein, The detection device comprises a metal sensor and a weighing module. Two sensing ends of the metal sensor are arranged in the first welding wire integration and the second welding wire integration, and two sensing ends of the weighing module are arranged at the bottom of the first welding wire integration and the second welding wire integration. The metal sensor and the weighing module are connected to the digital display, and the weighing module can monitor the weight of the first welding wire integration and the second welding wire integration.

3. The welding wire monitoring system of claim 1, wherein, The volume of the first welding wire integration is greater than that of the second welding wire integration.

4. The welding wire monitoring system of claim 1, wherein, The alarm device comprises two sound and light alarm lamps, which are electrically connected to the weighing module and the metal sensor, respectively, for flashing alarm and prompt.

5. The welding wire monitoring system of claim 4, wherein, The alarm device further comprises a stop switch, which is electrically connected to any sound and light alarm lamp. When the sound and light alarm lamp flashes and alarms, the stop switch can disconnect the circuit where the sound and light alarm lamp is located.

6. The welding wire monitoring system of claim 4, wherein, The alarm device further comprises a stop switch, which is electrically connected to any sound and light alarm lamp. When the sound and light alarm lamp flashes and alarms, the stop switch can disconnect the circuit where the sound and light alarm lamp is located.

7. The welding wire monitoring system of claim 1, wherein, The welding wire monitoring system further comprises two speed sensors, which are arranged at the wire outlet ends of the first welding wire integration and the second welding wire integration, respectively, for monitoring the wire outlet speed of the first welding wire integration and the second welding wire integration.

8. The welding wire monitoring system of claim 7, wherein, The speed sensor comprises two groups of sensor roller groups, which are arranged at intervals. The welding wire can be inserted between the two groups of sensor roller groups and slip out of the first welding wire integration or the second welding wire integration relative to the sensor roller groups. Each sensor roller group is provided with at least one sensor roller, and the sensor roller can detect the wire speed by its own rotating speed.

9. The welding wire monitoring system of claim 8, wherein, Each of the two groups of sensor roller groups comprises a plurality of sensor rollers arranged at intervals, and the sensor rollers are arranged at different positions.

10. A welding wire delivery apparatus characterized by, The welding wire monitoring system is used.

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