A welding machine monitoring circuit

Abstract

This utility model belongs to the field of test circuits and provides a welding machine monitoring circuit, including a main control module, a battery monitoring module, an energy metering module, a power failure monitoring module, a battery charging module, a self-switching power supply module, an AC-DC conversion module, and a first step-down module. The energy metering module collects energy parameters such as voltage, current, and power and feeds them back to the main control module; the AC-DC conversion module outputs 5V DC power to power the battery charging module, and the first step-down module powers the main control module; when AC power is lost, the battery continues to supply power, and the self-switching power supply module can switch to USB power supply; the power failure monitoring module detects the step-down voltage and feeds back a power failure signal; the main control module determines the welding machine status based on energy parameters and uploads the data remotely, and uploads location information periodically after a power failure; this utility model achieves high-efficiency production management by providing a highly efficient welding machine data acquisition and management circuit.

Description

Technical Field

[0001] This utility model relates to the field of test circuits, and in particular to a welding machine monitoring circuit. Background Technology

[0002] In large machine shops and shipyards, there are numerous welding machines of various models, sometimes numbering in the thousands. Furthermore, these factory areas are often vast, spanning several kilometers in length and width. Therefore, conventional wired communication methods, such as the RS485 bus, and local area network wireless methods, such as LoRa, Zigbee, and Wi-Fi, are inconvenient for data collection and management due to the large number of devices and the fact that individual devices may be randomly moved or powered off.

[0003] Currently, some welding machines have been moved to various corners of the factory and may not be used for a long time. As a result, the administrator cannot know the location and status of the welding machines, which makes it difficult to allocate personnel and equipment reasonably.

[0004] Currently, some staff members operate the welding machine but do not place the equipment in the designated location, which makes it time-consuming to find the equipment later. Utility Model Content

[0005] In view of the above technical problems, this utility model provides a welding machine monitoring circuit to provide an efficient welding machine data acquisition and management system, thereby achieving high production management efficiency.

[0006] Other features and advantages of this disclosure will become apparent from the following detailed description, or may be learned in part from practice of this disclosure.

[0007] This utility model discloses a monitoring circuit for an electric welding machine. The monitoring circuit includes a main control module and a battery monitoring module, an energy metering module, and a power failure monitoring module, all connected to the main control module. It also includes a battery charging module, a self-switching power supply module, an AC-DC conversion module, and a first step-down module, wherein: The power metering module is used to collect the power parameters of the welding machine and then feed them back to the main control module. The power parameters include at least one of voltage, current, power, and wattage. The battery monitoring module detects the battery level in the charging module based on ADC data acquisition. The AC-DC conversion module is used to convert the input AC power into 5V DC power to power the charging module; The charging module is used to input 5V DC power into the battery to charge it. The first step-down module is used to step down the 5V DC power to power the main control module. When the AC-DC conversion module does not input the AC power, the battery output voltage of the charging module is sent to the first step-down module so that the first step-down module can power the main control module. The self-switching power supply module includes a switching unit and a USB interface. The USB interface can output 5V DC power. When the USB interface outputs voltage, the switching unit controls the output voltage of the USB interface to power the first step-down module. The power failure monitoring module collects the voltage of the first step-down module based on the ADC to determine whether the AC power is interrupted, and feeds back to the main control module. The main control module includes a chip with 4G communication, GNSS positioning and logic transport functions. It is used to obtain the status of the welding machine based on the power parameters and remotely feed it back to the server. When it receives the power failure signal from the power failure monitoring module, it periodically uploads the location information to the server.

[0008] Furthermore, the monitoring circuit also includes a Flash module, which is connected to a second step-down module. The second step-down module is used to step down the 5V DC power to power the Flash module, and the Flash module is used to store the data input by the main control module.

[0009] Furthermore, the monitoring circuit also includes a USB programming module, which is connected to the main control module and is used to communicate between the main control module and external devices via a cable.

[0010] Furthermore, the monitoring circuit also includes a SIM module, which is connected to the main control module.

[0011] The technical solution disclosed herein has the following beneficial effects: 1. Use the main control module to communicate, record the usage of the device, and upload it to the server for convenient unified management of the device.

[0012] 2. When any device is powered off, it does not affect the communication of other devices. Compared to the 485 bus, if the host is powered off, it will affect the normal communication of the extension. Compared to Lora / Zigbee / Wify, 4G is faster, more stable, and easier to locate.

[0013] 3. When the device is powered off, the automatic power switching module switches to battery power and periodically uploads location information for easy device location.

[0014] 4. By using the power metering module, various parameters of the equipment are collected, providing a good basis for subsequent analysis of the equipment's usage, performance, and even the quality of welding. Attached Figure Description

[0015] Figure 1 This is a structural block diagram of the welding machine monitoring circuit in the embodiments of this specification; Figure 2 The circuit diagrams for the main control module, battery monitoring module, and power failure monitoring module in the embodiments of this specification are shown below. Figure 3 This is a circuit diagram of the power failure monitoring module in the embodiments of this specification; Figure 4 This is a circuit diagram of the battery monitoring module in the embodiments of this specification; Figure 5 This is a circuit diagram of the main control module in the embodiments of this specification; Figure 6 This is a circuit diagram of the energy metering module in the embodiments of this specification; Figure 7 This is a circuit diagram of the charging module in the embodiments of this specification; Figure 8 This is a partial circuit diagram of the self-switching power supply module in the embodiments of this specification; Figure 9 This is a partial circuit diagram of the self-switching power supply module in the embodiments of this specification; Figure 10 This is a partial circuit diagram of the self-switching power supply module in the embodiments of this specification; Figure 11 This is a circuit schematic diagram of the USB interface in the embodiments of this specification; Figure 12 This is a circuit schematic diagram of the Flash module in the embodiments of this specification; Figure 13 This is a circuit schematic diagram of the AC-DC conversion module in the embodiments of this specification; Figure 14 This is a circuit diagram of the first step-down module in the embodiments of this specification; Figure 15 This is a circuit diagram of the second step-down module in the embodiments of this specification; Figure 16 This is a circuit schematic diagram of the USB programming module in the embodiments of this specification; Figure 17 This is a circuit schematic diagram of the SIM module in the embodiments of this specification. Detailed Implementation

[0016] The exemplary implementation will now be described more fully with reference to the accompanying drawings.

[0017] The accompanying drawings are merely illustrative of this disclosure. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. It is understood that the scale of the various components in the drawings does not constitute a limitation of this disclosure.

[0018] like Figure 1-17 As shown in the embodiment of this specification, a welding machine monitoring circuit is provided. The detection circuit includes a main control module 1 and a battery monitoring module 2, an energy metering module 3, and a power failure monitoring module 4, which are respectively connected to the main control module 1. It also includes a battery charging module 5, a self-switching power supply module 6, an AC-DC conversion module 8, and a first step-down module 9, wherein: The power metering module 3 is used to collect the power parameters of the welding machine and then feed them back to the main control module 1. The power parameters include at least one of voltage, current, power and power. Battery monitoring module 2 uses ADC to collect and detect the battery level in the charging module; AC-DC converter module 8 is used to convert the input AC power into 5V DC power to power the charging module; The charging module is used to input 5V DC power into the battery to charge it; The first step-down module 9 is used to step down the 5V DC power to power the main control module 1. When the AC-DC conversion module 8 has no AC power input, the battery output voltage of the charging module is supplied to the first step-down module 9 so that the first step-down module can power the main control module 1. The self-switching power supply module 6 includes a switching unit and a USB interface. The USB interface can output 5V DC power. When the USB interface outputs voltage, the switching unit controls the output voltage of the USB interface to power the first step-down module 9. The power failure monitoring module collects the voltage of the first step-down module based on the ADC to determine whether the AC power is interrupted, and feeds back to the main control module 1; The main control module 1 includes a chip with 4G communication, GNSS positioning and logic transport functions. It is used to obtain the status of the welding machine based on power parameters and remotely feed it back to the server. When it receives a power failure signal from the power failure monitoring module, it periodically uploads the location information to the server.

[0019] The monitoring circuit also includes a Flash module 7, which is connected to a second step-down module 10. The second step-down module 10 is used to step down the 5V DC power to supply power to the Flash module 7. The Flash module 7 is used to store the data input by the main control module 1. By storing data in the Flash, when the signal of some devices is weak, the data is stored, and when the signal is restored, it is periodically retransmitted.

[0020] The monitoring circuit also includes a USB programming module 11, which is connected to the main control module 1 and is used to communicate between the main control module 1 and external devices via a cable.

[0021] The monitoring circuit also includes a SIM module, which is connected to the main control module 1.

[0022] As a supplement, such as Figure 2-5 As shown, the main control module 1 uses an EG810M 4G chip with GNSS positioning function to realize remote communication and positioning. The battery monitoring module 2 collects and detects the battery power through ADC. The power failure monitoring module 4 also obtains the voltage of the AC-DC conversion module 8 through ADC and feeds it back to the main control module 1 for the main control module 1 to make a judgment.

[0023] like Figure 6 As shown, the power metering module 3 uses mutual inductance power metering to obtain various power parameters of the welding machine.

[0024] like Figure 7 As shown, the charging module uses the 5V power obtained by stepping down the AC-DC converter module 8 to power the battery.

[0025] like Figure 8-11 As shown, Figure 8 Powered by battery, Figure 9 Power the converted 5V supply. Figure 10 Powered by USB Figure 11 The USB interface receives power, and the switching of power supply is performed by MOSFETs, which are controlled by their respective chips.

[0026] Figure 12 Flash module 7 stores the data provided by main control module 1.

[0027] like Figure 13 As shown, the AC-DC conversion module 8 converts 380V AC power to 5V DC power.

[0028] like Figure 14 As shown, the first step-down module 9 steps down the 5V DC power to 3.8V DC power, which is then supplied to the EG810M 4G chip of the main control module 1.

[0029] like Figure 15 As shown, the second step-down module 10 steps down the 5V DC power to 3.3V DC power, which is then supplied to the Flash module 7.

[0030] like Figure 16 As shown, the USB programming module 11 is connected to the main control module 1.

[0031] like Figure 17As shown, the SIM module serves as a remote connection.

[0032] Working principle: 1. When AC power is applied, the main control module 1 automatically switches to 5V power supply through the self-switching power supply module 6, and at the same time the battery charging module 5 automatically charges the battery.

[0033] 2. The main control module 1 periodically detects whether the parameters such as current, voltage, power, and power factor of the power metering module 3 exceed the threshold. When the threshold is exceeded, it is determined that the welding machine has entered the working state, and the valid data is saved to the Flash module 7. At the same time, the parameters are periodically uploaded to the remote server.

[0034] 3. When the AC380V power supply of the AC-DC conversion module 8 is interrupted, the main control module 1 detects the power failure signal through the power failure monitoring module 4. Then, the battery charging module 5 automatically switches to battery power supply to the main control module 1, so that the main control module 1 can continue to work and periodically upload location information to the remote server for easy device location.

[0035] 4. The self-switching power supply module 6 only needs to be plugged into the USB interface during the programming process, and the AC-DC conversion module 8 does not need to be powered by AC380V, which is safer and more convenient for workers to operate.

[0036] During normal use, only the AC-DC conversion module 8 provides 5V power and the battery provides power. Since the battery voltage of 4.2V is lower than 5V, and due to the unidirectional conductivity of the diode, the circuit automatically selects the higher voltage (5V) for power supply.

[0037] 5. Customers can install a digital twin interface / software on a host computer via a remote server to view equipment usage and location information in real time, facilitating equipment management. Beneficial effects: 1. Use the main control module 1 to communicate, record the usage of the device, and upload it to the server for convenient unified management of the device.

[0038] 2. When any device is powered off, it does not affect the communication of other devices. Compared to the 485 bus, if the host is powered off, it will affect the normal communication of the extension. Compared to Lora / Zigbee / Wify, 4G is faster, more stable, and easier to locate.

[0039] 3. When the device is powered off, the automatic switching power supply module 6 switches to battery power and periodically uploads location information to facilitate device location.

[0040] 4. Through the power metering module 3, various parameters of the equipment are collected, providing a good basis for subsequent analysis of the equipment's usage, performance, and even the quality of welding.

[0041] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the utility models disclosed herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein.

Claims

1. A monitoring circuit for an electric welding machine, characterized in that, The monitoring circuit includes a main control module and a battery monitoring module, an energy metering module, and a power failure monitoring module, all connected to the main control module. It also includes a battery charging module, a self-switching power supply module, an AC-DC conversion module, and a first step-down module, wherein: The power metering module is used to collect the power parameters of the welding machine and then feed them back to the main control module. The power parameters include at least one of voltage, current, power, and wattage. The battery monitoring module detects the battery level in the charging module based on ADC data acquisition. The AC-DC conversion module is used to convert the input AC power into 5V DC power to power the charging module; The charging module is used to input 5V DC power into the battery to charge it. The first step-down module is used to step down the 5V DC power to power the main control module. When the AC-DC conversion module does not input the AC power, the battery output voltage of the charging module is sent to the first step-down module so that the first step-down module can power the main control module. The self-switching power supply module includes a switching unit and a USB interface. The USB interface can output 5V DC power. When the USB interface outputs voltage, the switching unit controls the output voltage of the USB interface to power the first step-down module. The power failure monitoring module collects the voltage of the first step-down module based on the ADC to determine whether the AC power is interrupted, and feeds back to the main control module. The main control module includes a chip with 4G communication, GNSS positioning and logic transport functions. It is used to obtain the status of the welding machine based on the power parameters and remotely feed it back to the server. When it receives the power failure signal from the power failure monitoring module, it periodically uploads the location information to the server.

2. The welding machine monitoring circuit according to claim 1, characterized in that, The monitoring circuit also includes a Flash module, which is connected to a second step-down module. The second step-down module is used to step down the 5V DC power to power the Flash module. The Flash module is used to store the data input by the main control module.

3. The welding machine monitoring circuit according to claim 1, characterized in that, The monitoring circuit also includes a USB programming module, which is connected to the main control module and is used to communicate between the main control module and external devices via a cable.

4. The welding machine monitoring circuit according to claim 1, characterized in that, The monitoring circuit also includes a SIM module, which is connected to the main control module.

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