An intelligent alarm system for monitoring the flow of a welding shielding gas

Abstract

The application discloses an intelligent alarm system for monitoring welding protective gas flow, which realizes high-precision, real-time and unmanned monitoring of the welding protective gas flow through a non-contact optical detection mode and a modular split structure, is convenient to install, does not interfere with an original gas path, has wide adaptability to flowmeter types, and has a double-mode sound-light alarm mechanism, which significantly improves on-site perception of abnormal states, effectively avoids welding defects caused by abnormal gas flow, improves production automation level and quality control capability, and has significant technical novelty and practical value.

Description

Technical Field

[0001] This utility model belongs to the technical field of welding auxiliary equipment, specifically relating to an intelligent alarm system for monitoring the flow rate of welding shielding gas. Background Technology

[0002] In the welding process, a stable supply of shielding gas plays a crucial role in ensuring weld quality. It effectively isolates oxygen and nitrogen from the air, preventing oxidation of the molten pool and the formation of porosity, thereby ensuring the mechanical properties and corrosion resistance of the welded joint. As a key component for regulating and controlling the flow of shielding gas, the reliability of the gas valve directly affects the stability of the welding process. In actual welding operations, insufficient gas cylinder pressure, pipeline leaks, or valve malfunctions may cause the gas flow to deviate from the process requirements, leading to weld defects or even welding failure. Therefore, real-time monitoring of gas flow and timely alarm issuance in abnormal situations are of significant engineering importance for improving welding automation, ensuring product quality, and reducing material and labor waste.

[0003] Several devices for gas flow monitoring already exist in the technology, such as visual monitoring systems based on mechanical flow meters or devices that realize alarms through electrical signal conversion. These devices can provide flow abnormality alerts to a certain extent, but still have some limitations.

[0004] Most welding shielding gas flow detection devices on the market rely on operators to periodically visually check the position of the float ball in the float-type flow meter. This method not only relies heavily on human experience, but also cannot achieve real-time continuous monitoring, and is prone to missed reports due to personnel fatigue or negligence.

[0005] Some electronic monitoring devices use contact sensors or mechanical linkage structures, which have problems such as complicated installation, easy wear, and need to modify the original gas circuit system, affecting their reliability and applicability. Although some products have electrical alarm functions, most of their sensors are built-in, making it difficult to adapt to different models or specifications of flow meters, and lacking versatility and flexibility.

[0006] In addition, most existing devices have relatively simple alarm methods, and their visibility and hearing are poor in noisy welding environments, making it difficult to attract the attention of operators. Related literature also points out that existing gas flow alarm devices still need to be improved in terms of anti-interference ability, environmental adaptability and system integration. Other studies have mentioned that some detection devices require external power supply or rely on wired transmission, which limits their mobility and ease of installation.

[0007] Therefore, there is an urgent need in the existing technology for a smart monitoring solution for protective gas flow that is structurally sound, easy to install, provides timely alarms, and is highly reliable. Utility Model Content

[0008] The present invention aims to provide an intelligent alarm system for monitoring the flow rate of welding shielding gas, in order to solve the problems of low efficiency and poor reliability caused by manual inspection in the prior art, as well as the problems of complex installation, weak adaptability and untimely alarm of existing electronic monitoring devices. The system realizes continuous monitoring of gas flow and immediate alarm of abnormality through non-contact optical sensing and intelligent judgment, effectively ensuring the stability of the welding process and the quality of weld formation.

[0009] An intelligent alarm system for monitoring the flow rate of welding shielding gas consists of two main parts: a sensing module and an alarm module.

[0010] The sensing module includes a detector and a strap. The detector is designed with a rectangular structure, with an identification port at one end for non-invasive identification of the real-time position of the float inside the flow meter, and a wiring port at the other end for connecting to the alarm module.

[0011] The strap is made of a ring structure of high-elasticity silicone material. Its inner diameter can be flexibly adapted to the outer diameter of common flow meters, enabling quick and secure installation and removal without modifying the original air circuit. It has good equipment compatibility and ease of operation.

[0012] An infrared photoelectric sensor is embedded inside the identification port. Its transmitter and receiver are arranged opposite each other. By sensing the change in the beam obstruction state caused by the movement of the float in the airflow channel, it captures the ball's position signal in real time and converts it into an electrical signal output. This optical sensing method has the advantages of being resistant to electromagnetic interference and having no mechanical wear.

[0013] The alarm module is the core of the system's control and response. It includes alarm lights, buzzers, alarm circuit devices, battery packs, and power signal interfaces.

[0014] The alarm circuit device is based on a microcontroller unit, which has a pre-stored normal threshold range for the float position set according to different welding processes. The unit receives signals from the sensor module in real time, analyzes and compares the float position data, and once it detects that the float is continuously deviating from the preset range, it determines that the flow is abnormal and generates an alarm signal.

[0015] Upon receiving an accurate alarm signal, the microcontroller immediately activates the alarm light and buzzer, simultaneously emitting a strong visual and auditory alarm to ensure that operators are alerted promptly even in noisy welding environments.

[0016] The power signal interface features a multi-port composite design, with separate power charging and data communication ports. It can be connected to an external power source to charge the built-in battery pack for long-term continuous operation, and is also responsible for the stable transmission of data signals with the detector.

[0017] In addition, the alarm module is equipped with an integrated hanging rope on the top, which makes it easy to hang the entire module on nearby equipment such as flow meters or welding machines, further optimizing the convenience and integrity of the site layout.

[0018] Beneficial effects:

[0019] In summary, this equipment achieves high-precision, real-time, and unmanned monitoring of welding shielding gas flow rate through non-contact optical detection and a modular split structure. The system is easy to install, does not interfere with the original gas path, and has wide compatibility with a wide range of flow meter models. Its dual-mode audible and visual alarm mechanism significantly improves the on-site perception of abnormal conditions, effectively avoids weld defects caused by abnormal gas flow, and improves the level of production automation and quality control capabilities. It has significant technological novelty and practical value. Attached Figure Description

[0020] Figure 1 This is a subjective schematic diagram of an intelligent alarm system for monitoring the flow rate of welding shielding gas;

[0021] Figure 2 This is a schematic diagram of the sensor module assembly for an intelligent alarm system used to monitor the flow rate of welding shielding gas.

[0022] Figure 3 This is a detailed schematic diagram of the sensing module of an intelligent alarm system for monitoring the flow rate of welding shielding gas;

[0023] Figure 4 This is a detailed schematic diagram of an alarm module for an intelligent alarm system used to monitor the flow rate of welding shielding gas.

[0024] Figure 5 This is a schematic diagram of a gas cylinder valve for an intelligent alarm system used to monitor the flow rate of welding shielding gas.

[0025] In the diagram, 1 is the sensing module, 101 is the detector, 102 is the strap, 103 is the wiring port, 2 is the alarm module, 201 is the alarm light, 202 is the alarm circuit device, 203 is the battery pack, 204 is the power signal interface, 205 is the lanyard, 3 is the gas cylinder valve, 301 is the flow meter, and 302 is the float. Detailed Implementation

[0026] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.

[0027] Sensing module 1, detector 101, strap 102, connection port 103, alarm module 2, alarm light 201, alarm circuit device 202, battery pack 203, power signal interface 204, lanyard 205, gas cylinder valve 3, flow meter 301, float 302.

[0028] This invention provides an intelligent alarm system for monitoring the flow rate of welding shielding gas. The system can monitor the flow rate of welding shielding gas in real time and issue an audible and visual alarm in a timely manner when the gas flow rate is abnormal, effectively avoiding welding quality problems caused by unstable gas supply.

[0029] like Figure 1 As shown, the intelligent alarm system mainly includes a sensing module 1 and an alarm module 2. The sensing module 1 is responsible for monitoring the position of the float 302 inside the flow meter 301 in real time and issuing an alarm signal when there is an abnormality. The alarm module 2 is responsible for receiving the sensing signal and making a judgment, and activating the audible and visual alarm when there is a clear abnormality.

[0030] like Figure 3 As shown, the sensing module 1 includes a detector 101 and a strap 102. The detector 101 has a rectangular structure and is made of engineering plastic, which has good high temperature resistance and impact resistance. One end of the detector 101 is provided with an identification port, and an optical sensor is installed inside the identification port for non-contact identification of the real-time position of the float 302 inside the flow meter 301. The other end of the detector 101 is provided with a wiring port 103 for connecting to the alarm module 2 via a cable.

[0031] The optical sensor installed inside the identification port is a through-beam infrared photoelectric sensor. Its transmitter and receiver are positioned opposite each other on both sides of the inner wall of the identification port, forming a complete optical path. When the float 302 moves up and down inside the flow meter 301 under the action of airflow, it will block part or all of the light beam, causing a change in the signal at the receiver, thereby achieving accurate detection of the position of the float 302.

[0032] The strap 102 is an elastic annular silicone strap 102, the inner diameter of which is adapted to the outer diameter of the common flow meter 301. The strap 102 is set at the identification port end of the detector 101, and the identification port is detachably fixed to the flow meter 301 by elastic contraction force. This design not only ensures the stability of the installation, but also facilitates the installation and disassembly of the equipment.

[0033] like Figure 4 As shown, the alarm module 2 includes an alarm light 201, an alarm circuit device 202, a battery pack 203, and a power signal interface 204.

[0034] The power signal interface 204 is a multi-port interface, including a power charging port and a data communication port. The power charging port is connected to the battery pack 203 via a power cable and can be connected to an external power source to charge the battery pack 203. The data communication port is connected to the wiring port 103 of the detector 101 via a data cable and is used to transmit signals and power the sensing module 1.

[0035] The alarm circuit device 202 is the control core of the system, including a microcontroller unit, a signal processing circuit and a drive circuit. The microcontroller unit has pre-stored the normal range threshold of the float 302 position set according to different welding process requirements. The alarm circuit device 202 is electrically connected to the power signal interface 204, the alarm light 201 and the battery pack 203, and receives signals from the sensing module 1 in real time to analyze and compare the float 302 position data.

[0036] The alarm light 201 uses high-brightness LED beads and emits a clear flashing alarm when it receives a start signal. The alarm light 201 also integrates a buzzer for emitting an audible alarm. The buzzer is electrically connected to the alarm circuit device 202 and can be directly driven by a microcontroller unit.

[0037] The alarm module 2 is also equipped with a hanging rope 205 on the upper part. The lower end of the hanging rope 205 is connected to the alarm module 2, and the upper end can be hung on the flow meter 301 or its peripheral equipment for easy on-site layout and installation.

[0038] When the system is working, first fix the sensor module 1 to the flow meter 301 with the strap 102, ensuring that the identification port is facing the movement channel of the float 302 of the flow meter 301. Then, suspend the alarm module 2 in an appropriate position with the hanging rope 205 and connect the wiring port 103 of the detector 101 to the power signal interface 204 of the alarm module 2 with the connecting cable.

[0039] After the power is turned on, the system starts to work. The through-beam infrared photoelectric sensor in the sensing module 1 continuously monitors the position of the float 302 and transmits the detection signal to the alarm module 2 through the cable. The microcontroller unit in the alarm circuit device 202 analyzes the received signal in real time and compares the current position of the float 302 with the pre-stored normal range threshold.

[0040] When the position of the float 302 continues to deviate from the preset range, the microcontroller unit determines that the flow is abnormal, generates an alarm signal, drives the alarm light 201 to emit a flashing light, and at the same time starts the buzzer to emit a high-decibel alarm sound to remind the operator to deal with it in time.

[0041] Battery pack 203 is a rechargeable lithium battery that can be charged by connecting to an external power source through the power charging port, ensuring that the system can work continuously for a long time.

[0042] Implementation Example

[0043] A car manufacturing plant's welding workshop uses carbon dioxide gas shielded welding for car body welding, requiring real-time monitoring of the shielding gas flow rate.

[0044] 1. The operator first selects the sensor module 1 that matches the outer diameter of the flow meter 301 used in the workshop, puts the ring strap 102 on the outside of the flow meter 301, adjusts the position of the detector 101 so that the identification port is facing the transparent tube part of the flow meter 301, and ensures that the movement trajectory of the float 302 can be effectively monitored by the optical sensor.

[0045] 2. Hang the alarm module 2 on the special hook on the side of the welding machine using the hanging rope 205. Use the matching connecting cable to reliably connect the wiring port 103 of the detector 101 to the power signal interface 204 of the alarm module 2. Pay attention to the interface direction when connecting to ensure a firm connection.

[0046] 3. Turn on the power switch of alarm module 2. The system will perform a self-test. After the self-test is passed, the alarm light 201 will emit a constant light, indicating that the system has entered the normal working state. The operator can set the normal range threshold of the float 302 position according to the current welding process requirements by using the setting button on alarm module 2. The threshold setting is based on the gas flow range required in the welding process specification and is determined by the corresponding position of the float 302 in the flow meter 301.

[0047] 4. During the welding operation, the sensor module 1 continuously monitors the position of the float 302. When the gas supply is normal, the float 302 fluctuates within the set range and the alarm light 201 remains constantly lit. When a gas leak occurs or the gas cylinder pressure is insufficient, the position of the float 302 remains below the set lower limit value. The microcontroller unit of the alarm circuit device 202 detects this abnormal state and immediately generates an alarm signal.

[0048] 5. The alarm signal drives the alarm light 201 to switch to flashing mode, and at the same time the buzzer sounds an alarm. Even in a noisy workshop environment, it can still effectively attract the attention of the operator. After hearing the alarm, the operator can stop the welding operation in time, check the gas supply system, and after troubleshooting, press the reset button on the alarm module 2 to restore the system to normal monitoring status.

[0049] 6. When the battery pack 203 is low on power, the operator can connect the matching charger through the power charging port to charge the system. The system can still work normally during the charging process.

[0050] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An intelligent alarm system for monitoring the flow of a welding shielding gas, characterized in that include: Sensing module and alarm module; The sensing module includes a detector and a strap; The detector is a rectangular structure, with an identification port at one end for identifying the position of the float ball inside the flow meter, and a wiring port at the other end. The strap is located at the detection port of the detector, and the detection port is detachably connected to the flow meter; The alarm module includes an alarm light, an alarm circuit device, a battery pack, and a power signal interface; The power signal interface is connected to the detector's wiring port via a cable, transmitting signals and supplying power to the sensing module; The alarm circuit device is electrically connected to the power signal interface, alarm light and battery pack; The identification port is equipped with an optical sensor to monitor the position of the float in real time. When the position of the float exceeds the preset normal range, an alarm signal is generated and transmitted to the alarm circuit device through the connection port and cable. The alarm circuit device receives the alarm signal and drives the alarm light to emit visual and auditory alarms.

2. The intelligent alarm system for monitoring the flow rate of welding shielding gas according to claim 1, characterized in that, The optical sensor is used to identify the vertical movement position of the float through a non-contact optical sensing method.

3. An intelligent alarm system for monitoring the flow of shielding gas for welding as claimed in claim 2 wherein, The optical sensor is a through-beam infrared photoelectric sensor, with its transmitter and receiver positioned opposite each other on the inner wall of the identification port. The float moves within the channel between the transmitter and receiver to trigger the light beam.

4. The intelligent alarm system for monitoring the flow rate of welding shielding gas according to claim 1, characterized in that, The alarm module also includes a hanging rope, the lower end of which is connected to the alarm module, and the upper end of which is suspended from the flow meter or its peripheral equipment.

5. The intelligent alarm system for monitoring the flow of shielding gas for welding as claimed in claim 1 wherein, The power signal interface is a multi-port interface, which includes at least one power charging port and one data communication port. The power charging port is connected to the battery pack via a power cord, allowing an external power source to charge the battery pack. The data communication port is connected to the detector's wiring port via a data cable for transmitting the alarm signal.

6. The intelligent alarm system for monitoring the flow of shielding gas for welding as claimed in claim 1 wherein, The alarm module's alarm light is also equipped with a buzzer for emitting an audible alarm, and the buzzer is electrically connected to the alarm circuit device.

7. An intelligent alarm system for monitoring the flow of shielding gas for welding as claimed in claim 6 wherein, The alarm circuit device includes a microcontroller unit, which pre-stores a normal range threshold for the float position. When the alarm signal is received, it is compared with the pre-stored normal range threshold. When the float position continuously deviates from the preset range, an alarm signal is generated and the alarm light and buzzer are driven to sound an alarm.

8. The intelligent alarm system for monitoring the flow of shielding gas for welding as claimed in claim 1 wherein, The strap is an elastic ring strap, the inner diameter of which is adapted to the outer diameter of the flow meter.

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