Wire residual quantity determination system

Abstract

To provide a wire residual quantity determination system capable of suitably managing a wire residual quantity.SOLUTION: This wire residual quantity determination system stores a metal wire helically wound up from below and determines each of wire residual quantities in a plurality of containers from which wires can be taken out from above. The determination system comprises: a plurality of sensor units each of which is disposed in one container and detects a physical quantity obtained from the wire residual quantity in one container as a voltage value; a plurality of slave control units each of which is connected to the sensor unit and disposed in one container and obtains the voltage value from one sensor unit; and one host control unit that is connected to each slave control unit to receive the voltage value from each slave control unit and determines the wire residual quantity in each container.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a wire remaining amount determination system for determining the remaining amount of wire in a container. [Background technology]

[0002] Conventionally, in order to prevent welding from suddenly stopping midway through a weld line, a pack wire remaining amount display device is known, in which an electromagnetic proximity switch is disposed near a pack wire storage container to detect the presence or absence of welding wire in the storage container, as disclosed in Patent Document 1. Also disclosed is a configuration for collecting and displaying information from multiple remaining amount detection devices in one place. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Registered Utility Model No. 3057451 Summary of the Invention [Problem to be solved by the invention]

[0004] By using the invention of Patent Document 1, the remaining amount of welding wire can be known. However, the consumption amount of welding wire differs for each workpiece that a welding device such as a welding robot targets, and as a result, the consumption rate differs depending on the container. Therefore, even if a user recognizes the timing when the remaining amount has reached a certain value, the timing of ordering new welding wire varies, leading to situations where the order is placed too early or too late. Therefore, the problem of not having excess inventory is not solved by the invention of Patent Document 1, and a new method was required.

[0005] The present invention has been made in consideration of the above circumstances, and an object of the present invention is to provide a wire remaining amount determination system that can appropriately manage the remaining amount of wire. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, the wire remaining amount determination system of the present invention is a wire remaining amount determination system that determines the remaining amount of wire in each of a plurality of containers that contain a metal wire wound in a spiral shape from bottom to top and removes the wire from above, and includes a plurality of sensor units that are placed in each of the containers and detect a physical quantity obtained from the remaining amount of wire in each of the containers as a voltage value, a plurality of child control units that are connected to each of the sensor units and placed in each of the containers and acquire the voltage value from the one of the sensor units, and a parent control unit that is connected to each of the child control units, receives the voltage value from each of the child control units, and determines the remaining amount of wire in each of the containers. Effect of the Invention

[0007] In the wire remaining amount determination system according to the present invention, the remaining amount of wire can be appropriately managed. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a system configuration diagram of a wire remaining amount determination system. [Diagram 2] FIG. 2 is an external view showing the pail pack and the sensor unit and sub-controller attached to the pail pack. [Diagram 3] FIG. 4 is a schematic functional block diagram showing the functional configuration of a sensor unit, a child control unit, and a parent control unit. [Figure 4] 5A to 5C are diagrams illustrating examples of voltage values ​​of each sensor acquired by a detection result acquisition unit. [Diagram 5] FIG. 13 is a schematic configuration diagram of a sensor unit and a sub-controller as a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment of the wire remaining amount determination system according to the present invention will be described with reference to the accompanying drawings. The determination system according to the present invention is a system for centrally managing the remaining amount of wire in a plurality of containers that contain a metal wire wound in a spiral shape from below to above and that allows the wire to be taken out from above. In this embodiment, the wire remaining amount determination system according to the present invention will be described as being used in an automatic welding device or semi-automatic welding device (hereinafter simply referred to as a "welding device") for arc welding, and is applied to a case where the remaining amount of welding wire (metal wire) contained in a pail pack (container) is managed. A pail pack is also called a drum, and is a container that contains welding wire stacked in a spiral shape. The welding wire is taken out from the pail pack. The welding wire is a long coiled solid wire and flux-cored wire used for welding.

[0010] FIG. 1 is a system configuration diagram of a wire remaining amount determination system 1 (hereinafter referred to as "determination system 1").

[0011] FIG. 2 is an external view showing pail pack 2 and sensor unit 10 and sub control unit 20 attached to pail pack 2. As shown in FIG.

[0012] FIG. 3 is a schematic functional block diagram showing the functional configuration of the sensor unit 10, the slave control unit 20, and the master control unit 40. As shown in FIG.

[0013] 3, the determination system 1 has a battery 30, a sensor unit 10, a child control unit 20, and a parent control unit 40. At least one set of the battery 30, the sensor unit 10, and the child control unit 20 is arranged in each pail pack 2. In addition, one parent control unit 40 is arranged for the multiple batteries 30, the sensor units 10, and the child control units 20.

[0014] Each battery 30 is a power source for driving the sensor unit 10 and the slave control unit 20. The battery 30 constantly supplies power to the slave control unit 20. Meanwhile, the battery 30 is connected to the sensor unit 10 via a switch 31, and supplies power only to the sensor unit 10 when the switch 31 is turned on. The battery 30 is a primary battery, for example, consisting of multiple AA batteries (two in FIG. 3).

[0015] Each sensor unit 10 is a plurality of sensor units 10 each arranged in one pail pack 2. As shown in FIG. 2, each sensor unit 10 has a plurality of metal detection sensors 11, 12, and 13 (hereinafter simply referred to as “sensors 11 to 13”) and a support member 16.

[0016] Each of the sensors 11-13 detects a physical quantity obtained from the remaining amount of wire 3 in one pail pack 2 as a voltage value. Specifically, each of the sensors 11-13 outputs a voltage value in response to a disturbance in the magnetic field corresponding to the presence or absence of the wire 3 in an area including at least a predetermined range in the vertical direction from the location where the sensor 11-13 is disposed. The sensors 11-13 are, for example, three sensors consisting of an upper sensor 11, a middle sensor 12, and a lower sensor 13. The sensors 11-13 are wired to the child control unit 20 so as to transmit the detected voltage values.

[0017] Support member 16 supports three sensors 11-13 at a predetermined interval in the vertical direction on its back surface, which is the surface facing pail pack 2. Support member 16 is fixed to the outer surface of pail pack 2 by a required method so that it can be attached and detached to pail pack 2 every time pail pack 2 is replaced. In this way, sensors 11-13 are arranged along the vertical direction on the outer surface of pail pack 2. In this embodiment, an example will be described in which support member 16 supports three sensors 11-13, but the number is not limited to three and may be any other number greater than one.

[0018] The intervals between sensors 11-13 are determined according to the dimensions of pail pack 2 and the height of wire 3 when full, and are arranged, for example, so as to be uniform in the vertical direction. For example, support members 16 are arranged at 150 mm intervals so as to be at heights of 100 mm, 250 mm, and 400 mm from the bottom surface of pail pack 2.

[0019] As shown in FIG. 3, each sub-controller 20 includes a power supply controller 21, a remaining battery level acquirer 22, a detection result acquirer 23, a wireless communication unit 24, and a notifier 25.

[0020] The power supply control unit 21 controls the switch 31 between the battery 30 and the sensor unit 10. Specifically, the power supply control unit 21 turns on the switch 31 for a moment in a pulsed manner at predetermined time intervals (e.g., every hour) to power on the sensor unit 10 and detect the voltage.

[0021] The battery remaining capacity acquisition unit 22 acquires the remaining capacity of the battery 30. The battery remaining capacity acquisition unit 22 acquires the remaining capacity of the battery 30 at predetermined time intervals, for example, simultaneously with the timing when the power supply control unit 21 turns on the switch 31. The battery remaining capacity acquisition unit 22 transmits the remaining battery capacity to the parent control unit 40 via the wireless communication unit 24 every time it acquires the remaining battery capacity.

[0022] Detection result acquisition unit 23 acquires the voltage values ​​detected by each of sensors 11-13. That is, detection result acquisition unit 23 acquires the change over time in the remaining amount of wire 3 in each pail pack 2. Detection result acquisition unit 23 transmits a voltage value to parent control unit 40 via wireless communication unit 24 every time it acquires the voltage value.

[0023] For example, FIG. 4 is a diagram illustrating an example of the voltage values ​​of the sensors 11 to 13 acquired by the detection result acquisition unit .

[0024] When the voltage value is smaller than the first value (for example, the voltage value of the upper sensor in FIG. 4 is 164 mV), the detection result acquisition unit 23 judges the wire as "not detected" and that the wire is not within the detection range. When the voltage value is equal to or greater than the first value and equal to or less than a second value larger than the first value (for example, the voltage value of the middle sensor in FIG. 4 is 180 mV), the detection result acquisition unit 23 judges the wire as "weakly detected" and that at least a part of the wire is within the detection range. When the voltage value is larger than the second value (for example, the voltage value of the lower sensor in FIG. 4 is 243 mV), the detection result acquisition unit 23 may calibrate the acquired voltage value using a required calibration value set according to the surrounding environment, etc., and set the resulting voltage value as the voltage value.

[0025] 4 acquired by detection result acquisition unit 23, together with required information including information for identifying pail pack 2 and sensors 11-13 and detection date and time, to parent control unit 40. The wireless communication method may be appropriately selected from among known methods depending on the required communication distance and communication information volume.

[0026] The notification unit 25 notifies the user of required notifications for each pail pack 2. For example, the notification notifies that the remaining wire charge or the remaining battery charge has fallen below a predetermined threshold.

[0027] The parent control unit 40 has a wireless communication unit 41, a storage unit 42, a calculation unit 43, and a notification unit 44.

[0028] The wireless communication unit 41 is connected to each child control unit 20 by a wireless communication method corresponding to the wireless communication unit 24 of each child control unit 20. The wireless communication unit 41 receives information such as a voltage value and a remaining battery level from each child control unit 20.

[0029] The storage unit 42 stores information such as the voltage value and the remaining battery level received by the wireless communication unit 41. The storage unit 42 is configured to be able to refer to the stored information and output the information in a viewable manner, for example, when a request is received from an information terminal (such as a user's personal computer) connected directly to the parent control unit 40 or via a network.

[0030] The calculation unit 43 calculates the current remaining amount of wire 3 (e.g., the ratio of the current amount of wire 3 to the full amount) based on information about the wire 3 in each pail pack 2 stored in the memory unit 42. Specifically, the calculation unit 43 calculates the remaining amount of wire 3 from a total voltage value that is the sum of the voltage values ​​detected by the three sensors 11 to 13. For example, when the voltage value is acquired as shown in FIG. 4, the calculation unit 43 determines that the height of the wire 3 is at a position below the middle sensor 12, and calculates the remaining amount of wire 3 as the ratio of the current position to the height of the wire 3 when it is full.

[0031] Furthermore, the calculation unit 43 predicts when the remaining amount of wire 3 in each pail pack 2 will become equal to or less than a threshold value based on the change over time of the total voltage value. The calculation unit 43 predicts when the remaining amount will become equal to or less than a threshold value, for example, by machine learning from the change over time of the remaining amount of wire 3 stored in the storage unit 42. The threshold value is, for example, the remaining amount at the timing of replacing with a new pail pack 2 (wire 3). The threshold value may also be the remaining amount at a timing that goes back from the timing when the wire 3 needs to be replaced with a new one, the time required from ordering to delivery (for example, one week before the timing when the replacement is required). In addition to this, the calculation unit 43 may predict when the remaining amount of wire will become equal to or less than a predetermined threshold value set by the user, etc. In this case, it is preferable that the threshold value is set for each pail pack 2.

[0032] The calculation unit 43 can provide the user with the change in the remaining capacity of the wire 3 in real time by reading the sum of the acquired total voltage values, i.e., the change in the remaining capacity of the wire 3 over time, from the memory unit 42 as appropriate, and visualizing and outputting it using a graph or the like.

[0033] The notification unit 44 provides the user with necessary notifications based on the detection results of the calculation unit 43. The notification unit 25 notifies the user, for example, of the timing when the remaining charge of the wire 3 falls below a threshold, the timing to order a new wire 3 (a predetermined period before the timing when the remaining charge falls below the threshold), the fact that the remaining battery charge falls below a threshold and battery replacement is necessary, etc. The notification unit 25 may automatically place an order at the timing to order the wire 3.

[0034] The determination system 1 having such a configuration is extremely effective, for example, when managing many pail packs 2 connected to many welding devices in an integrated manner. Specifically, in a factory where, for example, several dozen pail packs 2 are used, it is difficult for a welding worker to visually manage the remaining amount of wire 3 in each pail pack 2. For this reason, a simple system for managing the remaining amount of wire 3 in each pail pack 2 in an integrated manner has been demanded.

[0035] A conventional system for determining the remaining amount of wire (see, for example, Patent Document 1) has a problem that it is difficult to attach a device for determining the remaining amount of wire to several dozens of pail packs 2. Even if the instantaneous remaining amount of wire is obtained, the rate at which the wire 3 in several dozens of pail packs 2 decreases varies depending on the work content of the welding device, and the timing of ordering inventory varies depending on the welding device to which the wire 3 is connected. For example, when comparing a pail pack 2 with a fast consumption rate and a pail pack 2 with a slow consumption rate, the pail pack 2 with the fast consumption rate needs to be ordered at a timing when the remaining amount of wire 3 is large, otherwise it may run out of stock. On the other hand, if the pail pack 2 with a slow consumption rate is ordered at the same timing as the pail pack with a fast consumption rate, the timing of ordering will be too early, and as a result, there is a risk that the inventory will have to be held for a long period of time.

[0036] In contrast, the determination system 1 in this embodiment detects the remaining amount of wire 3 in each pail pack 2 as a voltage value, which is managed by the parent control unit 40. The parent control unit 40 can obtain the change over time in the remaining amount of wire 3 based on the change in this voltage value. This allows the determination system 1 to not only obtain the instantaneous (intermittent) remaining amount of wire, but also to centrally manage the change over time in the remaining amount by the parent control unit 40. This allows the determination system 1 to appropriately know the timing to order wire 3, and to prevent the determination system 1 from having too much or too little inventory.

[0037] Furthermore, the determination system 1 has a simple configuration in which, for example, three sensors 11-13 are arranged in a vertical direction to obtain a voltage value corresponding to the presence or absence of the wire 3 within the detection range. The sensors 11-13 are connected to and integrated with the sub control unit 20, and can be attached to the outer surface simply by means of the support member 16, for example, which allows for easy attachment and detachment to the pail pack 2.

[0038] Furthermore, the determination system 1 turns on the sensors 11-13 at predetermined time intervals under the control of the slave control unit 20, thereby reducing the amount of power consumed by the sensors 11-13. Furthermore, the determination system 1 drives the sensors 11-13 and slave control unit 20 using an integrated battery 30, eliminating the need to secure separate power sources for the sensors 11-13 and sensor units 10 attached to dozens of pail packs 2, and the reduction in power consumption achieved by activating the sensors at predetermined time intervals as described above can extend the life of the battery 30 and reduce the need for frequent maintenance of the power source.

[0039] Furthermore, because the determination system 1 can obtain the change in voltage value over time, it can centrally manage the consumption tendency of the wire 3 and the remaining amount of wire 3 at any given time for every several dozen pail packs 2. Furthermore, because the determination system 1 can obtain the change in the remaining amount of wire 3 over time from the change in voltage value, it can also predict the consumption rate, and based on this, can predict the timing until ordering according to the consumption rate.

[0040] Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the claims. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims.

[0041] For example, the sensor unit 10 may be a weight sensor that measures the weight of the pail pack 2 (wire 3) instead of the above-mentioned metal detection sensor.

[0042] FIG. 5 is a schematic configuration diagram of a sensor unit 50 and a slave control unit 60 as a modified example.

[0043] The sensor unit 50 is a plurality of weight sensors 51-54, such as load cells, that output a voltage value according to the weight of the pail pack 2. The slave control unit 60 is connected to each of the weight sensors 51-54 and acquires the voltage values. The sensor unit 50 and the slave control unit 60 are disposed so as to be sandwiched between a pair of plate-like members 56, for example made of iron, having a predetermined thickness, via a spacer 57.

[0044] Such sensor unit 50 and slave control unit 60 are disposed on the installation surface of pail pack 2. For example, sensor unit 50 and slave control unit 60 are disposed on a dolly (not shown) that supports pail pack 2, and pail pack 2 is disposed on the above-mentioned plate-like member 56. For example, in the case where pail pack 2 is disposed on the dolly and used with a welding device, this has the advantage that measurement can be started immediately after delivery and placement at the site. [Explanation of symbols]

[0045] 1. Wire remaining amount judgment system (judgment system) 2 Pale Pack 3 Wire 10 Sensor unit 11~13 Metal detection sensor (sensor) 16 Support member 20 Sub-controller 21 Power supply control unit 22 Battery level acquisition unit 23 Detection result acquisition unit 24 Wireless Communication Section 25 Notification Department 30 batteries 31 Switch 40 Parent control unit 41 Wireless Communication Section 42 Storage section 43 Arithmetic section 44 Notification Department 50 Sensor Unit 51~54 Weight sensor (sensor) 56 Plate-shaped members 57 Spacer 60 Child control unit

Claims

1. A wire remaining amount determination system that determines the remaining amount of a metal wire in each of a plurality of containers that contains a metal wire wound in a spiral shape from below to above and removes the wire from above, comprising: a plurality of sensor units each disposed in one of the containers, each of which detects a physical quantity obtained from the remaining amount of the wire in the one of the containers by a voltage value; a plurality of slave control units each connected to the sensor unit, each disposed in the one container, and configured to acquire the voltage value from the one sensor unit; A wire remaining amount determination system comprising: a parent control unit connected to each of the child control units, receiving the voltage values ​​from each of the child control units, and determining the remaining amount of the wire in each of the containers.

2. 2. The wire remaining amount determination system according to claim 1, wherein the sensor unit has a plurality of metal detection sensors arranged along the vertical direction on the outer surface of the container and outputting the voltage value depending on the presence or absence of the metal wire within a predetermined range in the vertical direction from the location where the sensor unit is arranged.

3. The wire remaining amount determination system according to claim 1 , wherein the sensor unit includes a plurality of weight sensors arranged on a mounting surface of the container and configured to output the voltage value in accordance with the weight of the container.

4. The wire remaining amount determination system according to claim 1 , wherein the child control unit turns on the power of the sensor unit at predetermined time intervals to cause detection, and transmits the voltage value to the parent control unit each time the voltage value is obtained.

5. The wire remaining amount determination system according to claim 4 , wherein the sensor unit and the sub-controller are battery-powered.

6. The wire remaining amount determination system according to claim 1 , wherein the parent control unit acquires a change in the remaining amount of the wire in each container over time and predicts the timing of ordering the wire in each container based on the acquired change over time.

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