CN108303962A - A kind of ultrasonic fusing data monitoring device and method - Google Patents

Abstract

The invention discloses an ultrasonic welding data monitoring device and method, and relates to the field of ultrasonic welding devices. The device includes at least one ultrasonic welding machine, at least one ultrasonic welding machine monitor and an information management platform; the ultrasonic welding machine monitor is used to collect parameter data of the welding process and send the parameter data to the information management platform; the information management platform will Display the parameter data, and send the alarm upper limit threshold and alarm lower limit threshold to the ultrasonic welding machine monitor. When the ultrasonic welding machine monitor determines that the parameter data is greater than the alarm upper limit threshold or less than the alarm lower limit threshold, it will alarm; the device can monitor multiple Various production parameter data, remotely set alarm parameters, provide alarm messages for defective products, and improve production efficiency; real-time monitoring of output can be achieved without manual statistics, reducing labor intensity.

Description

An ultrasonic welding data monitoring device and method

technical field

The invention relates to the field of ultrasonic welding devices, and in particular to an ultrasonic welding data monitoring device and method.

Background technique

Ultrasonic welding technology is becoming more and more common in the plastic industry all over the world. It is a high-tech technology for welding thermoplastic products and can completely replace glue bonding. All kinds of thermoplastic plastic parts can be processed by ultrasonic welding technology without adding solvents, adhesives or other auxiliary products. The principle is to transmit ultrasonic energy to the welding area through the upper weldment, and use the large acoustic resistance at the interface of the two welds, and generate local high temperature to fuse the weldments together. At present, ultrasonic welding machines are usually used to complete the connection of weldments. This technology has the advantages of fast speed, strong welds, etc., and can realize automatic production and processing.

However, the current ultrasonic welding machines are generally unable to monitor production parameter data, or can only monitor a single voltage or current, often resulting in the appearance of defective products, let alone use a large amount of data to analyze and optimize production; and cannot record equipment output data, requiring artificial statistics , Increase labor intensity.

Contents of the invention

Embodiments of the present invention provide an ultrasonic welding data monitoring device and method, which are used to solve the problem that production parameters cannot be monitored in the existing ultrasonic welding process and the production of equipment needs to be manually counted.

An embodiment of the present invention provides an ultrasonic welding data monitoring device, including:

At least one ultrasonic welding machine, at least one ultrasonic welding machine monitor and information management platform;

The ultrasonic welding machine monitor is connected with the ultrasonic welding electromechanical, used to collect the parameter data of the welding process, and send the parameter data to the information management platform;

The ultrasonic welding machine monitor is electrically connected to the information management platform;

The information management platform displays the parameter data, and sends the alarm upper limit threshold and alarm lower limit threshold to the ultrasonic welding machine monitor;

When the ultrasonic welding machine monitor determines that the parameter data is greater than the upper alarm threshold or less than the lower alarm threshold, an alarm is issued.

Preferably, it also includes a switch, a cloud server and a database, the switch, the cloud server and the database are electrically connected in sequence, the switch is electrically connected to the ultrasonic welding machine monitor, and the cloud server is electrically connected to the information management platform;

The switch is used to receive the parameter data collected by the ultrasonic welding machine monitor and send the parameter data to the cloud server;

The cloud server sends the parameter data to the information management platform and database.

Preferably, the parameter data includes time point, voltage data, current data, air pressure data, frequency data, output data and welding time data.

Preferably, the ultrasonic welding machine monitor includes: an Ethernet chip, a first main control chip, a second main control chip, a voltage transformer, a current sensor, and an air pressure sensor;

The first main control chip and the second main control chip are respectively electrically connected to the Ethernet chip, and the voltage transformer, current sensor and air pressure sensor are respectively electrically connected to the first main control chip;

The voltage transformer is used to detect the voltage data of the welding process, and send the detected voltage data to the first main control chip;

The current sensor is used to detect the current data of the welding process, and send the detected current data to the first main control chip;

The air pressure sensor is used to detect the air pressure data during the welding process, and send the detected air pressure data to the first main control chip;

The first main control chip sends the time point, voltage data, current data, air pressure data, frequency data and welding time data to the Ethernet chip through the second main control chip.

Preferably, the ultrasonic welding machine monitor also includes an SD card, and the SD card is electrically connected to the second main control chip;

The SD card is used to store the time point, voltage data, current data, air pressure data, frequency data and welding time data received by the second main control chip, and record the number of times the second main control chip sends to the Ethernet chip.

Preferably, the information management platform includes at least one client, the client is a workshop PC webpage, and the client is used to log in to the information management platform and set the upper alarm threshold and the lower alarm threshold.

A method for monitoring ultrasonic welding data, comprising:

Send the collected welding process parameter data to the information management platform;

The parameter data is displayed on the information management platform and compared with the preset alarm upper limit threshold and alarm lower limit threshold. If the parameter data is greater than the alarm upper limit threshold or less than the alarm lower limit threshold, an alarm is determined and an alarm signal is sent.

Preferably, the parameter data includes time point, voltage data, current data, air pressure data, frequency data, output data and welding time data.

The embodiment of the present invention provides an ultrasonic welding data monitoring device and method, the device includes at least one ultrasonic welding machine, at least one ultrasonic welding machine monitor and an information management platform; the ultrasonic welding machine monitor is used to collect parameters of the welding process data, and send the parameter data to the information management platform; the information management platform is used to receive the parameter data and display the parameter data, and is also used to set the alarm upper limit threshold and the alarm lower limit threshold, and send the alarm upper limit threshold and the alarm lower limit threshold To the ultrasonic fusion machine monitor, the ultrasonic fusion machine monitor receives the alarm upper limit threshold and the alarm lower limit threshold, and judges that the parameter data is greater than the alarm upper limit threshold or less than the alarm lower limit threshold, then confirms the alarm and sends an alarm signal to the information management platform; the device can monitor A variety of production parameter data, remote setting alarm parameters, providing alarm messages for defective products, and improving production efficiency; data networking, not only convenient storage, but also large storage capacity, convenient display, convenient for subsequent data analysis, and optimized production; real-time monitoring of output, no need Artificial statistics, reduce labor intensity.

Description of drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only These are some embodiments of the present invention. Those skilled in the art can also obtain other drawings based on these drawings without creative work.

Fig. 1 is a structural diagram of an ultrasonic welding data monitoring device provided by an embodiment of the present invention;

Fig. 2 is a schematic diagram of the data collection process of the ultrasonic welding machine monitor provided by the embodiment of the present invention;

Fig. 3 is an alarm flow chart of an ultrasonic welding data monitoring device provided by an embodiment of the present invention;

Fig. 4 is a schematic flowchart of a method for monitoring ultrasonic welding data provided by an embodiment of the present invention.

Detailed ways

The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.

Figure 1 is a structural diagram of an ultrasonic welding data monitoring device provided by an embodiment of the present invention; as shown in Figure 1, the device mainly includes: at least one ultrasonic welding machine, at least one ultrasonic welding machine monitor and an information management platform;

The ultrasonic welding machine monitor is connected with the ultrasonic welding electromechanical, used to collect the parameter data of the welding process, and send the parameter data to the information management platform;

The ultrasonic welding machine monitor is electrically connected to the information management platform;

The information management platform displays the parameter data, and sends the alarm upper limit threshold and alarm lower limit threshold to the ultrasonic welding machine monitor;

When the ultrasonic welding machine monitor determines that the parameter data is greater than the upper alarm threshold or less than the lower alarm threshold, an alarm is issued.

The monitoring device is mainly aimed at monitoring the welding process of thermoplastic products by ultrasonic welding technology. In the specific implementation process, the monitoring device also includes: switches, cloud servers and databases, switches, cloud servers and databases are electrically connected in sequence, switches and ultrasonic welding Electrical connection of machine monitoring instrument, electrical connection of cloud server and information management platform;

The switch is used to receive the parameter data collected by the ultrasonic welding machine monitor, and send the received parameter data to the cloud server;

The cloud server receives the parameter data and sends the parameter data to the information management platform and database;

The database is used to receive and store the parameter data.

Specifically, in the monitoring of the welding process of thermoplastic products by ultrasonic welding technology, the welding process parameter data mainly collected by the monitoring device in the embodiment of the present invention includes time point, voltage data, current data, air pressure data, frequency data, output data and welding time.

Fig. 2 is a schematic diagram of the data collection process of the ultrasonic welding machine monitor provided by the embodiment of the present invention. As shown in Fig. 2, the parameter data of the welding process is monitored by the ultrasonic welding machine monitor in the device.

The ultrasonic welding machine monitor includes: Ethernet chip, first main control chip, second main control chip, voltage transformer, current sensor, air pressure sensor, SD card, sound and light alarm module and power supply module.

The first main control chip and the second main control chip are respectively electrically connected to the Ethernet chip, and the voltage transformer, current sensor, air pressure sensor and sound and light alarm module are respectively electrically connected to the first main control chip.

The SD card and the power module are respectively electrically connected to the second main control chip.

When the ultrasonic welding machine is welding thermoplastic products, the working power of the ultrasonic welding machine is 220V AC power frequency, and the collection of voltage data and current data uses voltage transformers and current sensors to realize real-time monitoring and collection of AC power. The detection principle In order to convert the high voltage and high current of the AC power supply into a low voltage that can be detected and processed by the single chip microcomputer through the voltage transformer and the current sensor, the detection range of the AC voltage is AC0V-AC400V, and the detection range of the AC current is AC0A-AC10A.

The voltage transformer of the ultrasonic welding machine monitor is used to detect the voltage data of the welding process, and send the detected voltage data to the first main control chip; specifically, the alternating voltage signal of the power supply is input into the current-type voltage transformer through the series current-limiting resistor The primary side winding of the voltage transformer is output through the secondary side of the voltage transformer, and the output matching resistor converts the output current signal into a voltage signal, and sends it to the first main control chip for sampling and processing.

The current sensor of the ultrasonic welding machine monitor is used to detect the current data of the welding process, and send the detected current data to the first main control chip; specifically, the current signal of the AC power supply is directly connected to the primary side winding of the current sensor, and the induced current Through the output of the secondary side of the sensor, the output matching resistor converts the current signal into a voltage signal, and sends it to the first main control chip for sampling and processing.

The air pressure sensor of the ultrasonic welding machine monitor is used to detect the air pressure data during the welding process, and send the detected air pressure data to the first main control chip; specifically, the air pressure sensor is used to perform analog-to-digital conversion on the voltage at the output point, that is, the air pressure Data, send the data to the first main control chip for sampling processing, the voltage range of the output terminal of the air pressure sensor is 0.5-4.5V.

The first main control chip is used to receive the frequency data and welding time data output by the monitoring circuit; specifically, the input capture function inside the first main control chip obtains the frequency data output by the timer, and the counter calculates the start point of the ultrasonic wave and the end point of the ultrasonic wave , to obtain the welding time data and send it to the first main control chip.

The clock circuit inside the first main control chip is used to record the time point of processing data when the ultrasonic welding machine performs welding processing.

The first main control chip sends the received time point, voltage data, current data, air pressure data, frequency data and welding time data to the second main control chip; the second main control chip is used to send the received time point, voltage data , current data, air pressure data, frequency data and welding time data are sent to the Ethernet chip.

The SD card is used to store the time point, voltage data, current data, air pressure data, frequency data and welding time data received by the second main control chip, and record the number of successful transmissions from the second main control chip to the Ethernet chip to form output data .

In specific use, both the first main control chip and the second main control chip use ATMEGA128A single-chip microcomputer.

Referring to Figure 1 and Figure 2, when the ultrasonic welding data monitoring device in the embodiment of the present invention is in use, the ultrasonic welding machine monitor is correspondingly fixed on the outside of the ultrasonic welding machine, and is electrically connected with the ultrasonic welding machine, and the ultrasonic welding machine monitor is used. The first main control chip, voltage transformer, current sensor, and air pressure sensor collect the time point, voltage data, current data, air pressure data, frequency data, output data, and welding time data of the welding process, and use the internal SD card of the ultrasonic welding machine monitor The recorded number of transmissions from the second main control chip to the Ethernet chip forms the production data, and the time point, voltage data, current data, air pressure data, frequency data, welding time data and production data collected by the ultrasonic welding machine monitor are composed of parameters data, and the ultrasonic welding machine monitor sends the collected parameter data to the switch.

The switch receives the parameter data sent by the ultrasonic fusion machine monitor, and sends the parameter data to the cloud server.

The cloud server receives the parameter data sent by the switch, and sends the parameter data to the information management platform and database.

The information management platform receives the parameter data and displays the parameter data. The information management platform also presets the alarm upper limit threshold and the alarm lower limit threshold, and sends the alarm upper limit threshold and the alarm lower limit threshold to the ultrasonic welding machine monitor.

The ultrasonic welding machine monitor receives the upper alarm threshold and the lower alarm threshold, and compares the collected parameter data with the upper alarm threshold and the lower alarm threshold. When the parameter data is greater than the upper alarm threshold or less than the lower alarm threshold, the sound and light alarm module is controlled. Make an alarm and send an alarm signal to the information management platform, and the information management platform receives the alarm signal and displays the alarm signal.

Fig. 3 is an alarm flowchart of an ultrasonic welding data monitoring device provided by an embodiment of the present invention. As shown in Fig. 3, the information management platform presets the upper alarm threshold and the lower alarm threshold, and sends the upper alarm threshold and the lower alarm threshold to To the cloud server, the cloud server sends the alarm upper limit threshold and the alarm lower limit threshold to the ultrasonic fusion machine monitor, and the ultrasonic fusion machine monitor receives the alarm upper limit threshold and the alarm lower limit threshold, and compares the detected parameter data with the alarm upper limit threshold and the alarm Compared with the lower limit threshold, if the parameter data is greater than the upper limit threshold of the alarm or less than the lower limit threshold of the alarm, the sound and light alarm module will be controlled to perform sound and light alarm, and at the same time, the state of the relay will be changed to remind the operator to remove the defective products, and the alarm signal will be sent to the cloud The server and the cloud server receive the alarm signal and send it to the information management platform for display, so that the operator can see the alarm signal on the web page of the PC in the workshop.

For the selection of the alarm upper limit threshold and the alarm lower limit threshold, the control variable method can be used to test and determine. If it is necessary to determine the alarm upper limit threshold and the alarm lower limit threshold of the air pressure data, keep the voltage data, current data, frequency data and welding time unchanged. .

For example: 100, 150, 200, 250, 300, 400, 500, 600, 700, 750, 800kpa and other air pressure parameters are used to produce 20 plastic parts for each set of air pressure parameters, and the safety test and tension of the produced plastic parts are carried out Tested, those that pass the test are regarded as good products, and those that fail the test are regarded as defective products.

If 200, 250, 300, 400, 500, 600, 700kpa are good products, and 100, 150, 750, 800kpa are all defective products, then the lower threshold is between 150kpa and 200kpa, and the upper threshold is between 700kpa and 750kpa. Then select the air pressure parameters of 160, 170, 180, and 190kpa to do the test. The air pressure parameters of 160, 170, and 180kpa are all defective products, and 190kpa is a good product. Then set the lower limit threshold of the air pressure parameter to 190kpa. The upper threshold is similar to this, assuming that the upper limit is determined to be 720kpa. Therefore, the air pressure threshold can be set on the information management platform to be less than 190kpa and greater than 720kpa. The thresholds of "voltage data, current data, frequency data, and welding time" are set similarly to air pressure.

In the embodiment of the present invention, there is no specific limitation on the values of the upper alarm threshold and the lower alarm threshold of the time point, voltage data, current data, frequency data, and welding time data.

The database in an ultrasonic welding data monitoring device provided by an embodiment of the present invention receives and stores parameter data of various welding processes, and for a large number of stored production parameter data, it can be analyzed by time series graph or comparison graph of big data in the later stage And other analysis algorithms analyze the stored production parameter data, analyze the factors that affect the production results and the law of production parameters, and then adjust and optimize the production parameters to improve production efficiency.

Based on the same inventive concept, the embodiment of the present invention provides a method for monitoring ultrasonic welding data. Since the principle of solving technical problems of this method is similar to the implementation method of an ultrasonic welding data monitoring device, the specific implementation of this method can be found in the device. The implementation process will not be repeated here.

Fig. 4 is a schematic flow chart of an ultrasonic welding data monitoring method provided by an embodiment of the present invention. As shown in Fig. 4, the method mainly includes the following steps:

Step 401, sending the collected welding process parameter data to the information management platform;

Step 402, the parameter data is displayed on the information management platform, and compared with the preset alarm upper limit threshold and alarm lower limit threshold, if the parameter data is greater than the alarm upper limit threshold or less than the alarm lower limit threshold, it is determined to alarm and send an alarm signal.

In summary, embodiments of the present invention provide an ultrasonic welding data monitoring device and method, the device includes at least one ultrasonic welding machine, at least one ultrasonic welding machine monitor and an information management platform; the ultrasonic welding machine monitor is used for Collect the parameter data of the welding process and send the parameter data to the information management platform; the information management platform is used to receive the parameter data and display the parameter data, and is also used to set the alarm upper limit threshold and the alarm lower limit threshold are sent to the ultrasonic fusion machine monitor, and the ultrasonic fusion machine monitor receives the alarm upper limit threshold and the alarm lower limit threshold, and judges that the parameter data is greater than the alarm upper limit threshold or less than the alarm lower limit threshold, then confirms the alarm and sends an alarm signal to the information management platform ;The device can monitor a variety of production parameter data, remotely set alarm parameters, provide alarm messages for defective products, and improve production efficiency; data networking, not only convenient storage, but also large storage capacity, convenient display, and subsequent data analysis to optimize production; Real-time monitoring of production without manual statistics, reducing labor intensity.

Those skilled in the art should understand that the embodiments of the present invention may be provided as methods, systems, or computer program products. Accordingly, the present invention can take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) having computer-usable program code embodied therein.

The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It should be understood that each procedure and/or block in the flowchart and/or block diagram, and a combination of procedures and/or blocks in the flowchart and/or block diagram can be realized by computer program instructions. These computer program instructions may be provided to a general purpose computer, special purpose computer, embedded processor, or processor of other programmable data processing equipment to produce a machine such that the instructions executed by the processor of the computer or other programmable data processing equipment produce a An apparatus for realizing the functions specified in one or more procedures of the flowchart and/or one or more blocks of the block diagram.

These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing apparatus to operate in a specific manner, such that the instructions stored in the computer-readable memory produce an article of manufacture comprising instruction means, the instructions The device realizes the function specified in one or more procedures of the flowchart and/or one or more blocks of the block diagram.

These computer program instructions can also be loaded onto a computer or other programmable data processing device, causing a series of operational steps to be performed on the computer or other programmable device to produce a computer-implemented process, thereby The instructions provide steps for implementing the functions specified in the flow chart or blocks of the flowchart and/or the block or blocks of the block diagrams.

While preferred embodiments of the invention have been described, additional changes and modifications to these embodiments can be made by those skilled in the art once the basic inventive concept is appreciated. Therefore, it is intended that the appended claims be construed to cover the preferred embodiment as well as all changes and modifications which fall within the scope of the invention.

Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and equivalent technologies thereof, the present invention also intends to include these modifications and variations.

Claims (8)

1. An ultrasonic welding data monitoring device, characterized in that, comprising: At least one ultrasonic welding machine, at least one ultrasonic welding machine monitor and information management platform; The ultrasonic welding machine monitor is electrically connected with the ultrasonic welding machine, used to collect parameter data of the welding process, and send the parameter data to the information management platform; The ultrasonic welding machine monitor is electrically connected to the information management platform; The information management platform displays the parameter data, and sends the upper alarm threshold and the lower alarm threshold to the ultrasonic welding machine monitor; When the ultrasonic welding machine monitor determines that the parameter data is greater than the upper alarm threshold or less than the lower alarm threshold, an alarm is issued. 2. The device according to claim 1, further comprising a switch, a cloud server and a database, the switch, the cloud server and the database are electrically connected in sequence, and the switch and the ultrasonic welding machine monitor Instrument and electrical connection, the cloud server is electrically connected to the information management platform; The switch is used to receive the parameter data collected by the ultrasonic welding machine monitor, and send the parameter data to the cloud server; The cloud server sends the parameter data to the information management platform and the database. 3. The device according to claim 1, wherein the parameter data includes time point, voltage data, current data, air pressure data, frequency data, output data and welding time data. 4. The device according to claim 3, wherein the ultrasonic welding machine monitor comprises: an Ethernet chip, a first main control chip, a second main control chip, a voltage transformer, a current sensor, and an air pressure sensor; The first main control chip and the second main control chip are respectively electrically connected to the Ethernet chip, and the voltage transformer, current sensor and air pressure sensor are respectively electrically connected to the first main control chip; The voltage transformer is used to detect the voltage data of the welding process, and send the detected voltage data to the first main control chip; The current sensor is used to detect the current data of the welding process, and send the detected current data to the first main control chip; The air pressure sensor is used to detect the air pressure data in the welding process, and send the detected air pressure data to the first main control chip; The first main control chip sends the time point, the voltage data, the current data, the air pressure data, the frequency data and the welding time data to the Ethernet through the second main control chip chip. 5. The device according to claim 4, wherein the ultrasonic welding machine monitor also includes an SD card, and the SD card is electrically connected to the second main control chip; The SD card is used to store the time point received by the second main control chip, the voltage data, the current data, the air pressure data, the frequency data and the welding time data, and record the The number of times the second main control chip sends to the Ethernet chip. 6. The device according to claim 1, wherein the information management platform includes at least one client, the client is a workshop PC webpage, and the client is used to log into the information management platform and Set the upper alarm threshold and the lower alarm threshold. 7. A method for monitoring ultrasonic welding data, comprising: Send the collected welding process parameter data to the information management platform; The parameter data is displayed on the information management platform and compared with the preset alarm upper limit threshold and alarm lower limit threshold, if the parameter data is greater than the alarm upper limit threshold or less than the alarm lower limit threshold, it is determined to give an alarm And send an alarm signal. 8. The method according to claim 7, wherein the parameter data includes time point, voltage data, current data, air pressure data, frequency data, output data and welding time data.