CN113199167A - Welding process quality monitoring and control terminal and welding monitoring system - Google Patents
Welding process quality monitoring and control terminal and welding monitoring system Download PDFInfo
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- CN113199167A CN113199167A CN202110449855.2A CN202110449855A CN113199167A CN 113199167 A CN113199167 A CN 113199167A CN 202110449855 A CN202110449855 A CN 202110449855A CN 113199167 A CN113199167 A CN 113199167A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
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- Optics & Photonics (AREA)
- Arc Welding Control (AREA)
Abstract
本发明公开了一种焊接过程质量监测及控制终端及焊接监测系统。终端包括：采样单元、总线单元、处理单元、显示单元、I/O执行单元、通讯单元和存储单元；总线单元、显示单元、I/O执行单元、通讯单元和存储单元分别与处理单元连接，采样单元与总线单元连接；采样单元对外提供多种传感器的接口，用于与监测焊机的多个传感器连接并实时采集焊接过程的焊接参数；总线单元用于将采用单元采集的焊接参数传输给处理单元；处理单元用于根据焊接参数判断是否有焊接质量问题，并根据焊接质量判断结果向焊接发出焊接动作的控制指令。实现提高焊接过程数据的传输及处理速度，并能够使焊接工位现场的操作人员及时发现焊接质量问题。
The invention discloses a welding process quality monitoring and control terminal and a welding monitoring system. The terminal includes: a sampling unit, a bus unit, a processing unit, a display unit, an I/O execution unit, a communication unit and a storage unit; the bus unit, the display unit, the I/O execution unit, the communication unit and the storage unit are respectively connected with the processing unit, The sampling unit is connected with the bus unit; the sampling unit provides a variety of sensor interfaces, which are used to connect with multiple sensors monitoring the welding machine and collect the welding parameters of the welding process in real time; the bus unit is used to transmit the welding parameters collected by the unit to the Processing unit; the processing unit is used for judging whether there is a welding quality problem according to the welding parameters, and sending a welding action control instruction to the welding according to the welding quality judgment result. It can improve the transmission and processing speed of welding process data, and enable operators at the welding station to discover welding quality problems in time.
Description
Technical Field
The invention relates to the technical field of welding process quality monitoring, in particular to a welding process quality monitoring and control terminal and a welding monitoring system.
Background
The method can be used for judging the quality of the welding process in real time by acquiring the data of the welding process in real time. At present, the existing welding data acquisition terminal equipment can only acquire parameters in the welding process, the acquired data are transmitted to an upper computer system, and the upper computer system processes the welding data.
The existing method for monitoring the quality of the welding process of the data acquisition terminal and the upper computer has the following problems:
1) the welding data analysis needs to be based on high-frequency data, the data frequency needs to be as high as 10kHz, the acquisition terminal and the upper computer are transmitted through a communication line, and the data transmission speed cannot meet the real-time requirement easily;
2) the upper computer is generally arranged in a control room, and operators on a welding station cannot see the processing result of an expert system of the upper computer, so that real-time online monitoring is difficult to realize;
3) the welding field environment is severe, the electric welding machine has large conduction interference on a power line, and a common PC machine is easy to interfere and unstable in work under a strong interference environment and inconvenient to install on site;
4) data collected on a welding site are more, sensors and transmitters with different hardware interfaces are required to be connected to some welding occasions, and an upper computer cannot be directly connected with the sensors and the transmitters.
Disclosure of Invention
The invention aims to provide a welding process quality monitoring and control terminal and a welding monitoring system, which can improve the transmission and processing speed of welding process data and enable operators on a welding station site to find out the problem of welding quality in time.
In order to achieve the above object, the present invention provides a welding process quality monitoring and control terminal, which is applied to a welding station field, and the terminal comprises: the device comprises a sampling unit, a bus unit, a processing unit, a display unit, an I/O execution unit, a communication unit and a storage unit;
the bus unit, the display unit, the I/O execution unit, the communication unit and the storage unit are respectively connected with the processing unit, and the sampling unit is connected with the bus unit;
the sampling unit is externally provided with interfaces of various sensors and is used for being connected with the sensors of the monitoring welding machine and acquiring welding parameters in the welding process in real time, and the acquisition frequency of the sampling unit is 0-10 kHz;
the bus unit is used for transmitting the welding parameters acquired by the adoption unit to the processing unit;
the processing unit is used for judging whether a welding quality problem exists according to the welding parameters, sending a control instruction of a welding action to welding according to a welding quality judgment result, carrying out non-real-time statistics and analysis on the welding parameters and storing originally sampled welding parameters and statistical and analysis data;
the display unit is used for displaying the welding quality judgment result in real time and displaying the statistics and analysis data;
the I/O execution unit is used for executing the control instruction sent by the processing unit in an I/O form so as to control the welding action of the welding machine;
the communication unit is used for providing a communication interface with the welding machine and the upper computer so as to send the control instruction sent by the processing unit to the welding machine or upload the state of the welding process quality monitoring and control terminal to the upper computer.
Optionally, the sampling unit includes an AD converter and an MCU coprocessor, the AD converter is configured to convert the analog signal uploaded by the sensor into a digital signal, and the MCU coprocessor is configured to preprocess the welding parameters acquired by the sensor.
Optionally, the bus unit comprises an LVDS serial board level interconnect bus.
Optionally, the processing unit comprises an MCU processor.
Optionally, the communication unit includes at least one of a 4G interface, a 5G interface, a bluetooth interface, a WIFI interface, and an ethernet interface.
Optionally, the storage unit includes at least one of a NANDFLASH memory, an SD card, and a hard disk.
Optionally, the portable electronic device further comprises a protective shell, wherein the sampling unit, the bus unit, the processing unit, the I/O execution unit, the communication unit and the storage unit are disposed in the protective shell, and the display unit is disposed on the protective shell.
Optionally, the welding parameters include welding current, welding voltage, wire feed speed, and welding gas flow.
The invention also provides a welding monitoring system which comprises the welding process quality monitoring and control terminal.
Optionally, the welding device further comprises a gas flow sensor, a current sensor, a voltage sensor and a pulse sensor which are connected with the welding process quality monitoring and control terminal;
the welding process quality monitoring and control terminal is arranged on a welding station site, is in communication connection with the welding machine and an upper computer in a monitoring room through an Ethernet, and is used for transmitting the real-time state of the welding machine to the upper computer and transmitting the welding quality problem to the upper computer in real time;
the gas flow sensor is arranged between the welding machine and a gas pipeline between the welding gas supply bottle;
the current sensor and the voltage sensor are arranged on a welding station, the current sensor is used for monitoring the welding current of the welding machine and sending the welding current to the welding process quality monitoring and control terminal, and the voltage sensor is used for monitoring the welding voltage of the welding machine and sending the welding voltage to the welding process quality monitoring and control terminal;
the pulse sensor is arranged on the wire feeder and used for collecting the wire feeding speed of the wire feeder and sending the collected wire feeding pulse signal of the wire feeder to the welding process quality monitoring and control terminal.
The invention has the beneficial effects that:
by integrating the sampling unit, the bus unit, the processing unit, the display unit, the I/O execution unit, the communication unit and the storage unit on the welding process quality monitoring and control terminal, real-time high-frequency sampling of welding parameters in a welding process is realized on the basis of the sampling unit, various sensor interfaces are provided to be convenient for connection with various sensors, whether welding quality problems exist or not is judged by the processing unit according to the welding parameters, a control instruction of welding action is sent to welding according to a welding quality judgment result, non-real-time statistics and analysis are simultaneously carried out on the welding parameters, and the welding parameters and the statistical and analysis data of original sampling are stored, compared with the prior art, the welding process quality monitoring and control terminal can complete real-time monitoring and control on the welding quality inside the acquisition terminal, and the problem of poor real-time performance caused by slow data transmission speed between the acquisition terminal and an upper computer in the prior art is solved, meanwhile, the welding process quality monitoring and control terminal is applied to the welding station field, so that an operator on the welding station can see the welding quality analysis and processing result in real time, and real-time online monitoring under the welding field environment can be realized.
The apparatus of the present invention has other features and advantages which will be apparent from or are set forth in detail in the accompanying drawings and the following detailed description, which are incorporated herein, and which together serve to explain certain principles of the invention.
Drawings
The above and other objects, features and advantages of the present invention will become more apparent by describing in more detail exemplary embodiments thereof with reference to the attached drawings, in which like reference numerals generally represent like parts.
FIG. 1 illustrates a functional block diagram of a welding process quality monitoring and control terminal according to one embodiment of the present invention.
FIG. 2 illustrates a schematic diagram of a weld monitoring system according to one embodiment of the present invention.
Detailed Description
The invention will be described in more detail below with reference to the accompanying drawings. While the preferred embodiments of the present invention are shown in the drawings, it should be understood that the present invention may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
FIG. 1 illustrates a functional block diagram of a welding process quality monitoring and control terminal according to one embodiment of the present invention.
As shown in fig. 1, a welding process quality monitoring and control terminal 1 is applied to a welding station field, and the terminal includes: a sampling unit 101, a bus unit 102, a processing unit 103, a display unit 104, an I/O execution unit 105, a communication unit 106, and a storage unit 107;
the bus unit 102, the display unit 104, the I/O execution unit 105, the communication unit 106 and the storage unit 107 are respectively connected with the processing unit 103, and the sampling unit 101 is connected with the bus unit 102;
the sampling unit 101 is externally provided with interfaces of various sensors and is used for being connected with the sensors of the monitoring welding machine and acquiring welding parameters in the welding process in real time, and the acquisition frequency of the sampling unit 101 is 9-11 kHz;
the bus unit 102 is used for transmitting the welding parameters acquired by the adoption unit to the processing unit 103;
the processing unit 103 is used for judging whether a welding quality problem exists according to the welding parameters, sending a control instruction of a welding action to the welding according to a welding quality judgment result, carrying out non-real-time statistics and analysis on the welding parameters and storing the originally sampled welding parameters and statistical and analysis data;
the display unit 104 is used for displaying the welding quality judgment result in real time and displaying statistics and analysis data;
the I/O execution unit 105 is configured to execute the control instruction sent by the processing unit 103 in an I/O format to control the welding operation of the welding machine;
the communication unit 106 is used for providing a communication interface with the welding machine and the upper computer so as to send a control instruction sent by the processing unit 103 to the welding machine or upload the state of the welding process quality monitoring and control terminal 1 to the upper computer.
In this embodiment, the sampling unit 101 includes an AD converter and an MCU coprocessor, the AD converter is configured to convert an analog signal uploaded by the sensor into a digital signal, and the MCU coprocessor is configured to preprocess a welding parameter acquired by the sensor.
Specifically, the sampling unit 101 is a high-speed sampling unit 101, the sampling frequency is 0-10kHz, the unit adopts an AD converter, and is combined with an MCU coprocessor to acquire welding process parameters in real time, and the acquired welding parameters include information such as welding current, welding voltage, wire feeding speed, gas flow, and the like.
In this embodiment, the bus unit 102 includes an LVDS serial board level interconnect bus.
Specifically, the bus unit 102 is a high-speed bus unit 102, which preferably uses serial LVDS as a high-speed board-level interconnection bus and is responsible for transmitting the welding parameters acquired by the high-speed sampling unit 101 to the computing unit. The LVDS (Low-Voltage Differential Signaling) Low-Voltage Differential Signaling is a Low-power consumption, Low-error-rate, Low-crosstalk and Low-radiation Differential Signaling technology, the transmission rate of the LVDS technology can reach over 155Mbps, the core of the LVDS technology is that data is transmitted in a very Low Voltage swing high-speed Differential mode, point-to-point or point-to-multipoint connection can be achieved, and a transmission medium of the LVDS technology can be a copper PCB (printed Circuit Board) connecting line or a balanced cable. The adoption of serial LVDS as a high-speed board-level interconnection bus can effectively improve the data transmission rate between the sampling unit 101 and the processing unit 103.
In this embodiment, the processing unit 103 includes an MCU processor.
Specifically, the processing unit 103 uses the main MCU processor to perform real-time calculation on the high-speed sampling parameters, determine whether there is a quality problem, and if there is a quality problem, control the operation of the welding machine, for example, when the welding current is found to be lower than a normal value, determine that the welding current is a weld leakage, and generate a processing command. The sampling parameters can be subjected to non-real-time statistics and analysis calculation, and the sampling raw data and the processing data can be stored.
In this embodiment, the communication unit 106 includes at least one of a 4G interface, a 5G interface, a bluetooth interface, a WIFI interface, and an ethernet interface.
Specifically, the communication unit 106 has a 4G interface, a 5G interface, a bluetooth interface, and an ethernet interface, and preferably uses the ethernet interface for communication, so as to conveniently execute the instruction sent by the computing unit in a communication form, or intelligently monitor and control the state of the terminal in the welding process transmitted by the upper computer, and preferably uses the ethernet transmission mode for the communication unit 106, so as to effectively avoid the interference of the welding machine on the terminal device.
In this embodiment, the storage unit 107 includes at least one of a NANDFLASH memory, an SD card, and a hard disk.
In particular, the storage unit 107 is preferably a DDR3 memory, executes commands of the processing unit 103, and may store the sampling data and the statistical analysis data by using NANDFLASH, SD cards or hard disks.
Preferably, the terminal further comprises a protective shell, the sampling unit 101, the bus unit 102, the processing unit 103, the I/O execution unit 105, the communication unit 106 and the storage unit 107 are disposed in the protective shell, and the display unit 104 is disposed on the protective shell. Preferably, the display unit 104 is a touch display screen.
As shown in fig. 2, an embodiment of the present invention further provides a welding monitoring system, which includes the welding process quality monitoring and control terminal 1 of the above embodiment.
The system also comprises a gas flow sensor 201, a current sensor 202, a voltage sensor 203 and a pulse sensor 204 which are connected with the welding process quality monitoring and control terminal 1;
the welding process quality monitoring and control terminal 1 is arranged on a welding station site, the welding process quality monitoring and control terminal 1 is in communication connection with a welding machine and an upper computer in a monitoring room through an Ethernet, and the welding process quality monitoring and control terminal 1 is used for transmitting the real-time state of the welding machine to the upper computer and transmitting the welding quality problem to the upper computer in real time;
the gas flow sensor 201 is arranged between a gas pipeline between the welding machine and the welding gas supply bottle;
the current sensor 202 and the voltage sensor 203 are arranged on a welding station, the current sensor 202 is used for monitoring the welding current of the welding machine and sending the welding current to the welding process quality monitoring and control terminal 1, and the voltage sensor 203 is used for monitoring the welding voltage of the welding machine and sending the welding voltage to the welding process quality monitoring and control terminal 1;
the pulse sensor 204 is disposed on the wire feeder, and is configured to collect a wire feeding speed of the wire feeder, and send a collected wire feeding pulse signal of the wire feeder to the welding process quality monitoring and control terminal 1.
The working process of the welding monitoring system specifically comprises the following steps:
1) real-time data acquisition
a) The welding process quality monitoring and control terminal 1 collects signals of welding current and welding voltage of the welding machine in real time. Welding current and voltage signals are acquired through a current sensor 202 and a voltage sensor 203. The current sensor 202 and the voltage sensor 203 output small signals of 0-5V or 4-20 mA to enter the welding process quality monitoring and control terminal 1.
b) The welding process quality monitoring and control terminal 1 collects gas flow signals in real time. The gas flow sensor 201 is connected in series in a loop of the gas cylinder and the welding machine through a gas pipe, and outputs a small signal of 0-5V or 4-20 mA to enter the welding process quality monitoring and control terminal 1.
c) The welding process quality monitoring and control terminal 1 collects the wire feeding speed in real time. The pulse sensor 204 collects the wire feeding speed of the wire feeder, and the number of pulses enters the welding process quality monitoring and control terminal 1.
2) Data real-time computation and processing
The processing unit 103 in the welding process quality monitoring and control terminal 1 actually judges the welding quality by the input welding current, welding voltage, gas flow and wire feeding speed; for example, when the welding current is found to be lower than a normal value, it is judged as a weld leakage, and a process command is generated.
3) Command execution
And when the welding quality problem is judged, such as welding leakage and welding deviation, sending a processing command to the welding machine through the Ethernet, and stopping the welding machine.
4) Execution result upload
The welding process quality monitoring and control terminal 1 transmits the real-time state of the welding machine to the upper computer system through the Ethernet and transmits the quality problem to the upper computer system in real time.
In conclusion, the welding process quality monitoring and control terminal can effectively improve the sampling, transmission and processing speed of welding process data, can enable operators on a welding station site to find out the problem of welding quality in time under the condition of meeting the real-time online monitoring of an upper computer, and meanwhile, terminal equipment is not easily interfered by a welding machine, works stably and is convenient to install on site.
Having described embodiments of the present invention, the foregoing description is intended to be exemplary, not exhaustive, and not limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments.
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| CN202110449855.2A CN113199167A (en) | 2021-04-25 | 2021-04-25 | Welding process quality monitoring and control terminal and welding monitoring system |
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Cited By (1)
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