CN102298858A - Welding operation simulator for CO2 gas shield arc welding - Google Patents
Welding operation simulator for CO2 gas shield arc welding Download PDFInfo
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- CN102298858A CN102298858A CN2011102421088A CN201110242108A CN102298858A CN 102298858 A CN102298858 A CN 102298858A CN 2011102421088 A CN2011102421088 A CN 2011102421088A CN 201110242108 A CN201110242108 A CN 201110242108A CN 102298858 A CN102298858 A CN 102298858A
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Abstract
The invention provides a welding operation simulator for CO2 gas shield arc welding. The simulator comprises a control cabinet, an operation console, and a simulation welding gun. The simulation welding gun includes a welding gun rod, a handle, an arc plastic housing, an electric touch pen, a spring, a mobile copper sheet, an inductive proximity switch, an inclination angle sensor, and a nozzle. One end of the electric touch pen is fixedly connected with the mobile copper sheet and the electric touch pen passes through a center of the nozzle that is connected with the mobile copper by the spring. The inductive proximity switch is installed at one end of the welding gun rod and the double-shaft inclination angle sensor is installed at the other end of the welding gun rod. One end of an insulating cylinder is sleeved around the periphery of the nozzle and the other end of the insulating cylinder is sleeved around the periphery of the welding gun rod, wherein the inductive proximity switch is installed at the welding gun rod. One end of the arc plastic housing is connected with the welding gun rod and the other end of the arc plastic housing is connected with the handle. The inductive proximity switch and the double-shaft inclination angle sensor are connected with a computer in the control cabinet; besides, the operation console comprises a touch screen that is used as a welding test panel, wherein the touch screen is connected with the computer in the control cabinet. According to the invention, a training cost is substantially reduced; meanwhile, the training can be carried out safely and efficiently.
Description
[technical field]
The invention belongs to welding analog and emulation training field, particularly a kind of CO
2Shielded welding operation training analogue means.
[background technology]
CO
2Shielded welding is a kind of new solder technology that eighties of last century grows up the fifties.Since over half a century, it has developed into a kind of important fusion welding method.Widespread use and auto industry, engineering machinery manufacturing industry, shipbuilding industry, locomotive manufacturing industry, manufacturing industry of the lift, boilers and pressure vessel manufacturing industry, the production of various metal constructions and metalworking machinery.
CO
2Shielded welding is as a kind of high efficiency welding method, obtained utilization widely in the every field of China's industrial economy.Especially in recent years, after China became " world's factory ", a large amount of processing of foreign trade metal, steel construction industries were greatly developed CO
2Shielded welding with its high productivity (higher 1～3 times) than manual welding, welding deformation is little and the characteristics of high performance-price ratio, has obtained unprecedented popularize, and becomes one of welding method that override selects.CO
2Shielded welding can be divided into two kinds of automatic weldering and semiautomatic weldings by method of operating.Curved welding seam for long straight bead and rule can adopt automatic weldering; For irregular or tortuous weld seam, then adopt semiautomatic welding, what the last application of production at present was maximum is semiautomatic welding.And as the main implementer of semiautomatic welding (holding the welding gun welding), welder's operative technique is determining the development and the application of this gate technique to a great extent.
Traditional C O
2The shielded welding welding training is the process of a high investment, need to consume a large amount of test specimen and wlding, and the difference of instructor's level is to the raising generation significant effects of standard welder operation and technical ability.Simultaneously, the arc light in the actual welding operating environment, splash, flue dust etc., new student's health and study is all impacted.Along with the progress of modern science and technology, transform the traditional welding training by computer technology, for reducing electric welder's training cost, create good Training Environment and have great importance.The welding analog training can make the welder on the simulated operation platform, places oneself in the midst of among the welding surroundings of emulation, carries out the welding analog training, grasps and learn correct basic operating technical ability, lays a solid foundation for carrying out actual welding operation.Yet, also do not have a kind of CO now
2Shielded welding welding operation simulator can supply elementary CO
2The shielded welding welder crosses the threshold and improves training.
[summary of the invention]
The object of the present invention is to provide a kind of CO
2Shielded welding welding operation simulator is for elementary CO
2The shielded welding welder crosses the threshold and improves training.
To achieve these goals, the present invention adopts following technical scheme:
A kind of CO
2Shielded welding welding operation simulator comprises switch board, operator's console and simulated welding gun; Described simulated welding gun comprises that welding gun bar, handle, arc plastic jacket, electric stylus, spring, mobile copper sheet, inductance are near switch, obliquity sensor and nozzle; Electricity stylus one end fixedly connected mobile copper sheet, electric stylus passes nozzle center, is connected by spring between nozzle and the mobile copper sheet; Welding gun bar one end is equipped with inductance near switch, and the other end is equipped with double-shaft tilt angle sensor; One insulating cylinder, one end is sheathed on the nozzle periphery, and the other end is sheathed on the welding gun bar periphery of inductance near switch is installed; Arc plastic jacket one end is connected and installed with the welding gun bar of double-shaft tilt angle sensor, and the other end connects handle; Inductance is near switch and computing machine in double-shaft tilt angle sensor is connected switch board; Operator's console comprises a touch-screen as test piece for welding, and this touch-screen connects the computing machine in the switch board.
Described insulating cylinder is a nylon ring.
Described operator's console also comprises shell and bracing frame, and described touch-screen is installed in the described shell, and described shell is installed on the support frame as described above; Support frame as described above be provided with regulate the touch-screen height and surface level between the apparatus for adjusting position at pitch angle.
The angle that described apparatus for adjusting position can be regulated between touch-screen and the surface level is 0 °, 10 °, 15 °, 20 °, 25 ° or 30 °.
Described CO
2Shielded welding welding operation simulator also comprises a helmet, and the described helmet comprises the simulation face shield and be installed in the video eyeglasses of simulating on the face shield that described video eyeglasses connects the video interface of computing machine in the switch board.
By data acquisition card connection computing machine, double-shaft tilt angle sensor changes 485 interfaces by RS232 and connects computing machine inductance near switch, and touch-screen connects computing machine by the OpenGL interface.
The model of described capture card is PCI-9112; The model of described double-shaft tilt angle sensor is CS-2TAS-02; The range of described inductance approach switch is 1-8mm.
Described CO
2Shielded welding welding operation simulator also comprises keyboard, mouse and the audio amplifier that connects described computing machine.
The two-dimentional track that the simulated welding gun of touch-screen collection moves thereon passes to computing machine in real time, inductance passes to computing machine near the data in real time of distance between the nozzle of switch collection and the touch-screen, and the soldering angle data in real time of the simulated welding gun of double-shaft tilt angle sensor collection passes to computing machine; Computing machine connects according to the data of the simulated welding gun distance between two-dimentional track data, nozzle and the touch-screen that moves on the touch-screen that receives and the soldering angle data of simulated welding gun, in real time display simulation welding picture on touch-screen.
Compared with prior art, the present invention has following beneficial effect: CO of the present invention
2Shielded welding welding operation simulator is applicable to crossing the threshold, improve and improving and train of welder's welding operation; Simulator is by reasonably being provided with sensor on simulated welding gun, be that the weldering plate is simulated welding with the touch-screen, and touch-screen obtains the real-time track that welding gun moves and passes to computing machine by the relevant mouse event function among the OpenGL; Be arranged at sensor in simulated welding gun arc length and the welding inclination angle can gather simulated welding gun simulation welding in real time the time and pass to computing machine; Computing machine carries out analyzing and processing to the data that collect, and presents the welding picture on touch-screen in real time.Simulator of the present invention can realize that the operation training of CO2 shielded welding is new, has not had flue dust, the high light in the true welding process and splashes, but also can experience real welding process in virtual scene; Make the student can grasp the welding feel equally, improve the welding skill, can reduce training cost greatly again, safety, efficient.
[description of drawings]
Fig. 1 is the overall theory diagram of the present invention;
Fig. 2 is the structural representation of simulator of the present invention;
Fig. 3 is the structural representation of operator's console of the present invention;
Fig. 4 is the structural representation of simulated welding gun of the present invention;
Fig. 5 is the split figure of Fig. 4;
Fig. 6 is the structural representation of the helmet of the present invention.
[embodiment]
Below in conjunction with accompanying drawing the present invention is done and to describe in further detail.
The present invention combines technology such as virtual reality, sensing technology and vision simulation, at research CO
2On the principle and characteristics basis of shielded welding operation, designed two-dimentional mouse type detection system based on touch-screen.In addition by the inductance in simulated welding gun, installed near switch and obliquity sensor, obtain welding gun end and the distance (promptly simulating arc length) of touch-screen and the inclination data of welding gun, finally finish the detection of five degree of freedom of welding gun.Under specific molten bath model, by processing and analysis to the above welding parameter that collects, generation comprises simulation, weld seam simulation, arc light and the spatter model of welding surroundings based on the real-time virtual welding scene of OpenGL, finally finishes the simulation to the welding behavior.
Fig. 1 is the principle of work block diagram of simulator of the present invention, and this device is divided into hardware platform and software platform two parts.Hardware platform provides the high Precision Detection of simulation welding rod position, the effect of software platform is that the welding rod data of hardware platform collection are handled and analyzed, the reconstruction of three-dimensional scene, this three-dimensional scenic and welding operation process interplayed, the operating process of welding all will truly be reflected in the three-dimensional scenic, and provide the arc light the same in the scene with true welding process, splash, the welding rod fusing, scenes such as molten bath formation, these scenes are that computing machine generates in real time according to welder technological parameter of setting in advance and the welder's service data that collects, and the simulation weld seam and the effect assessment of output welding operation, for the user provides good man computer interface.
See also Fig. 2 to shown in Figure 6, the hardware platform of simulator of the present invention mainly comprises: switch board 1, operator's console 2, simulated welding gun 3 and Helmet Mounted Display 4.
(1) simulation welding panel
See also shown in Figure 3, the simulation welding panel 2 comprise touch-screen 21, keyboard 22, mouse 23, audio amplifier 24, bracing frame 25 and shell 26, simulated welding gun 3 is fixed on shell 26 sides; When the simulation welding operation, touch-screen 21 is as test piece for welding, and the hand-held simulated welding gun 3 of operator is implemented welding on touch-screen 21.According to operator's different needs, regulate the height and the angle of operator's console by the apparatus for adjusting position of operator's console 2 back in addition.Because the obliquity sensor that is adopted is used to measure object degree of tilt with respect to the horizontal plane under static environment, its range is ± 60 °, welding gun 3 inclination angles when considering welding (comprise pitching and incline and roll the angle) are in ± 30 °, so the angle of touch-screen 21 planes and surface level should be 0-30 °.The angle of regulating is 0 °, 10 °, 15 °, 20 °, 25 ° and 30 ° six kinds.After each the adjustment, need on system interface, to select the weldering plate angle of this time welding operation according to this.
(2) simulated welding gun
See also Fig. 4 and shown in Figure 5, simulated welding gun 3 comprises that mainly welding gun bar 30, handle 31, arc plastic jacket 32, nylon ring 33, electric stylus 34, spring 35, mobile copper sheet 36, inductance are near switch 37, obliquity sensor 38 and nozzle 39.The material of nylon ring 33 is a nylon 66, its insulation and tool intensity height.The fixedly connected mobile copper sheet 36 of electricity stylus 34 1 ends, electric stylus 34 passes nozzle 39 centers, between nozzle 39 and the mobile copper sheet 36 spring 35 is installed, and spring 35 is extension spring; Welding gun bar 30 1 ends are equipped with inductance near switch 37, and the other end is equipped with double-shaft tilt angle sensor 38; Nylon ring 33 1 ends are sheathed on nozzle 39 peripheries, and the other end is sheathed on welding gun bar 30 peripheries of inductance near switch 37 are installed, and after installing, double-shaft tilt angle sensor 38 is vertically installed with respect to electric stylus 34; Mobile copper sheet 36 can move in nylon ring 33; Arc plastic jacket 32 1 ends are connected and installed with the welding gun bar 30 of double-shaft tilt angle sensor 38, and the other end connects handle 31, make to simulate true welding gun between handle 31 and the welding gun bar 30 and have certain radian.The profile of simulated welding gun 3 and true welding gun much at one, this has strengthened the authenticity of simulation.The simulation welding wire of welding gun 3 ends is electric stylus 34, its main effect be the simulation welding operation the time contact with touch-screen 21, the real-time track that touch-screen 21 moves by the relevant mouse event function acquisition welding gun 3 among the OpenGL also passes to computing machine.The inductance that is installed in welding gun 3 inside obtains welding gun 3 ends and the distance (promptly simulating arc length) of touch-screen 21 and the dip angle signal of welding gun 3 near switch 37 and obliquity sensor 38 by data collecting card.
Among the present invention, welding gun bar 30, electric stylus 34, spring 35, mobile copper sheet 36, inductance are near switch 37, obliquity sensor 38 and nozzle 39 coaxial settings; This device adopts is the CS-2TAS-02 type numeral double-shaft tilt angle sensor (measurement range: roll angle ± 60 ° of Xi'an culminant star observing and controlling company; The angle of pitch ± 60 °), it is based on the sensor of MEMS technology, is used to measure object degree of tilt with respect to the horizontal plane under static environment.The inclination angle that obliquity sensor 38 records is that the soldering angle data are changeed 485 interfaces by RS232 and passed to computing machine.
Nozzle 39 is long to the electric arc that the distance of touch-screen 21 is similar in the welding process, and what the measurement of this distance was adopted is that inductance is near switch 37.Inductance approach switch 37 belongs to a kind of position transducer that switching value output is arranged, and it is made up of LC high frequency oscillator and amplification treatment circuit, utilizes metal object when the vibration inductive head that can generate an electromagnetic field near this, makes interior of articles produce eddy current.This eddy current reacts near switch, makes near the decay of switch vibration ability, and the parameter of internal circuit changes, identify thus to have or not metal object approaching, and then the on-off of gauge tap.What this simulator adopted is 1-8mm near the switch range, protects the arc length of weldering with carbon dioxide gas and roughly coincide.Output signal near switch 37 is a voltage analog, and this signal is passed to computing machine by the capture card PCI-9112 collection that is installed in the switch board 1.In addition, because touch-screen 21 is nonmetal, so can not be measured object directly with touch-screen 21; The length that electric stylus 34 stretches out nozzle 39 in this welding gun equals mobile copper sheet 36 and inductance near the distance between the switch 37; Adopt spring 35 and mobile copper sheet 36, be converted into the survey inductance near the distance (as shown in Figure 5) of switch 37 with mobile copper sheet 36 with surveying electric arc length.
(3) Helmet Mounted Display
Helmet Mounted Display 4 (Fig. 6) is made up of simulation face shield 41 and the video eyeglasses 42 that is installed on the simulation face shield 41, and video eyeglasses 42 resolution that adopted are 1024 * 768, and video eyeglasses 42 connects computing machines; When the simulation welding, the operator can see the screen signal that computing machine transmits by the video eyeglasses 42 that is installed in simulation face shield 41 the insides, it is virtual welding scene, and can also see weldering plate in the reality scene by surplus light, the use of simulation face shield 41 makes the simulation welding immersion that has more more true to nature.
(4) switch board
Switch board 1 shell is to adopt true carbon dioxide gas to protect welding machine model, built-in main control computer and corresponding circuit.Front panel 11 is provided with various pushbutton switches on switch board 1, and power switch, computing machine open and the pilot lamp of pass, current/voltage shelves knob and an operate as normal.The switch board back side panel is provided with various connection jaws such as USB, VGA and power supply, can plug easily.The right side is set to open door, considers that simultaneously machine installs, and upper plate and back plate are and are designed to screw and fix, and all the other all adopt welding fixing.The design of switch board lower end has four rolling, convenient moving.
Simulator software is formed:
The software of simulator of the present invention mainly is made up of master routine, virtual scene, evaluation system and four parts of study examination system.
(1) master routine
The master routine framework uses Visual Basic.Net (being called for short VB.Net) to develop, and adopts VB.Net development platform ratio to be easier to realize the good surface appearance interface, can make beautiful and friendly program outward appearance, and modification and interpolation functional module are more convenient.
(2) virtual scene
The simulation of welding three-dimensional scenic also is a welding operation analog training system most important content.The welding three-dimensional scenic is the important interface that the welder exchanges with stimulating and training system, and the welder is viewed when training all to be the information that is provided by three-dimensional scenic, so the requirement that system is simulated for three-dimensional scenic is accurate, true to nature, real-time.Native system adopts OpenGL (Open Graphics Library) in conjunction with Microsoft Visual C++6.0 programmed environment.OpenGL compiles in bad border of C++ and operation as API (Application Program Interface).
Program is at first carried out initialization to window, draws initial picture---weldering plate vertical with screen, is of a size of the optimum resolution 1440 * 900 of touch-screen.In the welding process, also will finish the simulation of weld seam and the simulation that arc light splashes in the virtual scene, and, make the welder can be by observing that virtual scene is experienced and the welding posture of adjusting oneself reaches the purpose of training by real simulation to the welding behavior.
(3) welding evaluation experts system
The simulated training evaluation of result is very important ingredient for welder's stimulating and training system, evaluation of result is the welder to be simulated welding finish once comprehensively data analysis behind the current weld seam, and this also is to adopt computer system to carry out the advantage of welding training.Computer system is preserved the relevant useful information of all welding operations, and in welding training back in addition analytical calculation of data, represent welding process in mode very intuitively, if desired, can also reset to welding process.These information of system feedback can reflect targetedly that the welder simulates the problem that exists in the welding process, and remind the welder being improved in the training next time.Like this, the utilization factor as a result that the welder trains each time is very high, and the efficient of welding training is also corresponding to be improved.
(4) welding knowledge training system
Welding knowledge training system mainly comprise learning system can and examination system.Wherein the learning system HtmlHelp Workshop that adopts Microsoft company to provide carries out the integral manufacturing of system; the language that whole software is made adopts Html (hypertext link language); with expressing by various multimedia meanses such as literal, picture and animations, form a complete CO about the ultimate principle of SMAW and shielded welding aspect, various key points for operation
2The learning system of shielded welding welders training.
As a welding training theory study system, supporting with it examination system is a requisite part.It not only can check the grasp degree of welder to being gained knowledge, and has played the effect of review and consolidation.This system not only can be used as an independent examination system, also can be used as means of the interim learning evaluation of each chapters and sections.Module adopts Authorware7.0 to make in conjunction with the Access database, and examination system possesses examinee's functions such as login, test and information management, can also be by the mode of Internet issue, and realization welder Telnet is learnt and is taken an examination.
Traditional CO
2The welding operation that can't write down the welding student in the shielded welding welding training.Operation evaluation to the student can only rely on the observation of postwelding butt welded seam or trainer's real-time guidance.Do like this and both consumed the great amount of manpower financial resources, can not give the welding student again to improve rapidly.The present invention is directed to above problem, changed training pattern in the past, welding student's operation is noted fully really, in the postwelding evaluation, give clear reproduction then.Not only save the ample resources of training organization, and made the student remove learning training targetedly, improved learning efficiency and results of learning.In the welding operation training process, analog training device of the present invention has following characteristics: (1) welding operation position detecting module is good to the detection real-time of simulation welding rod position, the accuracy height; (2) system is described truly the welding track in the welding operation at postwelding, and is clear, can reflect the details in the welding operation.
Virtual welding training technology can be reproduced student's operation in real time by the form of virtual three-dimensional emulation, and the form playback that can also record a video is watched for the student.In addition, welding operation is estimated and is provided critical data and suggestion by expert system.Therefore, virtual welding analog technology is making welding training lively, and is concrete, on the basis of image, allows the student learn under the situation that feedback is arranged and instruct, and improves learning efficiency and teaching efficiency.The basis of simulation welding training system be the detection of welding operation position.Cooperate by multiple different sensor, detect the position of simulation welding rod in welder's welding process, and be translated into data and carry out analyzing and processing.The welding operation detection module is determining the degree true to nature of analog simulation module imitation and the confidence level that the welding evaluation module is estimated welding to the accuracy of detection of welding rod position.
Claims (9)
1. CO
2Shielded welding welding operation simulator is characterized in that, comprises switch board (1), operator's console (2) and simulated welding gun (3);
Described simulated welding gun (3) comprises that welding gun bar (30), handle (31), arc plastic jacket (32), electric stylus (34), spring (35), mobile copper sheet (36), inductance are near switch (37), obliquity sensor (38) and nozzle (39); The electricity stylus fixedly connected mobile copper sheets of (34) one ends (36), electric stylus (34) passes nozzle (39) center, is connected by spring (35) between nozzle (39) and the mobile copper sheet (36); Welding gun bar (30) one ends are equipped with inductance near switch (37), and the other end is equipped with double-shaft tilt angle sensor (38); One insulating cylinder, one end is sheathed on nozzle (39) periphery, and the other end is sheathed on welding gun bar (30) periphery of inductance near switch (37) is installed; Arc plastic jacket (32) one ends are connected and installed with the welding gun bar (30) of double-shaft tilt angle sensor (38), and the other end connects handle (31); Inductance is connected the interior computing machine of switch board (1) near switch (37) with double-shaft tilt angle sensor (38);
Operator's console (2) comprises a touch-screen as test piece for welding (21), and this touch-screen connects the computing machine in the switch board (1).
2. a kind of CO as claimed in claim 1
2Shielded welding welding operation simulator is characterized in that, described insulating cylinder is a nylon ring (33).
3. a kind of CO as claimed in claim 1
2Shielded welding welding operation simulator is characterized in that, described operator's console (2) also comprises shell (26) and bracing frame (25), and described touch-screen (21) is installed in the described shell (26), and described shell (26) is installed on the support frame as described above (25); Support frame as described above (25) be provided with regulate touch-screen (21) height and surface level between the apparatus for adjusting position at pitch angle.
4. a kind of CO as claimed in claim 3
2Shielded welding welding operation simulator is characterized in that, the angle that described apparatus for adjusting position can be regulated between touch-screen (21) and the surface level is 0 °, 10 °, 15 °, 20 °, 25 ° or 30 °.
5. a kind of CO as claimed in claim 1
2Shielded welding welding operation simulator is characterized in that, described CO
2Shielded welding welding operation simulator also comprises a helmet (4); the described helmet (4) comprises simulation face shield (41) and is installed in the video eyeglasses (42) of simulating on the face shield (41) that described video eyeglasses (42) connects the video interface of the interior computing machine of switch board (1).
6. a kind of CO as claimed in claim 1
2Shielded welding welding operation simulator; it is characterized in that; by data acquisition card connection computing machine, double-shaft tilt angle sensor (38) changes 458 interfaces by RS232 and connects computing machine inductance near switch (37), and touch-screen (21) connects computing machine by the OpenGL interface.
7. a kind of CO as claimed in claim 6
2Shielded welding welding operation simulator is characterized in that, the model of described capture card is PCI-9112; The model of described double-shaft tilt angle sensor (38) is CS-2TAS-02; The range of described inductance approach switch (37) is 1-8mm.
8. a kind of CO as claimed in claim 1
2Shielded welding welding operation simulator is characterized in that, described CO
2Shielded welding welding operation simulator also comprises keyboard (22), mouse (23) and the audio amplifier (24) that connects described computing machine.
9. a kind of CO as claimed in claim 1
2Shielded welding welding operation simulator, it is characterized in that, the two-dimentional track that the simulated welding gun (3) that touch-screen (21) is gathered moves thereon passes to computing machine in real time, the data in real time of distance passes to computing machine between the nozzle (39) that inductance is gathered near switch (37) and the touch-screen (21), and the soldering angle data in real time of the simulated welding gun (3) of double-shaft tilt angle sensor (38) collection passes to computing machine; Computing machine connects according to the simulated welding gun (3) that receives and goes up the data of distance between two-dimentional track data, nozzle (39) and the touch-screen (21) that moves and the soldering angle data of simulated welding gun (3) at touch-screen (21), goes up display simulation welding picture at touch-screen (21) in real time.
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| CN201110242108.8A CN102298858B (en) | 2011-08-23 | 2011-08-23 | Welding operation simulator for CO2 gas shield arc welding |
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| CN201110242108.8A CN102298858B (en) | 2011-08-23 | 2011-08-23 | Welding operation simulator for CO2 gas shield arc welding |
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