CN104379291A - System and method for monitoring weld quality - Google Patents

Abstract

An arc welding system and methods. The system is capable of monitoring variables during a welding process, according to wave shape states, and weighting the variables accordingly, detecting defects of a weld, diagnosing possible causes of the defects, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Description

For monitoring the system and method for welding quality

related application:it is submitted that the application continues (CIP) patent application as part, the U.S. Patent application No.12/775 of described continuation in part patent application requirement submission on May 7th, 2010, the priority of 729 and rights and interests, described U.S. Patent application No.12/775,729 require the U.S. Provisional Patent Application No.61/261 that on November 13rd, 2009 submits to, the priority of 079 and rights and interests, whole disclosures of described patent application are merged in herein by reference.

Technical field

Present general inventive concept relates to arc welding, more specifically, relate to system, the method and apparatus for following object: the variable during monitoring welding procedure and correspondingly determine variable weight, quantize welding quality, data that acquisition and use represent good welds, the output improving automatic Welding Process and the quality control improving automatic Welding Process, the best pre-seted welding of instructing the cost savings of correct solder technology, discriminating (identify) welding procedure and obtaining being used as different welding procedure or application arrange.

Background technology

Many different conditions and the total quality of parameter to final welding have contribution.Therefore, the manufacturer of arc welder has attempted the operation monitoring welding machine, with determine welding quality and welding machine operate in production equipment during efficiency.Authorizing the U.S. Patent No. 6 of Vaidya, 051, the one illustrating monitoring arc welder in 805 (calling in the following text " Vaidya ") is attempted, wherein, adopt computer or other programmable instruments to come average current and the efficiency of monitoring weld operation, the efficiency of welding operation is expressed as the ratio performing the time of welding and the total time of work shift.According to standard technique, this disclosed monitoring system comprises first control circuit, and this first control circuit adopts the form with the CPU of standard accessory (as RAM and EPROM).Second control circuit is connected to the first circuit, with input and output information during monitor procedure.Watch-dog is being disclosed as continuity a few hours or up to collection information in the time period of 999 hours.Watch-dog determination welding efficiency and monitoring are for determining the time of average current and the accumulative arc welding time for whole efficiency.

Vaidya discloses the ability of monitor current and feed rate of welding wire and air-flow during welding process.All this information is stored in applicable storage device, for the operating characteristic recovering welding machine during welding procedure subsequently.In this way, the productive rate of welding machine can be measured, with efficiency and other parameters of assessing the cost.As advised in Vaidya, the average current during other manufacturers have attempted measuring welding procedure by monitoring arc welder.But, measure average current, voltage, feed rate of welding wire or other parameters during welding procedure and use such data to record the performance of welding operation and unsatisfactory.In the past, supervising device does not understand just monitored parameter in advance.

Therefore, even if use in Vaidya the technology set forth to monitor the parameter of such as electric current, voltage or even feed rate of welding wire in the past, response has also caused confusion and cannot determine electric arc practical stability or cannot judge welding procedure be higher than or lower than desired parameters value.The information such for following object must be known: refusal accepts (reject) weld cycle and/or determine the quality of the welding carried out during this weld cycle with required precision.In a word, monitoring is used for the operation of arc welder of various welding procedure and unsatisfactory, because not may be used for the existing knowledge of the welding procedure evaluated between welding procedure implementation period.

In order to overcome these shortcomings, the U.S. Patent No. 6,441,342 (calling in the following text " Hsu ") of authorizing Hsu disclose when welding machine perform the Arc Welding Process select create about welding machine operation information time monitor watch-dog and the method for arc welder.Therefore, the intelligent data that the application of the high power computer technology of standard can produce based on identical precision and watch-dog uses.The watch-dog of Hsu and monitoring system adopt the Given information during welding procedure.This information is fixing, does not change.The particular aspects paying close attention to welding procedure concentrated by watch-dog, to adopt the priori suitable with actual performance.Therefore, during the particular aspects of welding procedure, determine the stability of the parameter selected and qualified size or level.Before monitoring, welding procedure is divided into multiple regular time section with known desired parameters.Then, can by known these data of computer technology process, to evaluate each side of weld cycle.

The arc welder that Hsu discloses by generating a series of quick repetitive pattern performs welding procedure.Each waveform forms the weld cycle with a circulation timei.Each weld cycle (that is, waveform) is created by the known waveform generator for controlling welding machine operation.These waveforms are divided into multiple state, as being divided into the multiple states in pulse welding technique, i.e. and background (background) electric current, acclivity, peak point current, decline slope and get back to the state of background current subsequently.By known drive waveforms being divided into multiple states of the time period being defined as produced arc characteristic, any one state selected in these states can be monitored.In fact, can multiplexed many states.Such as, in pulse welding technique, the state relevant to peak point current can be monitored.Hsu discloses by monitoring the state of welding procedure to carry out reading preferably more than the two-forty of 1.0kHz.During each peak current condition of the waveform used in pulse welding technique, each actual welding parameter of repeated detection, e.g., electric current, voltage or or even feed rate of welding wire.In this way, during the monitor procedure of peak current condition, have ignored acclivity, decline slope and background current.

Therefore, by this peak point current compared with known peak point current.The function of peak point current can be used detect the change of the true peak electric current exported from arc welder.In Hsu, the downside of utility command (command) peak point current and the minimum level of high side and maximum horizontal, repeatedly to determine the level of peak point current during each peak current condition of pulse welding waveform.No matter when electric current exceedes maximum or is less than minimum of a value, counts this event during each waveform.The total deviation of weld interval (that is, perform welding procedure or its certain pith duration) or event are counted.If this count value exceedes each waveform or the setting number during weld interval, then can give the alarm, warn this specific weld technique to experienced by less desirable welding situation.In fact, if count value exceedes maximum horizontal, then refuse (reject) this welding.This ability uses together with SS difference program, repeatedly reads peak point current, to sense standard extent during each peak current condition of waveform.In fact, this standard deviation is that root mean square (RMS) difference of being undertaken by computer program is calculated.In Hsu, calculate average peak current and record this peak point current and Realize and stability features.Also determine the RMS of the curtage of just monitored each state (such as, the peak current condition of impulse waveform).When monitoring peak current level or standard increment, the background current stage can be monitored by levels of current and duration.

Hsu disclose select state in waveform and by needed for this state with known command signal compared with the actual parameter of welding procedure during monitored state.This selection is based on the priori of waveform generator.Such as, under specific feed rate of welding wire WFS1, waveform generator is programmed, to regulate peak point current to control arc length.Then, when welding with this feed rate of welding wire WFS1, " being notified " watch-dog selects peak point current section as monitored state.But, under another feed rate of welding wire WFS2, waveform generator is programmed, control arc length (instead of peak point current) to regulate the background time (background time).Then, when welding with this feed rate of welding wire WFS2, " being notified " watch-dog selects the background time as monitored state and parameter.By contrast, posteriority (posteriori) watch-dog is not also known under different feeds rate of welding wire, should monitor the different aspect of waveform to detect arc stability.In this example, under the first feed rate of welding wire WFS1, monitoring the background time or under feed rate of welding wire WFS2, monitor peak point current will be unusual poor efficiency.Therefore, Hsu discloses this section utilizing the time period of the priori waveform of desirable value to monitor waveform.Just total waveform is not averaging with regard to energy actual monitored Arc Welding Process like this.

Compared with the normal processes of the output parameter experienced during only reading welding procedure, in Hsu, the feature of this watch-dog is to employ priori.Therefore, when welding machine normal behaviour welding procedure only in one during change in time and different time, by monitoring, enormously simplify the task of detecting this normal behaviour.The instruction of Hsu can not be applied to monitoring voltage in constant voltage technique, because during whole weld cycle, required voltage level is known feature.But, in other welding procedures, when during the different sections at waveform, both voltage and currents change all to some extent, before the actual parameter that the method for Hsu is monitored during accurately reading selected waveform segment, provide the pin-point reading of stability, RMS, standard deviation, mean value, minimum lower limit and maximum.

According to Hsu, when need not read overall output information to monitor with accurate precision, become welding process, as pulse welding and short circuit welding.As the seclected time in the selected state of waveform or each waveform of section, start watch-dog.Watch-dog compares actual parameter and desired parameters with the form of the command signal of the welding machine electric power that leads.In Hsu, can only monitor during some particular segments of waveform; But, in anomalous event, such as, when the arc is extinguished or when a short circuit occurs, realized the subprogram of computer operation by voltage sensing or current sense, to restart electric arc and/or to correct short circuit.The subprogram of these events and monitoring programme parallel running.Therefore, these abnormal integrated operations that can not affect watch-dog.These subprograms are constructed to abnormal state or time period.With with mode similar as mentioned above, monitor the parameter in the state of these exceptions or signal.

In Hsu, for the evaluation operation of welding machine or the object of efficiency, the manufacturing information about calendar time, changing shifts or even operator can be added up.By monitoring the particular segment of waveform or state monitors each weld cycle, can add up to pass in time and the undesirably event that experiences.Can also carry out trend analysis like this, made before the defective production weld seam of the actual generation of welding procedure (production welds), operator can take error correction.By trend analysis, defect analysis, accumulative defect, the charging to and relevant monitoring in real time to arc welder of all these projects, directly can disturb with immediate mode, to take the precautionary measures relative with error correction.

Summary of the invention

Total inventive concept is susceptible to for the variable during monitoring welding procedure and correspondingly determines the weight of described variable, quantizes welding quality, acquisition and use and represent the data of good welds, detect system, the method and apparatus of the possible cause of weld defect and diagnosis weld defect.The quality control that welding quality data consider the output increased of automatic Welding Process and automatic Welding Process, the best pre-seted welding of instructing correct solder technology, differentiate the cost savings of welding procedure and obtaining being used as different welding procedure or application are arranged.Illustrate by way of example and various aspects, multiple example system, the method for openly present general inventive concept in this article.

According to an exemplary, disclose a kind of method monitoring arc welder, described method is by creating the actual welding parameter between welding wire and workpiece that advances thus monitoring described arc welder when arc welder performs selected Arc Welding Process, and described selected technique is controlled by the command signal of the power supply of described welding machine.Described method comprises: (a) produces the waveform of a series of quick repetition, and each waveform forms the weld cycle with a circulation timei; B described waveform is divided into multiple state by (); (c) within the time period, with the selected welding parameter of inquiring that speed measurement occurs in a described waveform state, to obtain the data acquisition system of the welding parameter selected; D (), for each time period, calculates the stability value of described selected welding parameter from described data acquisition system; (e) by each stability value with expection stability value compared with, to judge whether the difference of described stability value and described expection stability value exceedes predetermined threshold; And if (f) described difference exceedes described threshold value, then based on described difference, the weight of described stability value is determined with size weight (magnitude weight), and contribute (contribution) based on the time of waveform state relative to its waveform, determine the weight of described stability value with time contribution weight.In this way, described method can assign multiple weight (such as, based on the deviation of its state and the degree/size of time contribution) to the parameter (that is, the item in data acquisition system) that records forming isolated point (outlier).In an exemplary embodiment, the measured value of the welding parameter outside limit value isolated point being defined as three (3) the individual standard deviations dropping on the mean value departing from welding parameter.Also be susceptible to the watch-dog integrated with arc welder for performing this illustrative methods.

According to an exemplary, disclose a kind of method quantizing welding quality, described method quantizes welding quality by creating the actual welding parameter between welding wire and workpiece that advances thus monitoring described arc welder when arc welder performs selected Arc Welding Process, and described selected technique is controlled by the command signal of the power supply of described welding machine.Described method comprises: (a) produces the waveform of a series of quick repetition, and each waveform forms the weld cycle with a circulation timei; B described waveform is divided into multiple state by (); In c time period that () repeats during weld interval, to inquire in speed measurement state described in one or more multiple selected welding parameter occurred; And (d) based on during the time period to the described measurement of described selected welding parameter, calculate multiple mass parameters of each described state, wherein, described mass parameter characterize described welding total quality measure.Also be susceptible to the watch-dog integrated with arc welder for performing this illustrative methods.

In an exemplary embodiment, described method also comprises: whether the value of each described mass parameter that calculates for each time period compared with corresponding prospective quality parameter value, is exceeded predetermined threshold with the difference of the quality parameter value calculated described in judging and described prospective quality parameter value by (e); And if (f) described difference exceedes described threshold value, then based on described difference, the weight of the quality parameter value calculated described in determining with size weight, and contribute based on the time of its state relative to the waveform comprising described state, the weight of the quality parameter value calculated described in determining with time contribution weight.Also be susceptible to the watch-dog integrated with arc welder for performing this illustrative methods.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, the described time period is roughly 250ms.

In an exemplary embodiment, described selected welding parameter comprise for each described state the described time period in the counting of the described measurement that each described selected welding parameter is taked, the average voltage voltage in the described time period, the rms voltage RMSV in the described time period, voltage variance V in the described time period _var, average current current, the rms current RMSI in the described time period and the electric current variance I in the described time period in the described time period _var, wherein, the described counting of the voltage sum/voltage measurement recorded in the time period described in voltage=, wherein

$\mathrm{RMSV}=\sqrt{\frac{{\mathrm{\Σ}}_{i=1}^N{\left({\mathrm{voltage}}_i\right)}^2}{N}}$

Wherein, V _var=RMSV-voltage, wherein, the described counting of the electric current sum/current measurement recorded in the time period described in current=, wherein

$\mathrm{RMSI}=\sqrt{\frac{{\mathrm{\Σ}}_{i=1}^N{\left({\mathrm{current}}_i\right)}^2}{N}}$

And wherein, I _var=RMSI-current.

In an exemplary embodiment, described mass parameter comprises the quantity count mean value QCA of each state, and described quantity count mean value QCA is calculated as:

$\mathrm{QCA}=\frac{{\mathrm{\Σ}}_{i=1}^N{\mathrm{count}}_i}{N}$

Wherein, N is the sum of weld cycle in the described time period, and wherein, count _irefer to the counting for the described measurement of specific one weld cycle in the described time period.

In an exemplary embodiment, described mass parameter comprises the quantity count standard deviation QCSD of each state, and described quantity count standard deviation QCSD is calculated as:

$\mathrm{QCSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{count}}_i-\mathrm{QCA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter comprises the quantity count standard deviation QCSD of each state, and described quantity count standard deviation QCSD is calculated as:

$\mathrm{QCSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{count}}_i-\mathrm{QCA})}^2}{N}$

In an exemplary embodiment, described mass parameter comprises the quality voltage mean value QVA of each state, and described quality voltage mean value QVA is calculated as:

$\mathrm{QVA}=\frac{{\mathrm{\Σ}}_{i=1}^N{\mathrm{voltage}}_i}{N}$

Wherein, N is the sum of weld cycle in the described time period, and wherein, voltage _irefer to the voltage measurement for specific one weld cycle in the described time period.

In an exemplary embodiment, described mass parameter comprises the quality voltage standard deviation QVSD of each state, and described quality voltage standard deviation QVSD is calculated as:

$\mathrm{QVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{voltage}}_i-\mathrm{QVA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter comprises the quality voltage standard deviation QVSD of each state, and described quality voltage standard deviation QVSD is calculated as:

$\mathrm{QVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{voltage}}_i-\mathrm{QVA})}^2}{N}$

In an exemplary embodiment, described mass parameter comprises the quality current average QIA of each state, and described quality current average QIA is calculated as:

$\mathrm{QIA}=\frac{{\mathrm{\Σ}}_{i=1}^N{\mathrm{current}}_i}{N}$

Wherein, N is the sum of weld cycle in the described time period, and wherein, current _irefer to the current measurement for specific one weld cycle in the described time period.

In an exemplary embodiment, described mass parameter comprises the quality current standard deviation QISD of each state, and described quality current standard deviation QISD is calculated as:

$\mathrm{QISD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{current}}_i-\mathrm{QIA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter comprises the quality current standard deviation QISD of each state, and described quality current standard deviation QISD is calculated as:

$\mathrm{QISD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{current}}_i-\mathrm{QIA})}^2}{N}$

In an exemplary embodiment, described mass parameter comprises the quality voltage mean of variance QVVA of each state, and described quality voltage mean of variance QVVA is calculated as:

$\mathrm{QVVA}=\frac{{\mathrm{\Σ}}_{i=1}^N{V}_{{\mathrm{var}}_i}}{N}$

Wherein, N is the sum of weld cycle in the described time period.

In an exemplary embodiment, described mass parameter comprises the quality voltage variance criterion difference QVVSD of each state, and described quality voltage variance criterion difference QVVSD is calculated as:

$\mathrm{QVVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(V_{\mathrm{vari}}-\mathrm{QVVA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter comprises the quality voltage variance criterion difference QVVSD of each state, and described quality voltage variance criterion difference QVVSD is calculated as:

$\mathrm{QVVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(V_{\mathrm{vari}}-\mathrm{QVVA})}^2}{N}$

In an exemplary embodiment, described mass parameter comprises the quality electric current mean of variance QIVA of each state, and described quality electric current mean of variance QIVA is calculated as:

$\mathrm{QIVA}=\frac{{\mathrm{\Σ}}_{i=1}^N{V}_{{\mathrm{var}}_i}}{N}$

Wherein, N is the sum of weld cycle in the described time period.

In an exemplary embodiment, described mass parameter comprises the quality electric current variance criterion difference QIVSD of each state, and described quality electric current variance criterion difference QIVSD is calculated as:

$\mathrm{QIVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(I_{\mathrm{vari}}-\mathrm{QIVA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter comprises the quality electric current variance criterion difference QIVSD of each state, and described quality electric current variance criterion difference QIVSD is calculated as:

$\mathrm{QIVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(I_{\mathrm{vari}}-\mathrm{QIVA})}^2}{N}$

Similar mass parameter (e.g., such as quality feed rate of welding wire mean value (QWA), quality feed rate of welding wire standard deviation (QWSD), quality feed rate of welding wire mean of variance (QWVA) and quality feed rate of welding wire variance criterion difference (QWVSD)) based on monitored feed rate of welding wire (WFS) also can be calculated in a similar fashion.

In an exemplary embodiment, described method also comprises: (e) uses the described mass parameter evaluation welding subsequently represented with module.Also be susceptible to the watch-dog integrated with arc welder for performing this illustrative methods.

According to an exemplary, disclose a kind of method evaluating multiple welding, described method is by creating the actual welding parameter between welding wire and workpiece advanced thus the multiple welding monitored described arc welder to evaluate the substantially identical Arc Welding Process of basis when arc welder performs welding according to Arc Welding Process, perform under substantially the same conditions, and described selected technique is controlled by the command signal of the power supply of described welding machine.Described method is included in each weld period: (a) produces the waveform of a series of quick repetition, and each waveform forms the weld cycle with a circulation timei; B described waveform is divided into multiple state by (); C (), within the time period, to inquire the selected welding parameter that speed measurement occurs in a described state, obtains the data acquisition system of described selected welding parameter; D (), for each time period, calculates the mass value of described selected welding parameter from described data acquisition system; (e) by each mass value compared with prospective quality value, to judge whether the difference of described mass value and described prospective quality value exceedes predetermined threshold; If f () described difference exceedes described threshold value, then based on described difference, determine the weight of described mass value with size weight, and contribute based on the time of described state relative to its waveform, determine the weight of described mass value with time contribution weight; And (g) use described weld interval during all described mass value that obtains, comprise the mass value of any weighting, determine the quality score of described welding.

In an exemplary embodiment, described method also comprises: if the quality score of (h) described welding is in the first preset range of quality score, then refusal accepts described welding; And if the quality score of (i) described welding is in the second preset range of quality score, then accept described welding.

In an exemplary embodiment, described method also comprises: (h) makes each welding quality score corresponding with it for good and all be associated.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, the described time period is roughly 250ms.

In an exemplary embodiment, described selected welding parameter is arc current.In an exemplary embodiment, described selected welding parameter is arc voltage.

According to an exemplary, disclose a kind of arc welder comprising integrated monitoring device to use and manually perform the individuality of Arc Welding Process (namely, operator) method of instruction is provided, described welding machine performs Arc Welding Process by creating the actual welding parameter between welding wire and workpiece advanced, described watch-dog can monitor actual welding parameter, and Arc Welding Process is controlled by the command signal of welding machine electric power.Described method comprises: (a) produces the waveform of a series of quick repetition, and each waveform forms the weld cycle with a circulation timei; B described waveform is divided into multiple state by (); (c) within the time period, with the selected welding parameter of inquiring that speed measurement occurs in a described state, to obtain the data acquisition system of described selected welding parameter; D (), for each time period, calculates the mass value of described selected welding parameter from described data acquisition system; (e) by each mass value compared with prospective quality value, to judge whether the difference of described mass value and described prospective quality value exceedes predetermined threshold; If f () described difference exceedes described threshold value, then based on described difference, determine the weight of described mass value with size weight, and contribute based on the time of described state relative to its waveform, determine the weight of described mass value with time contribution weight; G () uses the mass value comprising any weight to upgrade the current gross mass score of welding; H () judges in the preset range of the acceptable quality score of current gross mass score whether during welding procedure; And if (i) current gross mass score outside the preset range of acceptable quality score, then provides the information about corrective action to operator.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, the described time period is roughly 250ms.

In an exemplary embodiment, visually information is provided.In an exemplary embodiment, acoustically information is being provided.

In an exemplary embodiment, described information comprises the change in location of welding wire relative to workpiece of prompting.In an exemplary embodiment, described information comprises the change of welding wire relative to the rate travel of workpiece of prompting.

In an exemplary embodiment, information is provided with predetermined reporting rates to operator.In an exemplary embodiment, described reporting rates is less than 30 seconds.In an exemplary embodiment, described reporting rates is more than or equal to 30 seconds.

In an exemplary embodiment, if the current gross mass score of nearest change instruction in current gross mass score is likely fallen outside the preset range of acceptable quality score, then described information is provided.

In an exemplary embodiment, described method also comprises: if (j) current gross mass score is within the preset range of acceptable quality score, then provide the confirmation about carrying out corrective action to operator.

Disclose a kind of method evaluating the multiple operators performing Arc Welding Process, described method evaluates by creating the actual welding parameter between welding wire and workpiece that advances thus monitoring the described arc welder that is associated with each operator when each arc welder is used for performing described Arc Welding Process by its corresponding operating person the multiple operators performing described Arc Welding Process, and described Arc Welding Process is controlled by the command signal of the power supply of described welding machine.Described method comprises: for each operator, (a) produces numeric score, and the instruction of described numeric score is relative to the mass measurement of the welding formed according to described Arc Welding Process of predetermined base weld; B () measures the time quantum that described operator performs the cost of described Arc Welding Process; And (c) makes described numeric score and described weld interval be associated with described operator.

In an exemplary embodiment, described numeric score is produced by following steps: (a1) produces the waveform of a series of quick repetition, and each waveform forms the weld cycle with a circulation timei; (a2) described waveform is divided into multiple state; (a3) within the time period, to inquire the selected welding parameter that speed measurement occurs in a described state, to obtain the data acquisition system of described selected welding parameter; (a4) for each time period, the mass value of described selected welding parameter is calculated from described data acquisition system; (a5) by each mass value compared with prospective quality value, to judge whether the difference of described mass value and described prospective quality value exceedes predetermined threshold; (a6) if described difference exceedes described threshold value, then based on described difference, determine the weight of described mass value with size weight, and contribute based on the time of described state relative to its waveform, determine the weight of described mass value with time contribution weight; And (a7) use described Arc Welding Process during all described mass value that obtains, comprise the mass value of any weighting, to determine described numeric score.

According to an exemplary, disclose a kind of method of selected Arc Welding Process being carried out to cost effectiveness analysis, wherein, arc welder performs Arc Welding Process by creating the actual welding parameter between welding wire and workpiece advanced, and described selected technique is controlled by the command signal of the power supply of described welding machine.Described method comprises: (a) confirms multiple welding conditions that can affect integral solder quality; B () is for one of multiple welding change welding condition and for being welded and fixed remaining welding conditions all; C () is for each welding: (i) produces the waveform of a series of quick repetition, and each waveform forms the weld cycle with a circulation timei; (ii) described waveform is divided into multiple state; (iii) within the time period, to inquire the selected welding parameter that speed measurement occurs in a described state, to obtain the data acquisition system of described selected welding parameter; (iv) for each time period, the stability value of described selected welding parameter is calculated from described data acquisition system; (v) by each stability value with expection stability value compared with, to judge whether the difference of described stability value and described expection stability value exceedes predetermined threshold; (vi) if described difference exceedes described threshold value, then based on described difference, determine the weight of described stability value with size weight, and contribute based on the time of waveform state relative to its waveform, determine the weight of described stability value with time contribution weight; (vii) stability value obtained during use comprises the weld interval of any weighting stability value is to calculate the total quality score of welding; (viii) cost welded is determined; And (ix) makes quality score and cost be associated with welding.

In an exemplary embodiment, welding condition comprises one or more in welding wire characteristic, characteristic, protective gas flow velocity, protective gas composition and workpiece preheat temperature.

In an exemplary embodiment, cost comprise to generation weld relevant dollar spending.In an exemplary embodiment, cost has comprised the total time needed for welding.

In an exemplary embodiment, described stability value is the canonical statistics deviation of selected welding parameter.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, the described time period is roughly 250ms.

In an exemplary embodiment, described method also comprises: (d) exports the quality score and cost (or its corresponding mean value) that are associated with each welding.

According to an exemplary, disclose the method that welding parameter that a kind of use pre-sets obtains the welding with required quality, produce welding by creating the actual welding parameter between welding wire and workpiece advanced by the arc welder performing selected Arc Welding Process, described welding procedure is controlled by the command signal of the power supply of described welding machine.Described method comprises: (a) presents multiple set of selected welding parameter together with the quality score corresponding to each set to user, wherein, and the total quality of the welding that described quality score uses the set of selected welding parameter to obtain before quantizing; B () receives the input about using the set of which selected welding parameter to perform welding procedure from user; And (c) uses the set of the selected welding parameter corresponding to input to perform welding procedure.

In an exemplary embodiment, present welding parameter each selected with use to user and gather the cost performing welding procedure and be associated.

In an exemplary embodiment, described method also comprises: (d) is from the input of the minimum acceptable quality score of user's confirmation of receipt; And (e) filters out all set of the selected welding parameter corresponding with the associated quantity score lower than minimum acceptable quality score.

In an exemplary embodiment, described method also comprises: (d) is from the input of user's confirmation of receipt acceptable quality score range; And (e) filters out all set of the selected welding parameter corresponding with the associated quantity score outside qualified welding quality score range.

In an exemplary embodiment, a kind of method of Arc Welding Process of diagnosing is disclosed, described method by be created between the welding wire of propelling and workpiece for create weld seam actual welding parameter thus arc welder perform Arc Welding Process time monitor described arc welder.Described welding procedure is controlled by the command signal of the power supply of described welding machine.Described method comprises the waveform producing a series of quick repetition, and each waveform forms the weld cycle with a circulation timei, and described waveform is divided into multiple state.In the time period that described method repeats during being included in described welding procedure further, to inquire in speed measurement state described in one or more multiple welding parameters occurred.Described method also comprise based on during described welding procedure to the described measurement of described welding parameter, calculate multiple mass parameters of each one or more state described.Described method comprises at least one in the described multiple mass parameter of analysis and described multiple welding parameter further, diagnoses described Arc Welding Process with (localized) of one or more local or one or more possible reason of continuous print (continuous) defect by judging described weld seam.

Described method may further include by the value of each described mass parameter that calculates for each time period compared with corresponding prospective quality parameter value, whether exceedes predetermined threshold with the difference of the quality parameter value calculated described in judging and described prospective quality parameter value.If described difference exceedes described threshold value, described method also comprises based on described difference, the weight of the quality parameter value calculated described in determining with size weight, and contribute based on the time of its state relative to the described waveform comprising described state, the weight of the quality parameter value calculated described in determining with time contribution weight.

In an exemplary embodiment, a kind of for diagnosing the system of Arc Welding Process to be disclosed, described system by be created between the welding wire of propelling and workpiece for create weld seam actual welding parameter thus arc welder perform Arc Welding Process time monitor described arc welder.Described welding procedure is limited by the waveform of a series of quick repetition, and the waveform of described a series of quick repetition is controlled by the command signal of the power supply of described welding machine.Described system comprises logic state controller, and described logic state controller is used for described waveform segments to become a series of time slice state, and for selecting the circuit of specific waveforms state.System comprises supervising device further, described supervising device is for monitoring in time period of repeating during described welding procedure, to inquire in speed measurement state described in one or more multiple welding parameters occurred, to obtain the data arranged for described multiple welding parameter.Described system also comprises the circuit for calculating based on described monitored multiple welding parameters for multiple mass parameters of each described state.Described system comprises diagnostic logic circuit further, described diagnostic logic circuit for analyzing at least one in described multiple mass parameter and described multiple welding parameter, with one or more local by judging described weld seam or one or more possible reason of continuous print defect diagnose described Arc Welding Process.

Described system may further include the circuit for whether the value of each described mass parameter calculated for each time period being exceeded compared with corresponding prospective quality parameter value predetermined threshold with the difference of the quality parameter value calculated described in judging and described prospective quality parameter value.If described system can also comprise exceed described threshold value for described difference, the weight of the quality parameter value calculated described in determining with size weight based on described difference and the circuit of the weight of the quality parameter value calculated described in determining with time contribution weight relative to the time contribution of described waveform comprising described state based on its state.

According to the following detailed description to exemplary, claims and accompanying drawing, the many aspects of present general inventive concept and other embodiments will easily become clear.

brief Description Of Drawings

Below, with reference to accompanying drawing, present general inventive concept and embodiment thereof and advantage are described by way of example in more detail, in the accompanying drawings:

Fig. 1 is the combination block diagram of the watch-dog of the arc welder illustrated according to an exemplary and computer flow chart or program;

Fig. 2 is the current order curve map from waveform generator, and this curve map illustrates to have the time period of both fixing duration and variable duration or the command waveform of state according to being divided into of an exemplary;

Fig. 3 is according to the actual command signal of the arc current of the exemplary current curve diagram with the actual arc current parameters added with dotted line;

Fig. 4 be according to an exemplary for the internal signal of monitoring welding machine instead of the block diagram of one aspect of the present invention of welding parameter illustrated illustrated in Fig. 2 and Fig. 3;

Fig. 5 is the time base curves figure illustrating waveform, wire feeder command signal and actual wire feeder command signal as experienced in the exemplary shown in Fig. 4;

Fig. 6 is a part for the parameter curve of the horizontal monitoring features illustrated according to an exemplary;

Fig. 7 illustrates according to the block diagram of the disposal of stability during state selected by waveform shown in Fig. 2 and Fig. 3 of an exemplary and computer flow chart or program;

Fig. 8 is for the treatment of the block diagram of the information of the horizontal monitor stages from the exemplary shown in Fig. 1 and computer flow chart or program;

Fig. 9 is the flow chart of the method for weighting of the welding data parameter of the weighted sampling illustrated according to an exemplary;

Figure 10 is the diagram of the conceptual production line according to an exemplary;

Figure 11 is the flow chart of the guidance method illustrated according to an exemplary;

Figure 12 is the block diagram of the system for monitoring student illustrated according to an exemplary.

Figure 13 is the flow chart of the method for the monitoring student illustrated according to an exemplary.

Figure 14 A and Figure 14 B illustrates the form for the example data in the cost analysis of welding procedure according to an exemplary;

Figure 15 is the form of the preset data be associated with welding condition, welding machine and welding procedure illustrated according to an exemplary;

Figure 16 illustrates the schematic block diagram of the embodiment of the system for diagnosing Arc Welding Process; And

Figure 17 is the flow chart of method of the system diagnostics Arc Welding Process using Figure 16, described method by be created between the welding wire of propelling and workpiece for create weld seam actual welding parameter thus when arc welder performs Arc Welding Process monitoring arc welder.

describe in detail

Although present general inventive concept is allowed there is many multi-form embodiments, but these are conceived shown in the drawings and will be described in its specific embodiments herein, are now appreciated that the disclosure will only be regarded as the citing of the principle of present general inventive concept.Therefore, present general inventive concept is not intended to be limited to the illustrated specific embodiments illustrated herein.In addition, U.S. Patent No. 5,278, the disclosure of 390 and No.6,441,342 is incorporated to herein in full with way of reference, because these disclosures can provide the concrete aspect and/or progressive background that help better understand present general inventive concept.

It is below the definition of the exemplary term used in whole disclosure.The singulative of all terms and plural form all fall in each implication:

Include, but is not limited to " logic " of " circuit " synonym as used in this article for the hardware of n-back test (one or more) or action (one or more), firmware, software and/or its combine.Such as, based on required application or needs, logic can comprise by the microprocessor of software control, discrete logic (e.g., special IC (ASIC)) or other PLDs.In some cases, logic can also be fully embodied as software.

" software " or " computer program " includes, but is not limited to one or more computer-readable and/or executable instruction as used in this article, and these instructions cause n-back test, action and/or the behavior in a desired manner of computer or other electronic installations.These instructions can be implemented as various forms, e.g., comprise the subprogram of single utility program or the code deriving from dynamic link library, algorithm, module or program.Software can also be embodied as various forms, as, stand-alone program, function call, servlet (servlet), applet (applet), be stored in the executable instruction of instruction in a part for memory, operating system or other types.Those of ordinary skill in the art will be understood that, the form of software depends on (such as) requirement to required application, the requirement of the running environment to software and/or needing of designer/programmer.

As used in this article " computer " or " processing unit " include, but is not limited to anyly can to store, fetch (retrieve) and process data through programming or programmable electronics device.

Now, with reference to accompanying drawing, these accompanying drawings illustrate the various exemplary of present general inventive concept and adopt the application of this present general inventive concept, Fig. 1 that the block diagram that the Standard Machine borne computer in arc welder 10 realizes and flow chart or program are shown.Such as, welding machine 10 can be the arc welder Power Wave based on inverter (inverter) that Lincoln Electric company (Cleveland city, Ohio) sells.According to standard technique, welding machine 10 comprises the input of the three-phase electricity of conduct current power supply 12 L1, L2, L3.The controller of airborne computer operation operates the power supply based on inverter, to create positive potential at terminal 14 and to create negative potential at terminal 16.

By the selected waveform guiding actual welding circuit determined before is performed selected Arc Welding Process, this actual welding circuit is shown having the smooth inductor 18 of standard.Welding machine 10 performs Arc Welding Process to the welding wire 20 advanced from reel 22, and this reel 22 is driven with desired rate by feeder 24, and this feeder 24 runs with the speed of motor 26.The heat melting welding wire 20 of electric arc and workpiece 30, to deposit to the motlten metal deriving from welding wire on workpiece.In order to monitor the actual parameter of welding procedure, current divider 32 (supervising device) provides the output signal I from block 34 on circuit 34a _a.This signal represents the actual arc electric current of any preset time.In a similar fashion, sense the voltage between welding wire 20 and workpiece 30 with block 36 (supervising device), so the output V on circuit 36a _ait is the transient arc voltage of formation second welding parameter.The illustrated welding parameter illustrated of Fig. 1 is actual arc electric current I _awith actual arc voltage V _a.

Controlled to put into practice another parameter of the present invention be a feed rate (WFS), and this speed is caused by the rotation of motor 26.Therefore, as illustrated after a while, three readable welding parameters in outside of welding procedure are the arc current I in circuit 34a _a, arc voltage V in circuit 36a _awith feed rate of welding wire WFS readable in circuit 46b.The WFS in circuit 46b is read, the driven roller 24 that this tachometer or encoder 46c are connected to feeder gear-box or on being alternatively connected to attached by welding wire follower by tachometer or encoder 46c (supervising device).In FIG, illustrate and drive tachometer by push rolls.Such as, tachometer can also be driven by the output shaft of motor 26.

Power Wave arc welder comprises the waveform generator for creating a series of quick repetitive pattern, and each waveform (such as, the voltage/current waveform of simple sequence) forms the weld cycle with a circulation timei.These weld cycle are repeated, to limit weld interval during welding procedure.Authorizing the U.S. Patent No. 5 of Blankenship, 278, an embodiment of the welding machine of PowerWave shown in 390 10, wherein, welding machine is controlled by order circuit 42 each waveform that power supply 12 will export and is controlled the speed of motor 26 by order circuit 44.Order circuit 44 has the signal being driven the microprocessor identification on control 46 by the welding wire of motor 26, drives pwm pulse to export motor voltage in circuit 46a.In fact, the information on circuit 44 is digital and on circuit 46a command signal is simulation.Waveform generator 40 creates data signal in circuit 42,44, with control welding machine 10 to perform needed for welding procedure.External parameter I can be read by the supervising device be applicable to _a, V _aand WFS.

Each output waveform is divided into or is segmented into a series of time slice part or state by waveform generator 40.In an exemplary embodiment, watch-dog M is loaded into the program in the computer of welding machine 10, (except other object), and it is for the parameter during section that of reading waveform is selected.When not departing from the spirit and scope of present general inventive concept, software, hardware and combination thereof can be used to realize watch-dog M.The part that waveform is just monitored is determined by waveform generator 40.In fact, watch-dog M monitors various time period or the state of the waveform that generator 40 exports.In fact, waveform generator 40 select formed waveform multiple time period and by various State-output to command interface 70.Therefore, command interface 70 causes the parameter during the selected time period of measuring each waveform that generator exports.Information on command interface 70 or data comprise just monitored one or more state and various parameter I _a, V _aand/or the particular value of WFS or level.

The interface 70 of watch-dog M comprises the value of data together with the welding parameter just read of the particular state that identification is just processing.Data in level segment 81 analysis interface 70, with the relation based on level determination parameter.By actual parameter with derive from the selected state of the waveform of generator 40 during the parameter practising or record compare.During the particular segment or state of waveform, horizontal monitor stages 81 reads the actual parameter in circuit 34a, 36a and 46b.The instantaneous value of these actual parameters is stored in internal storage (regarding as report logic 82).Represented by oscillator 84, carry out the reading of actual parameter fast.In an exemplary embodiment, the reading of actual parameter is carried out with the speed of the 120kHz of pulse welding.This speed can be regulated; But speed is higher, the susceptibility of horizontal survey is higher.The deviation of actual welding parameter and minimum level or maximum horizontal is also determined in level monitoring 81.In this way, not only can store actual value, also store the data representing the deviation of actual read number compared with minimum level or maximum horizontal of the parameter of given state.Reporting memory or logic 82 record and the setting deviation of level and the real standard during the selected state of waveform during the given state of waveform.For whole weld cycle, these readings are added up, counts process in other words conj.or perhaps, to determine welding quality and any trend trending towards weld defect.

In an exemplary embodiment, the weight of these readings (such as, periodically accumulative reading set) is determined based on multiple standard.Such as, often reading can be added up by 250ms.In an exemplary embodiment, determine that the weight gathered contributes relative to the time of corresponding waveform with its time period based on itself and the inclined extent of desired value (such as, predetermined threshold, mean value).Such as, such method of weighting (such as, shown in Fig. 9 and in method of weighting 900 described below) can be realized in horizontal monitor stages 81 or any similar or relevant data processing stage.

Stability monitor stages 91 reads the actual welding parameter on circuit 34a, 36a and 46b with the fast velocity that oscillator 94 is determined.In an exemplary embodiment, the reading of actual parameter is carried out with the speed of the 120kHz of pulse welding.The standard deviation of actual welding parameter or absolute deviation during stability monitor stages 91 analyzes the state of the waveform of positive output.This deviation during the given state of reporting memory or logic 92 wave recording and the actual value during the selected stage of waveform.For whole weld cycle, these readings are added up, counts process in other words conj.or perhaps, to determine welding quality and any trend trending towards weld defect.

In an exemplary embodiment, the weight of these readings (such as, periodically accumulative reading set) is determined based on multiple standard.Such as, often reading can be added up by 250ms.In an exemplary embodiment, determine that the weight gathered contributes relative to the time of corresponding waveform with its time period based on itself and the inclined extent of desired value (such as, predetermined threshold, mean value).Such as, such method of weighting (such as, shown in Fig. 9 and in method of weighting 900 described below) can be realized in stability monitor stages 91 or any similar or relevant data processing stage.

When usage monitoring stage 81 or monitor stages 91, (skip) several waveform can be skipped over.In an exemplary embodiment, after homing sequence, monitor all waveforms, with the actual welding parameter during the various selected states of analysis waveform.Multiple states of given waveform in monitoring welding procedure, and separately for each state recording result, for analysis level uniformity, trend and stability.When Measurement sensibility, in watch-dog M, use standard deviation algorithm, to evaluate I _a, V _aand/or WFS.This Information Availability is in analyzing each section that is formed and have in various sections of the waveform of the whole weld cycle of given circulation timei.In fact, some state (e.g., the peak point current during impulse waveform) is monitored, to determine stability and the horizontal departure of pulse welding technique.In STT welding procedure, watch-dog M records the short circuit duration of each waveform, because these sections change in time according to the external condition of welding procedure.The change notification welding engineer of short circuit duration realizes regulating.

As shown in Figures 2 and 3, a series of quick repetitive pattern that the waveform generator 40 of standard produces is divided into time state.Output current command waveform is the impulse waveform 100 with peak point current 102 and background current 104, and peak point current 102 has the fixing duration of the time period A shown in Fig. 3, and background current 104 has the variable duration of the time period B shown in Fig. 3.Waveform is at moment t ₁-t ₄be divided into the time period, the particular state making command interface 70 receive generator 40 at any given time just to process.As in Fig. 3 by a dotted line shown in 110, the actual arc electric current deriving from the current divider 33 in Fig. 1 departs from the command current signal of waveform 100.

In selected functional status (e.g., state A or state B) period, the speed determined with oscillator 84 or oscillator 94 reads actual arc electric current I _a.In fact, this is single software oscillator.Along the deviation of coordinate direction between the command level that horizontal monitor stages 81 records actual parameter 110 and waveform 100.During selected state, the SS that stability monitor stages 91 reads actual parameter is poor.Usually, state A and the B of pulse welding process is monitored.But, can t be monitored ₁-t ₂between propradation and/or t ₃-t ₄the decline state of period, with the activity of the actual parameter during these states controlling or at least read waveform.As schemed illustrated explanation, the background time period, B had variable time, as used moment t ₁variable time position shown in.Therefore, just monitored state can have fixing duration or variable duration.When being in variable duration, monitor this state, until the duration terminates.Report logic 82 senses it as from moment (that is a, t ₄) arrive moment (that is, t subsequently ₁) level.As moment t ₁relative to moment t ₄during change, this time of each waveform being recorded as the level compared with known time, obtaining described known time by selecting the bond pattern of generator 40 from interface 70.

Watch-dog M monitors the actual welding parameter during the specific selected state of waveform; But watch-dog is also programmed, to operate computer to determine stability and/or the horizontal nature of internal signal (e.g., on circuit 46a to the actual input of motor 26).Utilize the signal shown in Fig. 5, in the flow chart shown in Fig. 4, illustrate the such internal control to signal on circuit 46a.

Microprocessor in wire feeder comprises subprogram, and this subprogram is the PID comparing cell being similar to error amplifier.In the diagram, schematically illustrated by this PID comparator as block 152, it has the command signal on the first input 46b (that is, feed rate of welding wire WFS) and circuit 44.The actual WFS on circuit 46b is read by tachometer or encoder, to read WFS, the driven roller 24 that this tachometer or encoder are connected to feeder gear-box or on being alternatively connected to attached by welding wire follower.The output 156 of PID is the voltage level of the input of pulse width modulator 158, and it is digitized in the microprocessor of feeder.The output of pulse width modulator is the command signal for motor 26 on circuit 46, for controlling the feed rate of welding wire of feeder 24.

According to an exemplary, watch-dog M comprises the handling procedure as schematically illustrated in Fig. 4, wherein, read the signal on circuit 156 by processing block 160 and read result output on circuit 162 as before relative to embodiment shown in Fig. 1 the input of the horizontal monitor stages 81 discussed and/or stability monitor stages 91.Therefore, (more than 1kHz) reads the internal signal on circuit 156 fast, with the stability of the level and/or this signal that check this internal signal.

Illustrate as illustrated in fig. 5, the waveform 100 of pulse welding extends the continuation becoming the waveform deriving from generator 40.As for feed rate of welding wire, command signal circuit 44 deriving from generator 40 adopts the form shown in Fig. 5.It comprises initial rising part 170 and last sloping portion 172.These two parts cause the command signal on circuit 44 to rise sharply or rapid drawdown.On circuit 44 signal these aberrant commands parts between, there is average feed rate of welding wire order, adopt this order to come stability and/or the horizontal departure of this internal signal on measurement circuit 156.In Figure 5, keep welding wire accelerating part 170, until speed is stabilized always.Also this time is monitored.Can use with the identical design shown in Fig. 4 with Fig. 5 to monitor other internal signals.Horizontal monitor stages judges whether the signal on circuit 156 exceedes minimum of a value or maximum for a long time.For wire feeder, in this ordinary representation feeder system, there is blocking.

Fig. 6 illustrates the design of horizontal monitor stages, and wherein, threshold value 180 is maximum parameter level and threshold value 182 is minimum parameter levels.When the parameter being illustrated as arc current exceedes threshold value 180 (represented by transient state 184), recorded current occurrences.In a similar manner, when electric current is less than minimum level 182 (represented by transient state 186), record low current event.In addition, the weight of these events can be determined based on multiple standard.In an exemplary embodiment, determine that the weight of each event is that the size departing from desired value (such as, predetermined threshold, mean value) based on it was contributed relative to the time of corresponding waveform with its time period.Such as, such method of weighting (such as, shown in Fig. 9 and in method of weighting 900 described below) can be realized in horizontal monitor stages 81, stability monitor stages 91 or any similar or relevant data processing stage.

Periodically carry out counting to weighted events to add up in other words conj.or perhaps, to provide the output of horizontal monitor stages 81 as shown in Figure 1.Such as, can every 250ms accumulated weights event.Therefore, horizontal monitor stages 81 detects the deviate 184 higher than predetermined threshold value and the deviate 186 lower than preset level.In interface 70, these levels are set by particular state.These states of waveform adopt the horizontal monitor stages 81 with threshold value, and other states of same waveform can stability in use monitor stages 91.Preferably, and in fact, these two monitor stages selected one or more states of waveform of all just inquiring for watch-dog M.

As illustrated by the disclosure in Fig. 4 and Fig. 5, during the embodiment monitoring shown in Fig. 1 derives from the selected state of the waveform of generator 40 or the level of the actual parameter of whole weld period internal control signal and/or stability.As previously described, the watch-dog M in Fig. 1 provides the weighted data of weld cycle for analytical work time period internal welding machine or whole operation.Determine and storage data after, use various routine analyzer to process data.According to an exemplary, analyze by two programs as shown in Figure 7 the weighting stability data deriving from monitor stages 91.Those skilled in the art with various computer program analysis stability data, can disturb to record, to show and to process or evaluate.

As shown in Figure 7, the result (that is, weighting stability value) of the monitor stages 91 of routine analyzer 200 usage monitoring device M.As embodiment, at monitoring moment t ₂-t ₃between the time state current peak part of waveform (that is, as shown in Figures 2 and 3) period, working procedure 200.Illustrate that routine analyzer 200 is for computer process, this flow process illustrates two systems of the result for the stability stage 91 during analyzing peak current condition, and in this peak current condition, the SS of the actual current in computational scheme 34a is poor.In fact, before monitor stages 91 calculates deviation, slightly postpone.At state t ₂-t ₃period reads I _abut ignore I in other cases _asampling select feature to be illustrated as sampling selector or wave filter 90a.Be incorporated to the time period t in wave filter 90a ₂-t ₃this program delay during beginning makes watch-dog can ignore fluctuation in electric current, and these fluctuations are each horizontal During experience in the various stages of output waveform.

Shown in Fig. 7 in programming flow process, read by the computer program being depicted as block 210 stability deriving from monitor stages 91 and export, indicated in the logic on the circuit 210a at each waveform end place that determines when moment t3, preset this block 210.Therefore, the stability of (capture) each waveform is caught by block 210.This stability data of catching is processed according to the routine analyzer that two independent.

First program comprises and exceedes analysis subroutine (pass analysis routine) 212.If the stability of given waveform exceedes the required threshold value arranged in block 212, then on circuit 214, export this information.If the stability of specific waveforms is lower than required threshold value, then in circuit 216, there is logical signal.During each weld cycle, start counter 220,222 by the logic on circuit 224.Therefore, in counter 220 or counter 222, signal is exceeded to the stability of welding cycle period each waveform and counts.Certainly, each state t is ignored ₂-t ₃part I, to make I _astable.Representing respectively as read block 220a, 222a, reading, store the result keeping these two counters in other words conj.or perhaps.In an exemplary embodiment, if the unstability that counter stage 222 adds up exceedes expection number, then, represented by block 226, refusal accepts this weld cycle.

Second of computer program 200 shown in Fig. 7 is analyzed implementation and is illustrated as block 230.This is the program started during weld cycle.Using total instability analysis of weld cycle accumulative during all waveforms as sum, wherein, 100 is the most stable electric arc.Represented by block 236, read, store or perhaps keep this stability integrating instrument and the output of analysis phase.If fetch phase 234 is lower than the stability of setting, then represented by block 238, refusal accepts this weld cycle.Those skilled in the art can design other programs to analyze obtaining the result of watch-dog M in autostability stage 91.Computer program 200 shows two kinds of implementations for analyzing obtained weighting stability data.Be configured to character or the problems of welded quality of the arc stability detected according to watch-dog, optionally can start these two kinds of implementations (start a kind of mode or another kind of mode or start this two kinds of modes simultaneously).Advantageously, the stability in the selected state of waveform is only read, because the stability in variable pulse is unavailable.

According to another exemplary, for the computer program of the result (that is, weighting read value) of the horizontal monitor stages 81 of analysis monitoring device M shown in Fig. 8.In the embodiment that this illustrates, horizontal analysis (level analysis) program 250 processes the output from the monitoring level stage 81 with two independent subprograms, and these two independent subprograms are confirmed as utilizing the minimum monitor stages 81a of wave filter 80c and utilizing the maximum monitor stages 81b of wave filter 80d.Can be used alone any one in these stages, or in fact, combine these stages.Subdivision 81a relates to the conversion 186 determined shown in Fig. 6, that is, actual parameter is lower than the event of threshold value minimum of a value 182.As program step 252 choice phase 81a, use the minimum level derived from the circuit 202a of generator 40.As represented, block 254 these events to each weld cycle count.During weld cycle, counter is started by the logic on circuit 254a.Counter 254 for be the sum of the waveform used in weld cycle.Represented by circuit 258, by the moment t to the output from generator 40 ₃appearance count, obtain the number of waveform.As previously indicated, usually ignore the Part I of state, inconsistent with the exception removed when any particular state starts.Block 260 is computer program flow process subprograms, for deriving from the accumulative minimum event 186 of monitor stages 81a divided by the several N deriving from counter 256.The mean value of minimum transition during which providing weld cycle, this mean value is provided to subprogram 262.Represented by block 262a, read, store or perhaps export average minimum transition.If this mean value is higher than the particular threshold number provided by waveform generator or program step 264, then program subprogram 266 judges that weld cycle is underproof.If qualified, then hold fire.But, if qualified subprogram 266 judges that this mean value is just close to several 264, then provide alarm signal by block 266a.Total defective property provides a welding refusal acknowledge(ment) signal by subprogram 266b.Those skilled in the art it is contemplated that the analysis (when this analysis relates to setting threshold value) implementing the minimum current deviation of actual parameter or conversion with other computer programs.

In fig. 8, maximum monitor stages 81b operates in conjunction with minimum stage 81a.Maximum horizontal is in and is derived from the circuit 202b of generator 40, and uses this maximum horizontal as program 270 choice phase 81b.Similar data message keeps identical quantity with programming.Counter 272 couples of state t ₂the quantity of the event 184 during-t3 counts.The mean value of event 184 during subprogram 280 is provided in weld cycle process the various waveforms formed.Represented by block 282a, read, store this mean value used in other words conj.or perhaps in block 282.In block 286, process qualified subprogram, wherein, the number realized by computer program in other words represented by block 284 exported by generator 40 compares with the mean value deriving from block 282, with when mean value is close to the setting number represented by block 284, as block 286a represents, provide alarm signal.Indicated by block 286, if reach this number, then perform refusal and accept subprogram.

In fact, implementation phase 81a and stage 81b together, and the mean value being derived from these two conversions of block 262 and 282 by the ghreshold numbers analysis of reading, to give the alarm and/or to refuse the given weld cycle of acceptance one.Therefore, in fact, analyze minimum level deviation, analyze maximum horizontal deviation and analyzing total horizontal departure.As schematic, pictorial illustration in Fig. 8, realize all these by computer program and analyze.Level segment 81a, 81b export the level conditions utilizing report logic 82 (as discussed) to store and/or show.As discussed herein, the weighting of the level conditions that level segment 81a, 81b export can be determined.

In view of above content, use size and time contribution weight can measurement parameter stability and then measure integral solder quality more accurately.In this way, the easness understanding numerical value or score can be calculated, to quantize the total quality welded.In an exemplary embodiment, based on monitored welding condition or parameter (e.g., those conditioned disjunction parameters of the exemplary monitoring shown in Fig. 1), between the 0-100 calculating welding or the welding score of 0%-100%.Such as, such method of weighting (such as, shown in Fig. 9 and in method of weighting 900 described below) can be realized in horizontal monitor stages 81, stability monitor stages 91 or any similar or relevant data processing stage.

Method of weighting 900 according to an exemplary shown in Figure 9.Such as, method of weighting can be realized in watch-dog M.In the initial step 902 of method of weighting 90, the waveform of weld cycle is divided into a series of time slice part or state.Then, in step 904, with given speed, the welding parameter (such as, voltage, current strength) corresponding with at least one state is sampled.In an exemplary embodiment, sampling rate is more than or equal to 120kHz.In an exemplary embodiment, the interruption that sampling rate processes to produce interrupt service routine (ISR) can be used.

The welding parameter of sampling is used to calculate welding data.In exemplary method of weighting 900, welding data comprise perform counting, voltage and, voltage squared and, current strength and and current strength quadratic sum.Execution counting starts from 0 and each sampling period (such as, every 120kHz) increases by 1.Voltage and with current strength with start from 0 and each sampling period increases sampling voltage and sampling current intensity respectively.Similarly, voltage squared and start from 0 with current strength quadratic sum and each sampling period increase respectively sampling voltage square with sampling current intensity square.

After the predetermined sampling period, in step 906, transmit sampling welding data, for process (as described below) further, welding data value is reset and is 0 and repeated sampling process (that is, step 904).In an exemplary embodiment, the sampling period is 250ms.Each set of sampling welding data is formed analyzes packet.After (such as, every 250ms) is further processed to analysis packet, the extra soldered data of the current welding quality grade characterizing corresponding states can be obtained.Can these extra soldered data be drawn and/or are averaging.In weld length (that is, weld cycle), the mean value of these grades is that welding provides total quality instruction.

By being further processed for the welding data of each sampling state to each analysis packet occurred in step 906, cause calculating extra soldered data.Extra soldered data comprise and perform counting, average voltage, voltage root mean square (RMS), voltage variance, current strength mean value, current strength RMS and current strength variance.The value counted from the execution of welding data copies the value of the execution counting of extra soldered data.Average voltage is calculated as voltage with (deriving from welding data) divided by performing counting.Voltage RMS is calculated as the square root by business voltage squared and (deriving from welding data) counted to get divided by execution.Voltage variance is calculated as voltage RMS and deducts average voltage.Current strength mean value is calculated as current strength with (deriving from welding data) divided by performing counting.Current strength RMS is calculated as the square root by business current strength quadratic sum (deriving from welding data) counted to get divided by execution.Current strength variance is calculated as current strength RMS and deducts current strength mean value.

After step 906, process subsequently depends on that current welding is that exercise welding (training weld) for determining welding quality parameter still will according to the normal weld of this welding quality parameter evaluation.Therefore, in step 908, judge that current welding is exercise welding or normal weld.In an exemplary embodiment, implied terms (such as, is inputted by user) unless otherwise instructed, otherwise welding is normal weld.

If judge that current welding is exercise welding in step 908, then for practising the major part of welding (such as, 20-30 second), preserve extra soldered data value below: perform counting, average voltage, voltage variance, current strength mean value and current strength variance, and other welding data value and extra soldered data value can be ignored.The major part of exercise welding is practice periods section.In an exemplary embodiment, practice periods section corresponds at least 80 and analyzes packet (that is, sample time section) continuously.

After this, in step 910, the extra soldered data value preserved during using practice periods section is to calculate welding quality parameter.Such as, calculate the following welding quality parameter of each sampling state: quality perform weighted mean value, quality perform counting criteria poor, quality voltage mean value, quality voltage standard deviation, quality current strength mean value, quality current strength standard deviation, quality voltage mean of variance, quality voltage variance criterion are poor, quality current strength mean of variance and quality current strength variance criterion poor.

Quality performs the mean value of the execution counting of all analysis packets processed during weighted mean value is calculated as practice periods section.Performing counting can be integer by rounding.Quality performs the standard deviation of execution counting relative to quality execution weighted mean value of each analysis packet processed during counting criteria difference is calculated as practice periods section.The mean value of the average voltage of all analysis packets that quality voltage mean value processes during being calculated as practice periods section.The average voltage of each analysis packet that quality voltage standard deviation processes during being calculated as practice periods section is relative to quality voltage standard error of the mean.The mean value of the current strength mean value of all analysis packets processed during quality current strength mean value is calculated as practice periods section.The current strength mean value of each analysis packet processed during quality current strength standard deviation is calculated as practice periods section is relative to quality current strength standard error of the mean.The mean value of the voltage variance of all analysis packets that quality voltage mean of variance processes during being calculated as practice periods section.The voltage variance of each analysis packet processed during quality voltage variance criterion difference is calculated as practice periods section is relative to the standard deviation of quality voltage variance.The mean value of the current strength variance of all analysis packets processed during quality current strength mean of variance is calculated as practice periods section.The current strength variance of each analysis packet processed during quality current strength variance criterion difference is calculated as practice periods section is relative to the standard deviation of quality current strength variance.As mentioned above, can be used as carry out measuring to welding subsequently the benchmark of deciding grade and level in other words conj.or perhaps based on these mass parameters when being identified the transmission of good welding qualified in other words.

If determine that current welding weld with exercise to form the evaluation contrasted and weld (that is, the welding requiring to evaluate its quality) in step 908, then welding data or extra soldered data do not need preservation.The substitute is, obtain and preserve the result of various Mass Calculation.These Mass Calculation are included in the existence of the various isolated point of initial detecting in step 914.Isolated point is data point or value, and it exceedes threshold distance apart with the mean value obtained by this data point or value.In an exemplary embodiment, isolated point be drop on distance average three standard deviations the limit outside value.

In method of weighting 900, the isolated point found in step 914 comprises execution isolated point, voltage isolated point, voltage variance isolated point, current strength isolated point and current strength variance isolated point.For each monitored state, evaluate each analysis packet, to detect the existence of any one in these isolated points.

If analyze packet to meet following relation, be then considered as performing isolated point: the absolute value > (it is poor that 3 × quality performs counting criteria) of (perform counting-quality and perform weighted mean value).If analyze packet to meet following relation, be then considered as voltage isolated point: the absolute value > (3 × quality voltage standard deviation) of (average voltage-quality voltage mean value).If analyze packet to meet following relation, be then considered as voltage variance isolated point: the absolute value > (3 × quality voltage variance criterion is poor) of (voltage variance-quality voltage mean of variance).If analyze packet to meet following relation, be then considered as current strength isolated point: the absolute value > (3 × quality current strength standard deviation) of (current strength mean value-quality current strength mean value).If analyze packet to meet following relation, be then considered as current strength variance isolated point: the absolute value > (3 × quality current strength variance criterion is poor) of (current strength variance-quality current strength mean of variance).

After these isolated points of detection, the two step weighted sums (that is, in step 916 and 918) of each isolated point are used to calculate the quality instruction of correspondence analysis packet.

Be defined as the first step (that is, step 916) of this isolated point determination weight relative to the size of the three standard deviation limit by each isolated point.Usually, the data point close to 0.3% or value can be fallen outside the three standard deviation limit, and then are regarded as isolated point.When the value of isolated point increases to the limit more than three standard deviations, the weight of this isolated point increases.Under four standard deviations, the full weight of isolated point is 100% and the weight limit of isolated point is 200% under five standard deviations.Usually, in normal data set, occur that the possibility of the isolated point of full (that is, 100%) weight is 15, in 787, have 1.

Therefore, in step 916, determine the weight of each isolated point according to such method.The absolute value that the weight being applied to each execution isolated point is calculated as (performing counting criteria more than the amount/quality of the three standard deviation limit poor), and weight limit value is 2.0.The absolute value that the weight being applied to each voltage isolated point is calculated as (amount/quality voltage standard deviations more than the three standard deviation limit), and weight limit value is 2.0.The absolute value that the weight being applied to each voltage variance isolated point is calculated as (poor more than the amount/quality voltage variance criterion of the three standard deviation limit), and weight limit value is 2.0.The absolute value that the weight being applied to each current strength isolated point is calculated as (amount/quality current strength standard deviations more than the three standard deviation limit), and weight limit value is 2.0.The absolute value that the weight being applied to each current strength variance isolated point is calculated as (poor more than the amount/quality current strength variance criterion of the three standard deviation limit), and weight limit value is 2.0.

The second step (that is, step 918) of this isolated point determination weight is defined as by the execution counting of each isolated point state.Specifically, what the value of each isolated point is multiplied by this isolated point state performs counting, illustrates that this state was contributed relative to the time of overall waveform thus.In this way, there is the larger state performing counting (that is, time of implementation) and produce the isolated point with corresponding larger weight.Therefore, along with the time of implementation of specific isolated point increases, the weight of this isolated point also will increase.

The weight of the isolated point in step 916 and 918 produces the set of final weighting isolated point, comprises final weighting and performs isolated point, final weighted voltage isolated point, final weighted voltage variance isolated point, final weighted current intensity isolated point and final weighted current intensity variance isolated point.In step 920, these final weighting isolated points are sued for peace, with produce each analysis packet final weighting isolated point and.After this, in step 922, the determination of the quality of each analysis packet instruction be calculated as by perfect mass value is deducted final weighting isolated point and, again divided by the business that perfect mass value obtains.The execution that this perfect mass value equals to analyze packet counts the quantity (being that is, in this case, 5) being multiplied by isolated point kind.

Therefore, instant quality instruction (that is, for current complete analysis packet) can be determined and communicate with welding machine or be otherwise utilized during welding process.In this way, when there are potential problems during (namely) welding process, just these potential problems can be detected, this with only carry out detecting after completing welding, likely too late so that the situation of any corrective action can not be taked to be formed contrast.

In addition, can to adding up to until the quality instruction mean value of arbitrary time point during welding process be averaging, to determine until the welding quality instruction of this time point.Such as, after completing welding process, can be averaging all each quality instructions, to obtain the total quality instruction, score, grade, classification etc. of whole welding.The instruction of the total quality of welding can be indicated (such as, being derived from exercise welding) to compare with predetermined quality, described predetermined quality instruction reflects the minimum quality indicated value of qualified welding.

In this way, in real time or can be close in real time, accurately, effectively, unanimously and/or automatically determine welding quality.This is especially favourable because on the range estimation of welding be not be always enough to judge welding quality and because operator possible can not detect recognize welding process in other words during can affect deviation or the other problems of integral solder quality.

In some example embodiments, the quality instruction of welding (namely, welding score) be evaluate under substantially the same conditions and according to substantially identical Arc Welding Process (as, during automatic (such as, robot) welding process) repeat the effective tool of the welding formed.By calculate each welding instantaneous, periodically and/or the welding score of entirety, automation quality control treatments can be suitable for electric arc welding process.Specifically, according to welding condition and electric arc welding process, start minimum qualified welding score or qualified welding score range to be defined as threshold value most.After this, the welding score of (instantaneous, periodically and/or entirety) is with threshold value compared with by welding at every turn, with fast and accurately judge to accept welding or refuse to accept welding.In addition, by evaluating the trend of the welding score of producing running or complete running, more easily can determine the problem in production process, and/or more easily can optimize production process.

Conceptual production line 1000 shown in Figure 10, wherein, the first welding score S1 1002, second welding score S2 1004 and the 3rd welding score S3 1006 is associated to the welding that the first workpiece WP1 1008, second workpiece WP2 1010 and the 3rd workpiece WP3 1012 perform respectively with the welding machine or welding bench 1014 comprising integrated monitoring device M 1016.Those of ordinary skill in the art will understand, and can perform different welding to same workpiece.

Then, by welding score compared with predetermined qualified welding score threshold, to judge accept or refuse to accept each welding.Or isolated system can be passed through or carry out this at independent position (such as, appraisal platform 1018) to compare by welding machine/welding bench.In an exemplary embodiment, the comparison between welding score and threshold value is manually performed.In an exemplary embodiment, perform automation and manually compare.In an exemplary embodiment, whether the manual examination (check) of corresponding welding is guaranteed to use welding score to judge.In an exemplary embodiment, the whole efficiency of welding score determination production line is used at least partly.

In an exemplary embodiment, one or more appraisal platform 1018 is set along production line 1000, to measure the welding of the moment in production process.If appraisal platform 1018 judges that the welding score of welding meets or exceedes predetermined qualified welding score threshold, then appraisal platform 1018 accepts welding by sending acceptance welding order 1020.In response to acceptance welding order 1020, the workpiece comprising qualified welding is allowed to move on along production line 1000, to be further processed.

On the contrary, if appraisal platform 1018 judges that the welding score of welding is reduced to lower than predetermined qualified welding score threshold, then appraisal platform 1018 is refused to accept welding by sending refusal acceptance welding order 1022.Accept welding order 1022 in response to refusal, the workpiece comprising defective welding leaves production line 1000 and is removed (such as, manually removing) from production line 1000 in other words.After this, the workpiece with the welding being rejected acceptance can stand further process, and such as, transformation or otherwise reparation are rejected the welding of acceptance or reclaim this workpiece completely.

In an exemplary embodiment, registration stores each acceptance welding order 1020 in other words and/or refusal accepts welding order 1022, for consulting subsequently and analyzing.In this way, the trend about soldering and/or production process more easily can be determined, and then, the whole efficiency being easier to improve the production line utilizing welding process can be made like this.

In some example embodiments, the welding quality instruction (that is, welding score) calculated can be used in innovative approach, instructs operator manually to perform Arc Welding Process in other words for providing instruction.Specifically, when operator is just using welding machine (such as, arc welder 10) when generating welding, by welding machine (such as, watch-dog M by welding machine) determine that the instantaneous and/or periodicity of welding welds score, and this score is for providing the direct feedback about current welding quality to operator.As mentioned above, these welding scores are based on more accurately reflecting that compared with only estimating and welding the weighted statistical of welding quality is measured.Specifically, by welding score compared with predetermined qualified welding score or qualified welding score range, whether be necessary with any corrective action of decision person.In addition, evaluate the welding score of each time, to determine whether to exist any trend (such as, showing as the continuous reduction of welding score) deviating from qualified welding score.

Guidance method 1100 according to an exemplary shown in Figure 11.In the beginning of method 1100, operator starts to perform welding procedure in step 1102.

During welding procedure, in step 1104, welding score (sampling the parameter recorded in other words based on one or more) is periodically calculated, to reflect current welded condition.Welding score can be calculated as instantaneous measure reflect current welded condition, or reflects the mean value of repetitive measurement of the welded condition during welding procedure in certain hour section (corresponding to repetitive measurement).In an exemplary embodiment, by being averaging calculating welding score to starting acquired all measured values from welding procedure, which reflects the integrality of current welding.

Then, in a step 1106, compared with welding score is welded score with predetermined threshold.Threshold value welding score is the minimum welding score of good qualified in other words welded condition.If welding score welds score greater than or equal to threshold value, then judge that current welded condition is as good in step 1108.Otherwise, judge that current welded condition is as difference in step 1108.

If current welded condition is good, then provide instruction to operator in step 1110, show that welding is good, this prompting correctly performs welding procedure.After this, in step 1112, register current welded condition, for follow-uply consulting, analyzing and/or other purposes.Then, guidance method 1100 proceeds, the soldering just performed with policer operation person as described above.

If current welded condition is poor, then in step 1114, provide instruction to operator, show that welding is poor, this prompting performs welding procedure improperly.After this, in step 1118, register current welded condition, for follow-uply consulting, analyzing and/or other purposes.Then, guidance method 1100 proceeds, the soldering just performed with policer operation person as described above.

Can with being enough to notify during welding procedure that any mode of operator provides above-mentioned instruction to operator.In an exemplary embodiment, visually provide instruction to operator, as provided in display unit that is integrated with welding machine or that be close to welding machine.In an exemplary embodiment, protectiveness face helmet (visor) that operator wears or the helmet indicate with visual manner display.In an exemplary embodiment, acoustically providing instruction to operator, as provided by loudspeaker that is integrated with welding machine or that be close to welding machine.In an exemplary embodiment, with audible means display instruction in the protective headgear worn operator.

In an exemplary embodiment, if current welded condition is poor, then in step 1116, operator receives about the instruction should taking which type of one or more corrective action.In an exemplary embodiment, during welding procedure, provide instruction in real time.Such as, the welding rod (that is, welding wire) that this instruction can relate to suggestion changes relative to the rate travel of workpiece relative to the change in location of workpiece or the welding wire of suggestion.

Various device and technology can be used to determine the corrective action taked possibly, as, operator and/or welding condition Modling model during being the welding procedure of good welds by causing empirical tests, and use the model data of gained to evaluate other operators performing similar soldering under similar conditions.Artificial intelligence and relevant emulation can also be used to set up this model.In addition, sensor can be used to set up this model.

In an exemplary embodiment, use one or more sensor to determine some aspects of welding procedure, such as, the Current Temperatures of workpiece, the level of protective gas of just sending and/or the composition of protection gas.In an exemplary embodiment, use one or more sensor to determine the environmental condition that may affect welding procedure, such as, wind condition and/or damp condition.In an exemplary embodiment, use one or more sensor to determine operator's condition that may affect welding procedure, such as, the angle that operator's hand is formed from the distance of workpiece and/or operator's hand and workpiece.By deriving from the data of these or other sensor compared with model data, to confirm that operator should take the instruction of which type of one or more corrective action.

In an exemplary embodiment, visually corrective action is provided to indicate to operator, as provided in display unit that is integrated with welding machine or that be close to welding machine.In an exemplary embodiment, with visual manner display instruction on the protectiveness face helmet worn operator or the helmet.In an exemplary embodiment, acoustically providing instruction to operator, as provided by loudspeaker that is integrated with welding machine or that be close to welding machine.In an exemplary embodiment, with audible means display instruction in the protective headgear worn operator.

Therefore, guidance method 1100 provides Real-time Feedback to operator during welding procedure, operator is easily known when weld to turn to poor condition from good condition and when weld to turn to good condition from difference condition.In addition, guidance method 1100 can point out intention to improve the corrective action of current (and then overall) welding condition.Change due to welding condition is usually caused by the action of operator, the solder technology that the feedback (comprising the corrective action of any prompting) that therefore guidance method 1100 provides instructs operator good.In addition, by continuing to confirm that good welded condition strengthens the good welds technology of operator.

Guidance method 1100 or its some aspects easily can also be suitable for the welding procedure being applied to emulation in other words.In an exemplary embodiment, guidance method 1100 is applied to the welding simulation device utilizing virtual reality technology.

In some example embodiments, the quality instruction of the performed welding of the operator calculated (namely, welding score) can be used in innovative approach, for the person that comes verification operation for specific welding machine, welding procedure or welding process, this is similar in general education the situation using grade.Such as, the welding score (such as, integral solder score) calculated according to guidance method 1100 or its some aspects provides platform easily for verification operation person.It is one or more welding scores that the predetermined threshold be verified welds score that operator must obtain exceeding for welding machine, welding procedure or welding process.If operator is not by checking, then guidance method 1100 can indicate operator's area for improvement.As described herein, additional functionality (such as, inner by welding machine or the outside software run provides) can be used measurement may be used for verification operation other parameters of person.Such as, guidance method 1100 can be revised, make it comprise and follow the trail of the time that operator's actual welding spends during welding procedure or welding process.As another embodiment, guidance method 1100 can be revised, make it comprise the amount of following the trail of the running stores (such as, welding wire) that operator uses during welding procedure or welding process.

Except for except verification operation person, weld score (with other parameters) and can also be used for distinguishing different operators.Such as, although two operators achieve by (passing) score and verify for specific welding machine, welding procedure or welding process, the score of these two operators may differ widely.Therefore, compared with the empirical tests operator that score is lower, another empirical tests operator that score can be selected much higher.

In some example embodiments, welding quality instruction (that is, weld score) calculated and other relevant parameters and information may be used for auxiliary direction, and person instructs multiple student's solder technology, technique, program, process etc.Welding course usually comprises theory part and puts into practice part.Theory part is normally instructed with the form of carrying out teaching, discuss or demonstrating in classroom or like environment.Usually, the welding school of students practise part or other environment is instructed to comprise each place (e.g., workplace) of the welding bench be similar in factory in course.Each student is assigned to his or she workplace, puts into practice part with what perform course.

Such as, by following the trail of the class attendance rate of each student during the discussion about theory part and/or participation, director is easy to estimate how long each student takes in the theory part of course.But director is difficult to each student of gauge and puts into practice how long part is actual takes at course, because director can not one to wait until between all working.Such as, between can constructing and/or assign a work, make preceptorial sight line only extend to single workplace, that is, the workplace that director is residing at present at every turn.The student of other workplaces may do and some things (such as, eat, sleep, say phone) of non-solder, and director not knowing.Director is also difficult to easily determine which student will benefit from preceptorial taking up personally by most probable at any given time.Therefore, director finally can at student spended time with it, although another student more needs preceptorial taking up personally.

The system 1200 for monitoring (e.g., Arc Welding Process) such as Students ' Learning solder technology, technique, program, processes according to an exemplary shown in Figure 12.System 1200 comprises and instructs region 1202, as classroom or workshop (shop), arranges eight workplaces 1204,1206,1208,1210,1212,1214,1216 and 1218 instructing in region 1202.Each workplace comprises welding machine.Specifically, first welding machine W1 1220 is arranged in the first workplace 1204, second welding machine W2 1222 is arranged in the second workplace 1206,3rd welding machine W3 1224 is arranged in the 3rd workplace 1208,4th welding machine W4 1226 is arranged in the 4th workplace 1210,5th welding machine W5 1228 is arranged in the 5th workplace 1212,6th welding machine W6 1230 is arranged in the 6th workplace 1214,7th welding machine W7 1232 is arranged in the 7th workplace 1216, and the 8th welding machine W8 1234 is arranged in the 8th workplace 1218.In addition, student is assigned to each workplace.Specifically, first student S1 1236 is assigned in the first workplace 1204 and works, second student S2 1238 is assigned in the second workplace 1206 and works, 3rd student S3 1240 is assigned in the 3rd workplace 1208 and works, 4th student S4 1242 is assigned in the 4th workplace 1210 and works, 5th student S5 1244 is assigned in the 5th workplace 1212 and works, 6th student S6 1246 is assigned in the 6th workplace 1214 and works, 7th student S7 1248 is assigned in the 7th workplace 1216 and works, and the 8th student S8 1250 is assigned in the 8th workplace 1218 and works.

Arrange and instruct region 1202, make director 1252 freely can move to another workplace and student's interaction from a workplace.

In an exemplary embodiment, each in welding machine W1, W2, W3, W4, W5, W6, W7 and W8 comprises integrated watch-dog M, and welding machine 10 is as shown in Figure 1 the same.When student is just using welding machine to generate welding, determining that the instantaneous and/or periodicity of welding welds score by welding machine (by watch-dog M), and using welding score to provide the direct feedback about current welding quality to student.As described in this article, these welding scores are based on more accurately reflecting that compared with only estimating and welding the weighted statistical of welding quality is measured.Specifically, score will be welded and qualifiedly weld score or qualified welding score range (such as, determining according to base weld before) is compared, to judge whether student must carry out any corrective action with predetermined.In addition, in each Time evaluation welding score, to determine whether to exist any trend (such as, showing as the continuous reduction of welding score) deviating from qualified welding score.

Welding machine W1, W2, W3, W4, W5, W6, W7 communicate with manufacturing monitoring system (PMS) 1254 with each network 1256 that passes through in W8.Network 1256 can be wired or wireless network.In an exemplary embodiment, network 1256 is ethernet networks.

When not departing from the spirit and scope of present general inventive concept, software, hardware and combination thereof can be used to realize PMS 1254.In an exemplary embodiment, PMS 1254 is embodied as at the upper software run of the all-purpose computer (such as, PC) being connected with peripheral unit (e.g., display unit 1258 and data storage 1260).In an exemplary embodiment, PMS 1254 can comprise the logic integrated with each welding machine, as when watch-dog M.As mentioned above, PMS 1254 carries out data communication by network 1256 with welding machine W1, W2, W3, W4, W5, W6, W7 and W8.

PMS 1254 is that welding data is collected and monitoring tools, its operationally (such as) have each institute and record the short-term of the statistical value welded for collecting and weld record for a long time.PMS 1254 can also follow the trail of other and produce relevant parameter and condition, e.g., and circuit consumption.In system 1200, PMS 1254 from each collection data welding machine W1, W2, W3, W4, W5, W6, W7 and W8, with determine generate welding process in each student S1, S2, S3, S4, S5, S6, S7 and S8 cost time quantum.The time quantum (that is, weld interval) of each student's cost in student S1, S2, S3, S4, S5, S6, S7 and S8 can be saved in data storage 1260, for subsequent retrieval (retrieval) and use by PMS 1254.In addition, PMS 1254 is by network 1256 from each reception welding score welding machine W1, W2, W3, W4, W5, W6, W7 and W8, and then these can be welded score and be saved in data storage 1260, for subsequent retrieval and use by PMS 1254.Therefore, PMS 1254 can produce and store the weld interval of multiple student and the record of welding score in multiple evaluation time section, and these records can be the affluent resources of director 1252 when instructing and evaluating student.

In addition, PMS 1254 can show the current welding score of current weld interval in conjunction with each student in student S1, S2, S3, S4, S5, S6, S7 and S8 of each student in student S1, S2, S3, S4, S5, S6, S7 and S8 in real time in display unit 1258.In this way, by observing display unit 1258, director 1252 can obtain the instantaneous and precise evaluation of the current state of each student and corresponding welding thereof.This allows director 1252 to distribute the his or her time for those students that the demand that shows is the highest better.

In system 1200, can adopt in any way, weld interval and welding score are shown as numeric data and/or graph data.In an exemplary embodiment, PMS 1254 provides the user interface based on webpage, this user interface support by web browser access data, consult data, generate report etc.

System 1200 easily changes scale, to hold any amount of student and multiple director.

The method 1300 of monitoring Students ' Learning solder technology, technique, program, process etc. (e.g., Arc Welding Process) according to an exemplary shown in Figure 13.Method 1300 relates to the multiple students performing Arc Welding Process in step 1302.In an exemplary embodiment, student under substantially the same conditions and perform substantially identical Arc Welding Process in the substantially identical time.

During Arc Welding Process, in step 1304, the welding score (sampling the parameter recorded in other words based on one or more) of each student is periodically calculated, to reflect the welded condition of current student.Welding score can be calculated as the transient measurement of welded condition reflect current student, or the mean value of the repetitive measurement of the welded condition of student during reflecting Arc Welding Process in certain hour section (corresponding to repetitive measurement).In an exemplary embodiment, by being averaging to starting acquired all measured values from Arc Welding Process the welding score calculating student, which reflects the integral solder state of current student.

During the evaluation time section of method 1300, determine the time quantum that each student performs Arc Welding Process (that is, actual welding) and spends in step 1306.Can use from the welding machine of each student collect can operating data to determine the weld interval of student.

In step 1308, each welding score student corresponding with it is made to be associated.Similarly, in step 1308, the student making each weld interval corresponding with it is associated.The identifying information of the welding machine distributing to each student (such as, sequence number) can be used to make to be associated from the data that welding machine is collected and/or welding machine produces (such as, welding score, weld interval) with corresponding student.

Once make welding score and weld interval be associated with corresponding student, just this information can be exported by any way in step 1310.Such as, can by all students and corresponding welding score thereof and the report output of weld interval to display unit, e.g., monitor.As another embodiment, can register about student and corresponding welding score thereof and the information of weld interval and be stored in data storage (e.g., disc driver or flash drive), for subsequent retrieval and use.In one exemplary embodiment, periodically output information.In an exemplary embodiment, output information at the end of evaluation time section.

The extra identifying information welding score and/or produce student weld interval can also be used.Such as, can by the welding score of student and/or weld interval compared with predetermined threshold.In this way, based on welding score and/or the weld interval of student, can judge that the welding of student is qualified or defective.

In some example embodiments, the welding score of the welding calculated may be used in innovative approach, to differentiate that the implicit costs of welding procedure are saved.In an exemplary embodiment, based on a series of welding performed according to welding procedure, carry out the cost analysis (such as, cost-benefit analysis cost effectiveness analysis, cost effectiveness analysis) of welding procedure.As shown in Figure 14 A to Figure 14 B, the data 1400 corresponding to exemplary weld can be used to carry out executory cost analysis.

First, the multiple welding conditions 1402 affecting integral solder quality are selected.Such as; in Figure 14 A and Figure 14 B; welding condition 1402 comprises welding wire characteristic (such as; welding wire composition 1404, gage of wire, coating), characteristic (such as, workpiece composition (composition) 1406, thickness of workpiece), protective gas flow velocity 1408, protective gas composition 1410 and/or workpiece preheat temperature 1412.Then, represented by 1414, for a series of welding, a welding condition in these welding conditions 1402 changes, and simultaneously represented by 1414, for a series of welding, remaining all welding conditions 1402 are fixing.

For each welding in a series of welding, also calculate welding score 1416 based on current welding condition 1402,1414.Welding score 1416 characterizes the measurement of the total quality of the welding generated under soldering conditions.As mentioned above, these welding scores are based on more accurately reflecting that compared with only estimating and welding the weighted statistical of welding quality is measured.

In addition, for each welding in a series of welding, determine the cost generating welding.In an exemplary embodiment, cost comprise to generation weld relevant dollar spending, this dollar spending is characterized as being the monetary cost 1418 of welding.In an exemplary embodiment, cost has comprised the total time needed for welding, and this cost is characterized as being the time cost 1420 of welding.Each welding in a series of welding welding score corresponding with it and cost are associated.

Figure 14 A and Figure 14 B comprises the data 1400 of two welding in a series of welding respectively; wherein; for a series of welding; among welding condition 1402, as shown in 1414, welding wire composition 1404, workpiece composition 1406, protective gas composition 1410 and workpiece preheat temperature 1412 are fixing; simultaneously for a series of welding; as shown in 1414, protective gas flow velocity 1408 changes (such as, increasing or decreasing).

For the welding corresponding to Figure 14 A, calculate and determine monetary cost 1418a, time cost 1420b and welding score 1416c in other words.For the welding corresponding to Figure 14 B, calculate and determine monetary cost 1418d, time cost 1420e and welding score 1416f in other words.Therefore; if it is determined that a < is d; b < e and c=f; then can derive the protective gas flow velocity 1408 of protective gas flow velocity 1408 higher than Figure 14 B of Figure 14 A; because compared with the protective gas flow velocity 1408 of Figure 14 B, by the protective gas flow velocity 1408 of Figure 14 A achieve simultaneously cost and time save and integral solder quality without any reduction.If relatively; judge a < d; b > > e and c=f; then can derive compared with the protective gas flow velocity 1408 of Figure 14 B; the protective gas flow velocity 1408 of Figure 14 A provides cost savings; and integral solder quality is without any reduction, but time cost significantly increases.

In this way, user easily can verify the impact of the welding condition of change on a series of (and then in corresponding welding procedure) integral solder quality.In this way, user can judge to change welding condition (and in which way) whether by the welding quality making user more be expected, the cost more expected or obtain both simultaneously.Therefore, when performing more welding and analyze corresponding data, can easily determine and evaluate any one or more welding condition on the impact of integral solder technique, the cost savings making it possible to make more wisdoms determine (such as, relative to the balance of money, time and quality).

Can be extended to this analysis, make it comprise extra a series of welding, wherein, in the welding of different series, different welding conditions changes.In this way, user can verify desirable value or the setting value of multiple welding condition, to realize results needed (such as, qualified welding quality and qualified cost).Then, the desirable value of these welding conditions or setting value can be kept in the brief introduction (profile) be associated with welding machine and welding procedure, fetch for follow-up identical welding machine and welding procedure and use, thereby increase user and will again realize the possibility of results needed.

In an exemplary embodiment, multiple this brief introduction (that is, selected welding parameter and/or the set of welding condition) being saved as (namely) pre-sets, and makes the user of beginning welding procedure can access these brief introductions.In an exemplary embodiment, multiple pre-seting together with corresponding to each welding score pre-seted is presented to user.Use before each welding Score quantifies and the integral solder quality pre-seting the welding parameter that is associated and welding condition and obtain.As mentioned above, these welding scores be based on compared with only estimating and welding more the weighted statistical of precise effects welding quality measure.Then, user one of can select to pre-set and perform welding procedure, and adding users pre-sets identical with the welding that welding condition is formed or the substantially similar welding of the welding parameter that is associated by realizing with using before thus.In an exemplary embodiment, provide user interface, can filter out to make user and not have match user to input the pre-seting of standard, such as, filter out to have and pre-set lower than those of the welding score that is associated of input threshold value.

Figure 15 illustrates and pre-sets 1500 according to an exemplary.Eachly pre-set 1500 and comprise and verify the welding score 1514 that pre-sets sequence number 1502, welding condition set 1504, welding machine information 1506, welding procedure information 1508, monetary cost 1510, time cost 1512 and be associated.Make to have pre-set sequence number 01 first preset 1516 with there is value a, the welding condition 1504 of b, c, d and e and welding machine M be associated.First pre-sets 1516 corresponds to welding procedure O.If user selects first to pre-set 1516 (namely, pre-set 01) under welding condition a, b, c, d and e, utilize welding machine M to perform welding procedure O, then user can expect that the welding obtained by welding procedure O is had the monetary cost being roughly t, the time cost being roughly v and is roughly the welding score of x.Pre-set 1500 and can comprise extra pre-seting, e.g., be associated with the various combination of welding condition 1504, welding machine 1506 and/or welding procedure 1508 second pre-sets 1518.

Except the monitored welding parameter described herein, additional welding parameter can be monitored for one or more state of waveform, and additional mass parameter can be calculated from described additional welding parameter, to detect more accurately and to differentiate weld defect.The pulsation rate (pulsing rate) of sound that additional welding parameter can comprise welding torch or welding torch position, the level of sound produced by Arc Welding Process, the frequency of at least one sound produced by Arc Welding Process and be produced by Arc Welding Process.The level that more additional welding parameter comprises the visible ray produced by Arc Welding Process, the frequency of at least one visible ray produced by Arc Welding Process and the pulsation rate of visible ray produced by Arc Welding Process.Level, the frequency of at least one infrared light produced by Arc Welding Process, the pulsation rate of infrared light produced by Arc Welding Process and welding wire that further additional welding parameter comprises the infrared light produced by Arc Welding Process send motor current level to.

According to embodiment, additional welding parameter is sensed by the sensor or supervising device being suitable for the such welding parameter of detection.Such as, sound can be sensed by microphone, and visible ray can be sensed by photodetector, and infrared light can be sensed by infrared detector, and welding wire is sent to motor current and can be sensed by current divider.Welding torch position can use the detection technology of one or more types (comprising, such as imaging sensor or magnetic sensor) to sense.Sensor can be arranged on various position, comprises, such as on welding torch, welding the helmet on or at general welding region.Additionally sensed welding parameter can be imported into watch-dog M by this way and by watch-dog M process, described mode is similar to other welding parameters as previously described herein and how is transfused to and processed mode.Other monitored and processed welding parameter can comprise the temperature of workpiece, the level of protective gas, the composition of protective gas, the wind speed of near workpieces, the humidity level of near workpieces and operator position.

Watch-dog M can be configured, and (the watch-dog M' of the upgrading such as, gone out as shown in Figure 16) calculates multiple mass parameter statistical value based on additionally monitored welding parameter.For the various additional welding parameter of one or more state of waveform, various mass parameter statistical value " mean value ", " standard deviation ", " mean of variance " and " variance criterion is poor " can be calculated by this way, and described mode is similar to as previously described herein for the how calculated mode of those mass parameter statistical values of voltage and current.In other words, mass parameter based on additional monitored welding parameter can be calculated by this way, and how described mode QVA, QVSD, QWA and QWSD be similar to for monitored voltage is calculated and for the how calculated mode of QIA, QISD, QIVA and QIVSD of monitored electric current.

Such as, watch-dog M can be configured to during welding procedure for one or more state computation sound levels mass parameter within a time period, such as quality acoustic level average (QSLA), quality acoustic level standard difference (QSLSD), quality acoustic level variance mean value (QSLVA) and quality acoustic level variance standard deviation (QSLVSD).Watch-dog M can also be configured to for one or more state computation sound frequency mass parameter within a time period, such as quality acoustic average frequency value (QSFA), quality acoustic frequency standard difference (QSFSD), quality acoustic frequency variance mean value (QSFVA) and quality acoustic frequency variance standard deviation (QSFVSD).In addition, watch-dog M can also be configured within a time period such as, for one or more state computation sound pulsation rate mass parameter, quality acoustic pulsation rate (pulse rate) mean value (QSPRA), quality acoustic pulsation rate standard deviation (QSPRSD), quality acoustic pulsation rate mean of variance (QSPRVA) and quality acoustic pulsation rate variance criterion difference (QSPRVSD).The sound of welding procedure is produced by the electric arc between wire-electrode (wire electrode) and workpiece.Specific sound property trends towards the particular state appearing at welding waveform.

Watch-dog M can be configured to during welding procedure for one or more state computation visible light level mass parameter within a time period, such as quality visible light level mean value (QVLLA), quality visible light level standard deviation (QVLLSD), quality visible light level mean of variance (QVLLVA) and quality visible light level variance criterion difference (QVLLVSD).Watch-dog M can also be configured to for one or more state computation visible frequency mass parameter within a time period, such as quality visible frequency mean value (QVLFA), quality visible frequency standard deviation (QVLFSD), quality visible frequency mean of variance (QVLFVA) and quality visible frequency variance criterion difference (QVLFVSD).In addition, watch-dog M can also be configured within a time period such as, for one or more state computation visible ray pulsation rate mass parameter, quality visible ray pulsation rate mean value (QVLPRA), quality visible ray pulsation rate standard deviation (QVLPRSD), quality visible ray pulsation rate mean of variance (QVLPRVA) and quality visible ray pulsation rate variance criterion difference (QVLPRVSD).The visible ray of welding procedure is produced by the electric arc between wire-electrode and workpiece.

Watch-dog M can be configured to during welding procedure within a time period such as, for one or more state computation infrared light leveling qualities parameter, quality infrared light level average (QIRLLA), quality infrared light level standard difference (QIRLLSD), quality infrared light level variance mean value (QIRLLVA) and quality infrared light level variance standard deviation (QIRLLVSD).Watch-dog M can also be configured within a time period such as, for one or more state computation infrared light frequency quality parameter, quality infrared light average frequency value (QIRLFA), quality infrared light frequency standard difference (QIRLFSD), quality infrared light frequency variance mean value (QIRLFVA) and quality infrared light frequency variance standard deviation (QIRLFVSD).In addition, watch-dog M can also be configured within a time period such as, for one or more state computation infrared light pulsation rate mass parameter, quality infrared light pulsation rate mean value (QIRLPRA), quality infrared light pulsation rate standard deviation (QIRLPRSD), quality infrared light pulsation rate mean of variance (QIRLPRVA) and quality infrared light pulsation rate variance criterion difference (QIRLPRVSD).The infrared light of welding procedure is produced by the electric arc between wire-electrode and workpiece.

Watch-dog M can be configured within a time period, send motor current mass parameter to for one or more state computation welding wire during welding procedure, and such as quality welding wire sends motor current mean value (QWFMIA) to, quality welding wire sends motor current standard deviation (QWFMISD) to, quality welding wire sends motor current mean of variance (QWFMIVA) to and quality welding wire sends motor current variance criterion difference (QWFMIVSD) to.Welding wire is sent motor current to and is produced by the motor of wire feeder during welding procedure.When the ignition tip that ignition tip becomes wearing and tearing or mistake is used, the displacement (shift) in motor current or spike (spike) may be observed during some state.

Again, various mass parameter statistical value " mean value ", " standard deviation ", " mean of variance " and " variance criterion is poor " can be calculated for various additional welding parameter by this way, and described mode is similar to as previously described herein for the how calculated mode of those mass parameter statistical values of voltage and current.In addition, according to embodiment, the value of each mass parameter calculated for each time period can compared with corresponding prospective quality parameter value, to judge whether the difference of quality parameter value and the prospective quality parameter value calculated exceedes predetermined threshold.If difference exceedes threshold value, can based on described difference, determine the weight of the quality parameter value calculated with size weight, and/or contribute based on the time of its state relative to the waveform comprising described state, determine the weight of the quality parameter value calculated with time contribution weight.

According to embodiment of the present invention, mass parameter (by determine weight or do not determined weight) and/or welding parameter can be used to diagnose Arc Welding Process.Figure 16 illustrates the schematic block diagram of the embodiment of the system 1600 for diagnosing Arc Welding Process.System 1600 corresponds to a part for arc welding system and comprises the watch-dog M'1610 of upgrading, and the watch-dog M' of described upgrading is similar to watch-dog M but is configured to monitor additional welding parameter discussed in this article further and the additional mass parameter of calculating correspondence further.System 1600 also comprises the diagnostic logic circuit (DLC) 1620 with the watch-dog M'1610 operation communication of upgrading.

Illustrate illustrated in Figure 16, the mass parameter calculated and/or the welding parameter monitored or their some subsets are passed to DLC 1620, and described DLC 1620 produces logical consequence based on described parameter manipulation.According to embodiment, DLC 1620 is first by analyzing mass parameter differentiates the local of weld seam or continuous print defect.Local defect be appear at welding procedure during the relatively short time period (such as, 2 seconds) in defect.Continuous print defect be appear at be essentially welding procedure the whole time (such as, 20 seconds) in defect.Some examples of defect comprise space in gas inclusions (porous (porosity), aperture blowing (blow hole), pore (worm hole)) in weld seam, the insufficient (incomplete) penetration of burning, entering workpiece of workpiece, splashing, the joint be not filled, undercut, the cracking of weld seam, weld seam and fusion (fusion) not enough.The defect of such type is well known in the art.The defect of other types also can be possible.

Some examples of the possible reason of defect comprise protective gas deficiency, ignition tip to workpiece apart from short, ignition tip to workpiece distance, the nozzle got clogged, surface of the work pollutes, gait of march is too slow, gait of march is too fast, feed rate of welding wire is too slow, feed rate of welding wire is too fast, sulfur content in workpiece or welding rod, from the excess moisture of welding rod and workpiece and too little welding rod angle.The reason of the defect of other types is also possible.

During exercise welding process, defect and DLC 1620 relevant to the reason of defect is correspondingly programmed and reason possible to defect and one or more is correctly associated.Therefore, during normal (non-exercise) welding process, DLC1620 can advise one or more possible reason of one or more defect be detected.Defect and one or more reason can be apprised of operator, correct problem to allow operator.DLC 1620 such as can organized the reason of decision tree to defect to be isolated.

As embodiment, system 1600 can detect porous (appearing at some state) as two continuous print defects during appearing at welding procedure and splashing (appearing at some other state) by analyzing mass parameter.DLC 1620 can run through welding procedure by not enough to the appearance of the continuous print defect of two in respective state and protective gas relevant.Operator may find that the valve of gas tank is pent during welding procedure subsequently.

Figure 17 is the flow chart using the system 1600 of Figure 16 to diagnose the method 1700 of Arc Welding Process, described method by be created between the welding wire of propelling and workpiece for create weld seam actual welding parameter thus when arc welder performs Arc Welding Process monitoring arc welder.Welding procedure is controlled by the command signal of the power supply of welding machine.In the step 1710 of method 1700, the waveform of a series of quick repetition is produced, and each waveform forms the weld cycle with a circulation timei.In step 1720, waveform is divided into multiple state.In step 1730, measured to inquire speed in the time period that the multiple welding parameters occurred in one or more state repeat during welding procedure.

In the step 1740 of method 1700, based on the measurement of welding parameters during welding procedure, multiple mass parameter is calculated for each state.In step 1750, at least one in multiple mass parameter and multiple welding parameter is analyzed, with one or more local by judging weld seam or one or more possible reason of continuous print defect diagnose Arc Welding Process.

In a word, arc welding system and method are disclosed.System can according to the variable during waveform condition monitoring welding procedure and correspondingly determine data that the weight of variable, the defect detecting weld seam, the possible reason of diagnosis defect, the total quality quantizing weld seam, acquisition and use represent good weld seam, the best pre-seted welding that the seed output and quality improving automatic soldering technique controls, instructs correct solder technology, differentiates the cost savings of welding procedure and obtain to be used as different welding procedure or application arranges.

Provide the above explanation to specific embodiments by way of example.In the disclosure provided, those skilled in the art will not only understand present general inventive concept and attendant advantages, but also will find the obvious variations and modifications to disclosed structure and method.Such as, present general inventive concept is not limited to one in manual welding process or automation (such as, robot) welding procedure usually, but is easily applicable to any one on the contrary.In addition, present general inventive concept is easily applicable to different welding procedures and technology (such as, all distortion of arc welding, e.g., Stick (manual welding) and TIC welding).Therefore, seek, contain all this kind of change in the spirit and scope falling into the present general inventive concept limited as appended claims and equivalents thereof and amendment.

Reference number

10 arc welder 81a subdivisions

12 power supply unit 81b stages

14 terminal 82 logics

16 terminal 84 oscillators

18 inductor 90a wave filters

20 welding wire 91 stages

22 reel 92 logics

24 feeder 94 oscillators

26 motor 100 waveforms

30 workpiece 102 peak point currents

32 current divider 104 background currents

34 piece of 110 line

152 pieces, 34a circuit

Export for 36 piece 156

36a circuit 158 modulator

40 160 pieces, generators

42 circuit 162 circuits

44 circuit 170 rising parts

46 drived control 172 sloping portions

46a circuit 180 threshold value

46b circuit 182 minimum level

46c encoder 184 transient state

70 interface 186 transient states

80c wave filter 200 routine analyzer

80d wave filter 202a circuit

81 stage 202b circuits

210 piece of 270 program

210a circuit 272 counter

212 subprogram 280 subprograms

214 282 pieces, circuits

216 circuit 282a blocks

220 284 pieces, counters

220a block 286 pieces

222 counter 286a blocks

222a block 286b block

224 circuit 900 methods

226 piece of 902 initial step

230 piece of 904 step

234 stage 906 steps

236 piece of 908 step

238 piece of 910 step

250 routine analyzer 914 steps

252 program step 916 steps

254 piece of 918 step

254a circuit 920 step

256 counter 1000 production lines

258 circuits 1002 weld score S1

260 piece of 1004 welding score S2

262 subprograms 1006 weld score S3

262a block 1010 WP2

264 program step 1012 WP3

266 subprogram 1014 welding benches

266a block 1016 watch-dog

266b subprogram 1018 appraisal platform

1020 welding order 1232 W7

1022 welding order 1234 W8

1100 method 1236 S1

1102 step 1238 S2

1104 step 1240 S3

1106 step 1242 S4

1108 step 1244 S5

1110 step 1246 S6

1112 step 1248 S7

1114 step 1250 S8

1116 step 1252 directors

1118 step 1254 PMS

1200 system 1256 networks

1202 instruct region 1258 display unit

1204 workplace 1260 data storage

1206 workplace 1300 methods

1208 workplace 1302 steps

1210 workplace 1304 steps

1212 workplace 1306 steps

1214 workplace 1308 steps

1216 workplace 1310 steps

1218 workplace 1400 data

1220 W1 1402 welding conditions

1222 W2 1404 welding wire compositions

1224 W3 1406 workpiece compositions

1226 W4 1408 gas flow rates

1228 W5 1410 gas compositions

1230 W6 1412 temperature

The 1414 1514 welding scores be expressed

1416 welding scores 1516 pre-set

1418 monetary cost 1600 systems

The watch-dog that 1420 time costs 1610 are upgraded

1500 pre-set 1620 DLC

1502 pre-set sequence number 1700 method

1504 welding condition 1710 steps

1506 welding machine information 1720 steps

1508 technique information 1730 steps

1510 monetary cost 1740 steps

1512 time costs

Claims (27)

1. diagnose the method for Arc Welding Process for one kind, described method by be created between the welding wire (20) of propelling and workpiece (30) for create weld seam actual welding parameter thus arc welder (10) perform Arc Welding Process time monitor described arc welder (10), described welding procedure is controlled by the command signal of the power supply (12) of described welding machine (10), and described method comprises:

Produce the waveform (100) of a series of quick repetition, each waveform (100) forms the weld cycle with a circulation timei;

Described waveform is divided into multiple state;

In the time period repeated during described welding procedure, to inquire in speed measurement state described in one or more multiple welding parameters occurred;

Based on during described welding procedure to the described measurement of described welding parameter, calculate multiple mass parameters of each one or more state described; And

Analyze at least one in described multiple mass parameter and described multiple welding parameter, with one or more local by judging described weld seam or one or more possible reason of continuous print defect diagnose described Arc Welding Process.

2. method according to claim 1, also comprises:

By the value of each described mass parameter that calculates for each time period compared with corresponding prospective quality parameter value, whether exceed predetermined threshold with the difference of the quality parameter value calculated described in judging and described prospective quality parameter value; And

If described difference exceedes described threshold value, then based on described difference, the weight of the quality parameter value calculated described in determining with size weight, and contribute based on the time of its state relative to the described waveform comprising described state, the weight of the quality parameter value calculated described in determining with time contribution weight.

3. method according to claim 1 and 2; wherein for state described in one or more, described multiple welding parameter comprise following in two or more: the temperature of arc current, arc voltage, feed rate of welding wire, described workpiece, the level of protective gas, the composition of protective gas, the wind speed of described near workpieces, the humidity level of described near workpieces and operator position.

4. according to the method described in claims 1 to 3, wherein for state described in one or more, described multiple welding parameter comprise following in two or more: welding torch position, the level of the sound produced by described Arc Welding Process, the frequency of at least one sound produced by described Arc Welding Process, the pulsation rate of the sound produced by described Arc Welding Process, the level of the visible ray produced by described Arc Welding Process, the frequency of at least one visible ray produced by described Arc Welding Process, the pulsation rate of the visible ray produced by described Arc Welding Process, the level of the infrared light produced by described Arc Welding Process, the frequency of at least one infrared light produced by described Arc Welding Process, the pulsation rate of the infrared light produced by described Arc Welding Process and welding wire send motor current level to.

5. according to the method described in Claims 1-4, wherein for state described in one or more within the described time period, described multiple mass parameter comprise following in two or more: quantity count mean value (QCA), quantity count standard deviation (QCSD), quality voltage mean value (QVA), quality voltage standard deviation (QVSD), quality current average (QIA), quality current standard deviation (QISD), quality voltage mean of variance (QVVA), quality voltage variance criterion difference (QVVSD), quality electric current mean of variance (QIVA) and quality electric current variance criterion difference (QIVSD).

6. according to the method described in claim 1 to 5, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality feed rate of welding wire mean value (QWA), quality feed rate of welding wire standard deviation (QWSD), quality feed rate of welding wire mean of variance (QWVA) and quality feed rate of welding wire variance criterion difference (QWVSD).

7. according to the method described in claim 1 to 6, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality acoustic level average (QSLA), quality acoustic level standard difference (QSLSD), quality acoustic level variance mean value (QSLVA) and quality acoustic level variance standard deviation (QSLVSD).

8. according to the method described in claim 1 to 7, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality acoustic average frequency value (QSFA), quality acoustic frequency standard difference (QSFSD), quality acoustic frequency variance mean value (QSFVA) and quality acoustic frequency variance standard deviation (QSFVSD).

9. according to the method described in claim 1 to 8, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality acoustic pulsation rate mean value (QSPRA), quality acoustic pulsation rate standard deviation (QSPRSD), quality acoustic pulsation rate mean of variance (QSPRVA) and quality acoustic pulsation rate variance criterion difference (QSPRVSD).

10. according to the method described in claim 1 to 9, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality visible light level mean value (QVLLA), quality visible light level standard deviation (QVLLSD), quality visible light level mean of variance (QVLLVA) and quality visible light level variance criterion difference (QVLLVSD).

11. according to the method described in claim 1 to 10, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality visible frequency mean value (QVLFA), quality visible frequency standard deviation (QVLFSD), quality visible frequency mean of variance (QVLFVA) and quality visible frequency variance criterion difference (QVLFVSD).

12. according to the method described in claim 1 to 11, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality visible ray pulsation rate mean value (QVLPRA), quality visible ray pulsation rate standard deviation (QVLPRSD), quality visible ray pulsation rate mean of variance (QVLPRVA) and quality visible ray pulsation rate variance criterion difference (QVLPRVSD).

13. according to the method described in claim 1 to 12, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality infrared light level average (QIRLLA), quality infrared light level standard difference (QIRLLSD), quality infrared light level variance mean value (QIRLLVA) and quality infrared light level variance standard deviation (QIRLLVSD).

14. according to the method described in claim 1 to 13, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality infrared light average frequency value (QIRLFA), quality infrared light frequency standard difference (QIRLFSD), quality infrared light frequency variance mean value (QIRLFVA) and quality infrared light frequency variance standard deviation (QIRLFVSD).

15. according to the method described in claim 1 to 14, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality infrared light pulsation rate mean value (QIRLPRA), quality infrared light pulsation rate standard deviation (QIRLPRSD), quality infrared light pulsation rate mean of variance (QIRLPRVA) and quality infrared light pulsation rate variance criterion difference (QIRLPRVSD).

16. according to the method described in claim 1 to 15, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality welding wire sends motor current mean value (QWFMIA) to, quality welding wire sends motor current standard deviation (QWFMISD) to, quality welding wire sends motor current mean of variance (QWFMIVA) to and quality welding wire sends motor current variance criterion difference (QWFMIVSD) to.

17. according to the method described in claim 1 to 16, one or more defect wherein said comprise following in one or more: the space in the insufficient (incomplete) penetration of burning, entering described workpiece of the gas inclusions (porous, aperture blowing, pore) in described weld seam, described workpiece, splashing, the joint be not filled, undercut, the cracking of described weld seam, described weld seam and fusion not enough.

18. according to the method described in claim 1 to 17, one or more possible reason wherein said comprise following in one or more: protective gas is not enough, ignition tip to workpiece apart from short, ignition tip to workpiece distance, the nozzle got clogged, surface of the work pollutes, gait of march is too slow, gait of march is too fast, feed rate of welding wire is too slow, sulfur content in too fast, the described workpiece of feed rate of welding wire or welding rod, from the excess moisture of described welding rod and workpiece and too little welding rod angle.

19. 1 kinds for diagnosing the system of Arc Welding Process, described system is by being created in the actual welding parameter for the formation of weld seam between the welding wire (20) of propelling and workpiece (30) thus monitoring described arc welder (10) when arc welder (10) performs Arc Welding Process, described welding procedure is limited by the waveform (100) of a series of quick repetition, the waveform (100) of described a series of quick repetition is controlled by the command signal of the power supply (12) of described welding machine (10), and described system comprises:

Logic state controller, described logic state controller is used for each described waveform (100) to be segmented into a series of time slice state;

For selecting the circuit of specific waveforms state;

Supervising device, described supervising device for monitoring in time period of repeating during described welding procedure, to inquire in speed measurement state described in one or more multiple welding parameters occurred, to obtain the data arranged for described multiple welding parameter;

For calculating the circuit for multiple mass parameters of each described state based on described monitored multiple welding parameters; And

Diagnostic logic circuit, described diagnostic logic circuit for analyzing at least one in described multiple mass parameter and described multiple welding parameter, with one or more local by judging described weld seam or one or more possible reason of continuous print defect diagnose described Arc Welding Process.

20. systems according to claim 19, also comprise:

For whether the value of each described mass parameter calculated for each time period being exceeded compared with corresponding prospective quality parameter value the circuit of predetermined threshold with the difference of the quality parameter value calculated described in judging and described prospective quality parameter value; And

If exceed described threshold value for described difference, the weight of the quality parameter value calculated described in determining with size weight based on described difference and the circuit of the weight of the quality parameter value calculated described in determining with time contribution weight relative to the time contribution of described waveform comprising described state based on its state.

21. systems according to claim 19 or 20, wherein for state described in one or more, described multiple welding parameter comprise following in two or more: the temperature of arc current, arc voltage, feed rate of welding wire, described workpiece, the level of protective gas, the composition of protective gas, the wind speed of described near workpieces, the humidity level of described near workpieces and operator position, and/or wherein for state described in one or more, described multiple welding parameter comprise following in two or more: welding torch position, the level of the sound produced by described welding procedure, the frequency of the sound produced by Arc Welding Process, the pulsation rate of the sound produced by described Arc Welding Process, the level of the visible ray produced by described Arc Welding Process, the frequency of the visible ray produced by described Arc Welding Process, the pulsation rate of the visible ray produced by described Arc Welding Process, the level of the infrared light produced by described Arc Welding Process, the frequency of the infrared light produced by described Arc Welding Process, the pulsation rate of the infrared light produced by described Arc Welding Process and welding wire send motor current level to, and/or wherein for state described in one or more within the described time period, described multiple mass parameter comprise following in two or more: quantity count mean value (QCA), quantity count standard deviation (QCSD), quality voltage mean value (QVA), quality voltage standard deviation (QVSD), quality current average (QIA), quality current standard deviation (QISD), quality voltage mean of variance (QVVA), quality voltage variance criterion difference (QVVSD), quality electric current mean of variance (QIVA) and quality electric current variance criterion difference (QIVSD), and/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality feed rate of welding wire mean value (QWA), quality feed rate of welding wire standard deviation (QWSD), quality feed rate of welding wire mean of variance (QWVA) and quality feed rate of welding wire variance criterion difference (QWVSD).

22. according to claim 19 to the system described in 21, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality acoustic level average (QSLA), quality acoustic level standard difference (QSLSD), quality acoustic level variance mean value (QSLVA) and quality acoustic level variance standard deviation (QSLVSD); And/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality acoustic average frequency value (QSFA), quality acoustic frequency standard difference (QSFSD), quality acoustic frequency variance mean value (QSFVA) and quality acoustic frequency variance standard deviation (QSFVSD); And/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality acoustic pulsation rate mean value (QSPRA), quality acoustic pulsation rate standard deviation (QSPRSD), quality acoustic pulsation rate mean of variance (QSPRVA) and quality acoustic pulsation rate variance criterion difference (QSPRVSD).

23. according to claim 19 to the system described in 22, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality visible light level mean value (QVLLA), quality visible light level standard deviation (QVLLSD), quality visible light level mean of variance (QVLLVA) and quality visible light level variance criterion difference (QVLLVSD); And/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality visible frequency mean value (QVLFA), quality visible frequency standard deviation (QVLFSD), quality visible frequency mean of variance (QVLFVA) and quality visible frequency variance criterion difference (QVLFVSD); And/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality visible ray pulsation rate mean value (QVLPRA), quality visible ray pulsation rate standard deviation (QVLPRSD), quality visible ray pulsation rate mean of variance (QVLPRVA) and quality visible ray pulsation rate variance criterion difference (QVLPRVSD).

24. according to claim 19 to the system described in 23, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality infrared light level average (QIRLLA), quality infrared light level standard difference (QIRLLSD), quality infrared light level variance mean value (QIRLLVA) and quality infrared light level variance standard deviation (QIRLLVSD); And/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality infrared light average frequency value (QIRLFA), quality infrared light frequency standard difference (QIRLFSD), quality infrared light frequency variance mean value (QIRLFVA) and quality infrared light frequency variance standard deviation (QIRLFVSD); And/or wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality infrared light pulsation rate mean value (QIRLPRA), quality infrared light pulsation rate standard deviation (QIRLPRSD), quality infrared light pulsation rate mean of variance (QIRLPRVA) and quality infrared light pulsation rate variance criterion difference (QIRLPRVSD).

25. according to claim 19 to the system described in 24, wherein for state described in one or more within the described time period, described multiple mass parameter comprises: quality welding wire sends motor current mean value (QWFMIA) to, quality welding wire sends motor current standard deviation (QWFMISD) to, quality welding wire sends motor current mean of variance (QWFMIVA) to and quality welding wire sends motor current variance criterion difference (QWFMIVSD) to.

26. according to claim 19 to the system described in 25, one or more defect wherein said comprise following in one or more: the space in the insufficient (incomplete) penetration of burning, entering described workpiece of the gas inclusions in described weld seam, described workpiece, splashing, the joint be not filled, undercut, the cracking of described weld seam, described weld seam and fusion not enough.

27. according to claim 19 to the system described in 16, one or more possible reason wherein said comprise following in one or more: protective gas is not enough, ignition tip to workpiece apart from short, ignition tip to workpiece distance, the nozzle got clogged, surface of the work pollutes, gait of march is too slow, gait of march is too fast, feed rate of welding wire is too slow, sulfur content in too fast, the described workpiece of feed rate of welding wire or welding rod, from the excess moisture of described welding rod and workpiece and too little welding rod angle.