CN105388873A - Universal wireless spot welding machine distributed control system - Google Patents
Universal wireless spot welding machine distributed control system Download PDFInfo
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- CN105388873A CN105388873A CN201510918279.6A CN201510918279A CN105388873A CN 105388873 A CN105388873 A CN 105388873A CN 201510918279 A CN201510918279 A CN 201510918279A CN 105388873 A CN105388873 A CN 105388873A
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- 238000003466 welding Methods 0.000 title abstract description 28
- 230000005540 biological transmission Effects 0.000 claims abstract description 11
- 238000004891 communication Methods 0.000 claims description 26
- 239000004973 liquid crystal related substance Substances 0.000 claims description 5
- 230000035515 penetration Effects 0.000 claims description 5
- 238000009434 installation Methods 0.000 abstract description 6
- 238000012423 maintenance Methods 0.000 abstract description 6
- 230000008901 benefit Effects 0.000 abstract description 3
- 238000007726 management method Methods 0.000 description 13
- 238000005516 engineering process Methods 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 3
- 230000006855 networking Effects 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000001360 synchronised effect Effects 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 230000002457 bidirectional effect Effects 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 230000005520 electrodynamics Effects 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000013024 troubleshooting Methods 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the network communication
- G05B19/41855—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the network communication by local area network [LAN], network structure
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Arc Welding Control (AREA)
- Numerical Control (AREA)
- General Factory Administration (AREA)
Abstract
The invention provides a universal wireless spot welding machine distributed control system. The universal wireless spot welding machine distributed control system includes spot welding machines, wireless base stations, an Ethernet switch, a PC server and a workshop-level management system; the spot welding machines are provided with wireless controllers; the wireless controllers are connected with the spot welding machines through a CAN bus; data unvarnished transmission can be realized between the wireless controllers and the wireless base stations through a wireless network; the wireless base stations are connected with the Ethernet switch, and are connected with the PC server through an industrial Ethernet; the PC server is connected with the Ethernet switch; and data sharing can be realized between the PC server and the workshop-level management system through the industrial Ethernet. The universal wireless spot welding machine distributed control system of the invention has the advantages of convenient installation and maintenance, greatly-decreased cost, flexible working modes and complete functions, and can improve welding quality.
Description
Technical field
The invention belongs to spot welder distribute control field, especially relate to a kind of wireless universal spot welder Distributed Control System (DCS).
Background technology
At industrial automation, traditional control system experienced by the development course of field mounted pneumatic instrument control system, electrodynamic element combined type control system, Centralized Control System, collecting and distributing control system.Generally the field bus system of present widespread use become the 5th generation control system.Fieldbus has several some advantage lower: save hardware investment, saving erected cost, save maintenance costs, the accuracy improving system and reliability.But traditional fieldbus adopts wired mode, encounter the problem being much difficult to overcome in application at the scene: at some large-scale workshops that is welded, crane span structure and cable especially construction cost are more and more higher; Spot welder needs when needing to redefine riding position to reinstall crane span structure and cable, and the riding position underaction of equipment limits fieldbus in the application of occasion of being inconvenient to connect up; Due to severe site environment or human factor, whole system all can be made normally to work for the open circuit of any one bus line or short circuit and complexity is searched in trouble spot, adds the difficulty of system maintenance; Have 40 multiple fieldbus in the world at present, incompatible to each other, typical fieldbus has CAN, RS485, Profibus, HART, LonWorks etc.What spot welder control system originally adopted is CAN.
Along with ZigBee, bluetooth, the wide model application of the wireless communication techniques such as WiFi, Distributed Control System is also progressively adopting wireless communication technique to replace wire communication technology, wireless technology take electromagnetic wave as transmission medium, avoid wired system installation and maintenance cost high, change upgrading inconvenient, plug connector failure rate is high, device location is limited, the problems such as troubleshooting difficulty, spot welder forms WLAN by common wireless technology, the control integration to the spot welder course of work can be realized, improve production distribution and significant increase spot welder task performance, contrasted by monitoring and measured data, analyze, effective trouble saving occurs, ensure quality of welding spot.
Summary of the invention
In view of this, the present invention is intended to propose a kind of wireless universal spot welder Distributed Control System (DCS), with overcome the installation and maintenance that wired mode exists with high costs, change that upgrading is inconvenient, cable and connector failure rate is high, device location limited etc. defect and deficiency.
For achieving the above object, technical scheme of the present invention is achieved in that
A kind of wireless universal spot welder Distributed Control System (DCS), comprises spot welder, wireless base station, Ethernet switch, PC server, Shop Floor Management System; Described spot welder is provided with wireless controller; Described spot welder is connected by CAN with described wireless controller; Described wireless controller realizes data penetration transmission by wireless network and described wireless base station; Described wireless base station is connected with described Ethernet switch, is connected with described PC server by Industrial Ethernet; Described PC server is connected with described Ethernet switch, realizes data sharing by Industrial Ethernet and described Shop Floor Management System.
Further, the built-in control panel circuit of described spot welder, this control panel circuit comprises single-chip microcomputer, synchronization control module, high-current detector, power switch, power module, input control circuit, output control circuit, RS485 communication control circuit, CAN control circuit; Described single-chip microcomputer is connected with described synchronization control module, high-current detector, power switch, power module, input control circuit, output control circuit, RS485 communication control circuit, CAN control circuit.
Further, described wireless controller comprise single-chip microcomputer, power module, wireless communication module, CAN interface, instruction module is set; Described single-chip microcomputer and described power module, wireless communication module, CAN interface, indicate model calling is set.
Further, described wireless controller realizes data penetration transmission by wireless communication module and described wireless base station.
Further, described PC server comprises PC main frame, liquid crystal display, laser printer, UPS uninterrupted power source; Described PC is connected with described liquid crystal display, laser printer, UPS uninterrupted power source; Described PC main frame built-in ethernet card.
Further, described PC server via Ethernet card and described wireless base station realize two-way communication.
Further, described PC server via Ethernet card and described Shop Floor Management System realize data sharing.
Relative to prior art, a kind of wireless universal spot welder Distributed Control System (DCS) of the present invention has following advantage:
(1) convenient for installation and maintenance, the cost of the present invention significantly reduces: wireless network utilizes wireless transmission to replace traditional cable transmission, do not need communication crane span structure, communication cable and various connector are installed separately, thus save hardware investment, greatly reduce the cost of labor of hardware installation simultaneously, owing to there is not the bus failure such as electric discontinuity of cable or short circuit, not having the problems such as connector infringement, system reliability is high, failure rate is low;
(2) flexible working mode of the present invention: without the constraint of communication crane span structure, cable, spot welder freedom of movement, wireless network can temporarily randomness lay, self-organization of network, do not need human intervention, be applicable to very much that some are anxious, danger, inclined application scenario, when needs increase field control spot welder, without the need to setting up new crane span structure and cable, only need increase a wireless controller, both save investment, the workload of decrease design, installing; Spot welder both can work in networking mode, also can work in unit (off line) mode.When system jam or when shutting down, spot welder can enter off-line working state automatically.
(3) complete function: achieve the functions such as quality of welding spot detection, welder fault monitoring, welding condition management, the control of welding transformer three-phase grid balance, management of information database in set of system, greatly alleviate managerial personnel's workload, improve production distribution and scheduling, improve plant factor and production efficiency;
(4) welding quality is improved: by recording the data in welding process, contrast, help to analyze welding quality situation, review culprit, the generation of quality accident can be stopped to the full extent, significant increase spot welder task performance, for client's examination and excitation provide precision data.
Accompanying drawing explanation
The accompanying drawing forming a part of the present invention is used to provide a further understanding of the present invention, and schematic description and description of the present invention, for explaining the present invention, does not form inappropriate limitation of the present invention.In the accompanying drawings:
Fig. 1 is the structural representation of a kind of wireless universal spot welder Distributed Control System (DCS) described in the embodiment of the present invention;
Fig. 2 is the spot welder master control borad structural representation described in the embodiment of the present invention;
Fig. 3 is the wireless controller structure schematic diagram described in the embodiment of the present invention;
Fig. 4 is the PC server architecture schematic diagram described in the embodiment of the present invention.
Embodiment
It should be noted that, when not conflicting, the embodiment in the present invention and the feature in embodiment can combine mutually.
In describing the invention, it will be appreciated that, term " " center ", " longitudinal direction ", " transverse direction ", " on ", D score, " front ", " afterwards ", " left side ", " right side ", " vertically ", " level ", " top ", " end ", " interior ", orientation or the position relationship of the instruction such as " outward " are based on orientation shown in the drawings or position relationship, only the present invention for convenience of description and simplified characterization, instead of indicate or imply that the device of indication or element must have specific orientation, with specific azimuth configuration and operation, therefore limitation of the present invention can not be interpreted as.In addition, term " first ", " second " etc. only for describing object, and can not be interpreted as instruction or hint relative importance or imply the quantity indicating indicated technical characteristic.Thus, one or more these features can be expressed or impliedly be comprised to the feature being limited with " first ", " second " etc.In describing the invention, except as otherwise noted, the implication of " multiple " is two or more.
In describing the invention, it should be noted that, unless otherwise clearly defined and limited, term " installation ", " being connected ", " connection " should be interpreted broadly, and such as, can be fixedly connected with, also can be removably connect, or connect integratedly; Can be mechanical connection, also can be electrical connection; Can be directly be connected, also indirectly can be connected by intermediary, can be the connection of two element internals.For the ordinary skill in the art, above-mentioned term concrete meaning in the present invention can be understood by concrete condition.
Below with reference to the accompanying drawings and describe the present invention in detail in conjunction with the embodiments.
As shown in Figure 1, the present invention includes multiple stage spot welder, wireless controller, wireless base station, Ethernet switch, PC server and Shop Floor Management System; Far and near according to spot welder relative position in shop production line process layout, spot welder is divided into several wireless control network, and each wireless network controls at most 64 spot welders; The CAN data-interface that spot welder passes through in the integrated CAN control circuit of internal main control panel is connected with the CAN data-interface on wireless controller; Wireless controller realizes data penetration transmission by wireless network and wireless base station; The distance of wireless controller and wireless base station is no more than 100 meters; Wireless base station is connected to PC server by Industrial Ethernet; PC server realizes data sharing by Industrial Ethernet and workshop management system.
As shown in Figure 2, spot welder master control borad mainly comprises single-chip microcomputer, synchronization control module, high-current detector, power switch, power module, input control module, output module, RS485 communication control circuit, CAN control circuit.Single Chip Microcomputer (SCM) system adopts PHILIPS51 series monolithic, comprises data-carrier store, program storage, power filtering capacitor, electrify restoration circuit, CAN interface, RS485 bus interface; Synchronization control module provides the synchronizing signal with synchronized; High-current detector realizes closed-loop control by detecting welding current in real time; Power switch provides the power supply needed for full machine; Input control circuit is used for control and comprises the input signals such as startup, reset, monotroded point, clamping; Output control circuit is used for control and comprises the output signal such as fault, welding end of a period, clamping, air valve output; RS485 communication control circuit is used for carrying out serial communication with welding parameter instrument, can realize arranging separate unit spot welder welding condition; CAN communication control circuit and wireless controller carry out CAN data communication, realize the management of spot welder distribute control.
As shown in Figure 3, wireless controller mainly comprise single-chip microcomputer, power module, wireless communication module, CAN interface, instruction module is set.Wireless controller, as a part for spot welder, is directly installed on spot welder, is connected with the CAN data-interface on spot welder master control borad by CAN interface; Spot welder CAN protocol data and wireless network protocol data are carried out bumpless transfer by wireless controller built-in protocol conversion module automatically; Wireless controller has super low-power consumption and high reliability, adopt time synchronized and multichannel frequency hopping, support that multi-hop is opened up and mend structure and full redundancy path transmission, self-organization of network selfreparing and bidirectional data transfers, realized and wireless base station communication by wireless data Signal Transparent Transmission Technology.
As shown in Figure 4, PC server hardware is primarily of compositions such as PC main frame, liquid crystal display, laser printer, UPS uninterrupted power sources.PC server realizes two-way communication by the inner integrated Ethernet card of PC main frame and wireless base station; PC server realizes data sharing by the inner integrated Ethernet card of PC main frame and Shop Floor Management System; PC server software system is primarily of compositions such as Windows operating system, SQLServer database, VisualStudio development environment, Office office software, spot welder Distributed Control System (DCS) softwares; PC server is used for operating point welding machine Distributed Control System (DCS) software, and spot welder Distributed Control System (DCS) software can realize the functions such as welding machine management of information database, user account rights management, workshop system information sharing such as spot welder working state monitoring, spot welding point Welding quality test, the management of spot welder technological parameter, spot welder equipment information management, welding transformer three-phase equilibrium control, welding parameter/solder failure/welding technology.
The course of work of the present invention is as follows: spot welder is at each automatic networking, automatic off-grid, welding application, wireless controller is sent to after related data being packed when having welded and broken down, wireless controller is sent to wireless receiving base station by wireless network, after wireless base station receives the packet of radio node, PC server is sent to by Industrial Ethernet, the timing of PC server control integration system is read data from Ethernet interface and is carried out display after data being carried out to corresponding process of unpacking and is also automatically saved to system database, monitor at any time with standby user, analyze quality of welding spot, the process that PC server performs user's specified command is just in time contrary, the control command sent by PC server enters wireless receiving base station through Ethernet, wireless base station is sent to corresponding wireless controller according to the address maps of self, then sends into spot welder internal control plate by wireless controller.Spot welder both can work and networking mode, also can work in unit (off line) mode, and when system jam or when shutting down, spot welder can enter off-line working state automatically.
The foregoing is only preferred embodiment of the present invention, not in order to limit the present invention, within the spirit and principles in the present invention all, any amendment done, equivalent replacement, improvement etc., all should be included within protection scope of the present invention.
Claims (7)
1. a wireless universal spot welder Distributed Control System (DCS), is characterized in that: comprise spot welder, wireless base station, Ethernet switch, PC server, Shop Floor Management System; Described spot welder is provided with wireless controller; Described spot welder is connected by CAN with described wireless controller; Described wireless controller realizes data penetration transmission by wireless network and described wireless base station; Described wireless base station is connected with described Ethernet switch, is connected with described PC server by Industrial Ethernet; Described PC server is connected with described Ethernet switch, realizes data sharing by Industrial Ethernet and described Shop Floor Management System.
2. a kind of wireless universal spot welder Distributed Control System (DCS) according to claim 1, it is characterized in that: the built-in control panel circuit of described spot welder, this control panel circuit comprises single-chip microcomputer, synchronization control module, high-current detector, power switch, power module, input control circuit, output control circuit, RS485 communication control circuit, CAN control circuit; Described single-chip microcomputer is connected with described synchronization control module, high-current detector, power switch, power module, input control circuit, output control circuit, RS485 communication control circuit, CAN control circuit.
3. a kind of wireless universal spot welder Distributed Control System (DCS) according to claim 1, is characterized in that: described wireless controller comprise single-chip microcomputer, power module, wireless communication module, CAN interface, instruction module is set; Described single-chip microcomputer and described power module, wireless communication module, CAN interface, indicate model calling is set.
4. a kind of wireless universal spot welder Distributed Control System (DCS) according to claim 3, is characterized in that: described wireless controller realizes data penetration transmission by wireless communication module and described wireless base station.
5. a kind of wireless universal spot welder Distributed Control System (DCS) according to claim 1, is characterized in that: described PC server comprises PC main frame, liquid crystal display, laser printer, UPS uninterrupted power source; Described PC main frame is connected with described liquid crystal display, laser printer, UPS uninterrupted power source; Described PC main frame built-in ethernet card.
6. a kind of wireless universal spot welder Distributed Control System (DCS) according to claim 5, is characterized in that: described PC server via Ethernet card and described wireless base station realize two-way communication.
7. a kind of wireless universal spot welder Distributed Control System (DCS) according to claim 5, is characterized in that: described PC server via Ethernet card and described Shop Floor Management System realize data sharing.
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Cited By (3)
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CN106181007A (en) * | 2016-08-26 | 2016-12-07 | 天津七所高科技有限公司 | A kind of spot-welded standard parameter automatic switchover system |
CN106843129A (en) * | 2017-03-15 | 2017-06-13 | 重庆长安汽车股份有限公司 | Automotive welding production line spot welding data-management application method |
CN107813070A (en) * | 2016-09-12 | 2018-03-20 | 中国科学院沈阳自动化研究所 | A kind of welding quality on-line monitoring and the wireless detection device and method of processing time matrix |
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CN104749977A (en) * | 2015-02-11 | 2015-07-01 | 上海广为焊接设备有限公司 | Control circuit of integrated electric welding machine based on wireless transmission |
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CN101303593A (en) * | 2008-06-26 | 2008-11-12 | 天津七所高科技有限公司 | Intelligent spot welding machine centralized control networking management system |
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CN107813070A (en) * | 2016-09-12 | 2018-03-20 | 中国科学院沈阳自动化研究所 | A kind of welding quality on-line monitoring and the wireless detection device and method of processing time matrix |
CN107813070B (en) * | 2016-09-12 | 2020-07-31 | 中国科学院沈阳自动化研究所 | Wireless detection device and method for online monitoring and working hour statistics of welding quality |
CN106843129A (en) * | 2017-03-15 | 2017-06-13 | 重庆长安汽车股份有限公司 | Automotive welding production line spot welding data-management application method |
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