Wave-soldering intelligent control method and control system for wave-soldering furnace
Technical Field
The invention relates to the field of wave soldering of circuit boards, in particular to an intelligent control method and system for wave soldering of a wave furnace.
Background
In the electronic industry, the performance of products is concerned by each research and development, but as the production and manufacturing industry, the efficiency and the quality are the center for creating value in the production and manufacturing, along with the development of science and technology, the electronics are more and more precise at present, the manufacturing requirement is more and more high, the automation is the human core of the current industry 4.0, various requirements are realized through automatic welding, the wave-soldering of a wave-crest furnace is basically adopted in the current automatic welding, the wave-crest welding achieves the welding purpose by directly contacting the welding surface of a plug-in board with high-temperature liquid tin, the high-temperature liquid tin keeps an inclined surface, and the liquid tin forms a phenomenon similar to waves by a special device, the main material is a soldering tin bar, the automation degree is high, the labor investment is low, and the production efficiency is high in the welding process.
However, the market demand is mainly in the form of small work orders and multiple models, i.e. the specifications of the circuit boards are diversified, and the current production method in the manufacturing enterprise is as follows: one wave crest furnace corresponds to a circuit board with one specification, namely, to finish the production of multiple machine types, multiple wave crest furnaces need to be configured, so that the trouble that the wave crest furnaces are not enough is caused, and on the other hand, the labor or working hour investment is too high; for example, patent No. CN201320839463.8 discloses a wave soldering production line capable of automatically adjusting the coating stroke of soldering flux according to the width of a PCB, which includes a PCB conveying trough at the front end of the wave soldering production line, a wave soldering tin immersion furnace, a wave soldering spraying device, and a control mechanism, wherein a connection table is additionally arranged between the PCB conveying trough and the wave soldering tin immersion furnace, one end of a PCB conveying guide rail mounted on the connection table is provided with a set of PCB width detection side device, the size of the PCB substrate is collected by a metal sensor of the PCB width detection device, the control mechanism of the wave soldering tin immersion furnace scans PCB width data obtained by a driving circuit according to the width of the metal sensor, the wave soldering spraying device is controlled by a spraying stroke driving circuit to drive a soldering flux nozzle to move according to the width size of the actually measured PCB substrate, the soldering flux spraying is performed on the PCB, and then the tin immersion of the PCB substrate is completed at the rear end of the wave soldering tin immersion furnace, In the wave soldering process, although the soldering change in the width direction is achieved to some extent, a plurality of different wave furnaces and a large amount of labor or man-hours are required for circuit boards having different length and size.
Therefore, a brand new wave crest furnace is urgently needed, the jet flow height can be automatically adjusted according to different products, the simultaneous production of different products is met, a plurality of wave crest furnaces are not needed, and excessive manpower and labor hour are not needed.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide an intelligent wave soldering control method and system for a wave crest furnace, which can automatically adjust the height of jet flow according to different products so as to meet the production requirements of different products, does not need a plurality of wave crest furnaces and does not need to invest excessive manpower and working hours.
The technical purpose of the invention is realized by the following technical scheme: an intelligent control method for wave soldering of a wave crest furnace is characterized by comprising the following steps:
step 1, presetting wave-soldering parameters; the wave-soldering parameters comprise jig codes, jet flow height parameters, motor frequency parameters, jig length parameters and preheating distance parameters;
step 2, scanning the scanning codes on all the jigs, and inputting the decoded jig codes into a controller for queuing;
step 3, the jig inductor scans the length of the jig at the initial conveying position, and the controller judges the preheating distance according to the length of the jig;
and 4, judging whether the jig reaches the jet flow position after the preheating distance is finished by the controller, when the jig reaches the jet flow position, extracting corresponding jet flow height parameters by the controller according to the current jig code and sending the jet flow height parameters to the frequency converter, and changing the rotating speed of the motor by the frequency converter through frequency conversion so as to change the jet flow height.
Preferably, in step 1, the jig code, the jet height parameter, and the motor frequency parameter form a first storage table and are stored in a first storage area of the controller.
Preferably, the wave-soldering parameters in step 1 further include a first pulse quantity parameter, and the method for determining the length of the jig in step 3 is as follows: the controller judges the length of the jig according to the first pulse quantity sensed by the jig sensor.
Preferably, the wave-soldering parameters in step 1 further include a second pulse quantity parameter, and the method for determining whether the jig reaches the jet flow position by the controller in step 4 includes: the controller judges whether the moving distance of the jig is equal to the preheating distance according to the second pulse quantity sensed by the chain speed sensor.
Preferably, the first pulse amount, the jig length parameter, the preheating distance parameter, and the second pulse amount constitute a second storage table and are stored in the second storage area.
An intelligent wave soldering control system of a wave crest furnace comprises the wave crest furnace, and is characterized by further comprising a controller, a code scanning device, a jig sensor and a frequency converter;
the code scanning device is connected with the controller and used for scanning the jig codes and inputting the jig codes into the controller;
the jig sensor is connected with the controller, the jig sensor scans the length of the jig at the conveying initial position, and the controller judges the preheating distance according to the length of the jig;
the frequency converter is connected with the controller, and the controller judges whether the jig reaches the jet flow position after the preheating distance is finished so as to control the jet flow height by controlling the frequency converter.
Preferably, the device further comprises a chain speed sensor, wherein the chain speed sensor is connected with the controller and used for detecting whether the jig is conveyed to the jet flow position or not.
Preferably, a touch screen is also included.
Preferably, the controller includes a storage unit, a register unit, and a control unit;
the storage unit is used for storing a jig code, a jet flow height parameter, a motor frequency parameter, a first pulse quantity parameter, a jig length parameter, a preheating distance parameter and a second pulse quantity parameter;
the registering unit is used for storing jig codes obtained by scanning corresponding scanning codes on the jig by the code scanning device and queuing all the jig codes;
the control unit is used for receiving the signal sent by the jig sensor and judging the preheating distance, receiving the signal sent by the chain speed sensor and judging whether the jig runs the preheating distance to reach the jet flow position or not, and is used for calling the motor frequency parameter in the storage unit according to the jig code in the register unit and sending the parameter to the motor.
Preferably, the controller further comprises a temporary storage unit; the temporary storage unit inquires the motor frequency parameter in the storage unit according to the jig code in the register unit and calls and stores the motor frequency parameter when the jig code is input into the register unit.
Preferably, the scan code includes a two-dimensional code and a barcode.
In conclusion, the invention has the following beneficial effects:
the jet flow height can be automatically adjusted according to different products, so that the production of different products is met, a plurality of wave crest furnaces are not needed, and excessive manpower and working hours are not needed.
Drawings
Fig. 1 is a schematic structural diagram of a wave-soldering control system of a wave-soldering furnace in embodiment 1 of the invention;
fig. 2 is a flowchart of an intelligent wave soldering control method for a wave furnace in embodiment 5 of the present invention.
Detailed Description
The following are specific embodiments of the present invention and are further described with reference to the drawings, but the present invention is not limited to these embodiments.
Example 1: aiming at the condition that the existing wave crest furnace can only be correspondingly welded with a circuit board with one specification, the embodiment discloses the following technical scheme, the jet flow height can be automatically adjusted according to different products so as to meet the production requirements of different products, a plurality of wave crest furnaces are not needed, and excessive manpower and working hours are not needed.
As shown in fig. 1, an intelligent control system for wave soldering of a wave furnace comprises the wave furnace, a controller, a code scanning device, a fixture sensor and a frequency converter; the wave crest furnace comprises a conveying device, a plurality of jigs are arranged on the conveying device, the conveying device can be a conveying belt or a conveying chain, and in the example, the conveying device adopts the conveying chain;
the code scanning device is connected with the controller and used for scanning the jig codes and inputting the jig codes into the controller; when the device is installed, the code scanning device is connected with the input end of the controller.
The jig sensor is connected with the controller, the jig sensor scans the length of the jig at the conveying initial position, and the controller judges the preheating distance according to the length of the jig; when the fixture is installed, the fixture sensor is connected with the input end of the controller.
The frequency converter is connected with the controller, and the controller judges whether the jig reaches the jet flow position after the preheating distance is finished so as to control the jet flow height by controlling the frequency converter. When the device is installed, the frequency converter is connected with the output end of the controller, the other end of the frequency converter is connected with the motor, the rotating speed of the motor is controlled, then the jet flow height is controlled, and the jig sensor is preferably installed at the entrance of the conveying chain entering the furnace body.
During operation, the worker scans scanning codes on all jigs by the code scanning device, the code scanning device obtains jig codes, the jig codes are input into the controller to be queued, after the jigs are scanned by the jig sensor at the conveying initial position, the controller obtains corresponding jig length and judges the preheating distance, when the jigs are conveyed forwards to pass through the preheating distance to reach the jet flow position, the controller calls preset corresponding motor frequency parameters according to the jig codes and sends the corresponding motor frequency parameters to the frequency converter, the frequency converter changes the frequency of the motor to change the rotating speed of the motor, the jet flow height is changed, and welding is completed.
The controller includes a storage unit, a register unit, and a control unit.
The storage unit is used for storing a jig code, a jet flow height parameter, a motor frequency parameter, a first pulse quantity parameter, a jig length parameter, a preheating distance parameter and a second pulse quantity parameter.
The registering unit is used for storing jig codes obtained by scanning corresponding scanning codes on the jig by the code scanning device and queuing all the jig codes.
The control unit is used for receiving the signal sent by the jig sensor and judging the preheating distance, receiving the signal sent by the chain speed sensor and judging whether the jig runs the preheating distance to reach the jet flow position or not, and is used for calling the motor frequency parameter in the storage unit according to the jig code in the register unit and sending the parameter to the motor.
The storage unit comprises a first storage area and a second storage area.
Preferably, the jig code, the jet height parameter and the motor frequency parameter form a first storage table and are stored in a first storage area of the controller, and the first storage table refers to table one:
table one: first memory table
D (tool code)
|
H (jet height)
|
f (frequency of motor)
|
D1
|
0.1m
|
500HZ
|
D2
|
0.12m
|
600HZ
|
D3
|
0.14m
|
700HZ
|
D4
|
0.16m
|
800HZ
|
D5
|
0.18m
|
900HZ
|
D6
|
0.2m
|
100HZ
|
D7
|
0.22m
|
1100HZ
|
D8
|
0.24
|
1200HZ
|
D9
|
0.26
|
1300HZ
|
D10
|
0.28
|
1400HZ |
And the first pulse quantity, the jig length parameter, the preheating distance parameter and the second pulse quantity form a second storage table and are stored in a second storage area, and the reference is made to a table II.
Table two: second memory table
N1 (first pulse quantity)
|
L1 (jig length)
|
L (preheating distance)
|
N2 (second pulse quantity)
|
30
|
0.3m
|
0.6m
|
60
|
35
|
0.35m
|
0.7m
|
70
|
40
|
0.4m
|
0.8m
|
80
|
45
|
0.45m
|
0.9m
|
90
|
50
|
0.5m
|
1.0m
|
100
|
55
|
0.55m
|
1.1m
|
110
|
60
|
0.6m
|
1.2m
|
120
|
65
|
0.65m
|
1.3m
|
130
|
70
|
0.7m
|
1.4
|
140
|
75
|
0.75m
|
1.5
|
150 |
In this embodiment, the device further comprises a chain speed sensor for detecting whether the jig is conveyed to the jet flow position, and the chain speed sensor is preferably installed at the chain outlet of the furnace body.
In this embodiment, according to the first pulse amount detected by the jig sensor, the controller can determine the corresponding length of the jig, the preheating distance of the jig, and the second pulse amount required by the jig to finish the preheating distance, when the numerical value of the second pulse amount sensed by the chain speed sensor is equal to the value set in the database, that is, the jig reaches the jet flow position, the controller extracts the corresponding jet flow height parameter according to the current jig code and sends the jet flow height parameter to the frequency converter, and the frequency converter changes the rotation speed of the motor through frequency conversion, thereby changing the jet flow height.
In order to conveniently inquire the wave soldering state and facilitate the page switching control, the device also comprises a touch screen.
The touch-sensitive screen is connected with the controller, can be provided with on the touch-sensitive screen and sweep a yard on & off switch, and the workman clicks and sweeps a yard on & off switch, and bar code scanner and controller switch-on, the information branch of academic or vocational study that bar code scanner swept out convey the controller in, click again and sweep a yard on & off switch, bar code scanner and controller do not communicate, can effectively prevent the maloperation like this, bring unnecessary troublesome.
The scanning code can be a two-dimensional code and can be a bar code.
Preferably, in this example, the controller may be a single chip microcomputer, and may be a PLC controller.
Preferably, in this example, the fixture sensor may be a photoelectric sensor or an optical fiber sensor.
Preferably, in this example, the chain speed sensor can be a photoelectric sensor or a fiber optic sensor.
Preferably, in this example, the code scanning device may be a scanning gun.
Example 2: different from the embodiment 1, the controller further comprises a temporary storage unit; the temporary storage unit inquires the motor frequency parameter in the storage unit according to the jig code in the register unit and calls and stores the motor frequency parameter when the jig code is input into the register unit. The setting ensures that the control unit does not directly search and call data in the storage unit, but directly calls the data in the temporary storage unit, and the control efficiency is better.
Example 3: different from the embodiment 2, the device further comprises a speed measurement photoelectric switch for detecting the chain speed. The speed measuring photoelectric switch is connected with the controller and used for detecting the chain speed of the conveying chain, changing the preheating time and improving the wave-soldering efficiency. Because different jigs length size is different, and the same preheating distance is to different jigs, and the effect of preheating is different, consequently, the chain speed value is indefinite, and is decided according to jig length.
Example 4: an intelligent control method for wave soldering of a wave crest furnace comprises the following steps:
step 1, presetting wave-soldering parameters; the wave-soldering parameters comprise jig codes, jet flow height parameters, motor frequency parameters, jig length parameters and preheating distance parameters;
the jig code, the jet flow height parameter and the motor frequency parameter are set correspondingly, that is, when the jig code is searched by the program, the corresponding jet flow height parameter and the corresponding motor frequency parameter can be obtained; the jig length parameter and the preheating distance parameter are set correspondingly, that is, when the jig length parameter is searched by the program, the corresponding preheating distance parameter can be obtained.
Step 2, scanning the scanning codes on all the jigs, and inputting the decoded jig codes into a controller for queuing;
after the fixture codes are sequentially arranged, the program is sequentially executed from beginning to end, and the program jumps to the next fixture code after the program is executed once.
Step 3, the jig inductor scans the length of the jig at the initial conveying position, and the controller judges the preheating distance according to the length of the jig;
and 4, judging whether the jig reaches the jet flow position after the preheating distance is finished by the controller, when the jig reaches the jet flow position, extracting corresponding jet flow height parameters by the controller according to the current jig code and sending the jet flow height parameters to the frequency converter, and changing the rotating speed of the motor by the frequency converter through frequency conversion so as to change the jet flow height.
Preferably, the jig code, the jet height parameter and the motor frequency parameter constitute a first storage table and are stored in a first storage area of the controller. The jig code, the jet flow height parameter and the motor frequency are stored in the first storage area, and program searching and extracting are facilitated.
Preferably, the wave-soldering parameters in step 1 further include a first pulse quantity parameter, and the method for determining the length of the jig in step 3 is as follows: the controller judges the length of the jig according to the first pulse quantity sensed by the jig sensor.
Preferably, the wave-soldering parameters in step 1 further include a second pulse quantity parameter, and the method for determining whether the jig reaches the jet flow position by the controller in step 4 includes: the controller judges whether the moving distance of the jig is equal to the preheating distance according to the second pulse quantity sensed by the chain speed sensor.
Preferably, the first pulse amount, the jig length parameter, the preheating distance parameter, and the second pulse amount constitute a second storage table and are stored in the second storage area.
The four are stored in the second storage area, pairwise mutual correspondence between the four is realized, namely, according to the fact that the jig sensor detects the first pulse quantity, the corresponding jig length, the preheating distance of the jig and the second pulse quantity required by the jig for walking away the preheating distance can be determined, when the numerical value of the second pulse quantity sensed by the chain speed sensor is equal to the value set in the database, namely the jig reaches the jet flow position, the controller extracts the corresponding jet flow height parameter according to the current jig code and sends the jet flow height parameter to the frequency converter, and the frequency converter enables the rotating speed of the motor to be changed through frequency conversion, so that the jet flow height is changed.
Embodiment 5 is different from embodiment 4 in that a step 5 is further provided between step 2 and step 3, and when the decoded jig code is input into the controller, the step 5 extracts and temporarily stores the jet flow height parameter corresponding to the jig code in the controller. The jig is conveyed to a jet flow position after passing through the preheating section, and the controller directly extracts the jet flow height from the temporarily stored data according to the current jig code.
As shown in fig. 2, in embodiment 5, an intelligent control method for wave soldering of a wave furnace specifically includes the following steps
1: pre-storing wave-soldering parameters;
2: acquiring a jig code through a code scanning device;
3: the controller obtains the jig codes and queues the jig codes, and meanwhile, corresponding wave soldering parameters are extracted and temporarily stored according to the jig codes when the controller obtains the codes;
4: the controller judges the preheating distance according to the jig code;
5: after the jig is preheated, the jig reaches a jet flow position, and the controller calls the temporarily stored wave soldering parameters and sends the parameters to the frequency converter;
6. the frequency converter receives the instruction of the controller, changes the rotation frequency of the motor, and accordingly changes the height of the jet flow.
The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.