CN107644579B - Magnetic induction type manual electric arc welding simulation training instrument - Google Patents

Magnetic induction type manual electric arc welding simulation training instrument Download PDF

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Publication number
CN107644579B
CN107644579B CN201711032603.XA CN201711032603A CN107644579B CN 107644579 B CN107644579 B CN 107644579B CN 201711032603 A CN201711032603 A CN 201711032603A CN 107644579 B CN107644579 B CN 107644579B
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China
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magnetic
welding
simulation
led lamp
mounting box
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Expired - Fee Related
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CN201711032603.XA
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Chinese (zh)
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CN107644579A (en
Inventor
刘鹰
梁刚
刘春群
韦泉
黄运涛
周柱龙
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Guangxi Agricultural Vocational College
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Guangxi Agricultural Vocational College
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Abstract

The invention discloses a magnetic induction type manual electric arc welding simulation training instrument which comprises a simulation welding workpiece group, a simulation welding rod group and a simulation electric welding machine, wherein an ultrasonic ranging sensor arranged at one end of a magnetic stripe mounting box is connected with a power socket through a power line arranged at the bottom of the magnetic stripe mounting box; the pneumatic triplet, the two-position three-way manual reversing valve, the two-position five-way electromagnetic reversing valve and the single-rod double-acting air cylinder are sequentially connected, a one-way throttle valve is further connected between the two-position five-way electromagnetic reversing valve and the single-rod double-acting air cylinder, and the power switch is connected with the conversion power supply. The power socket is connected with a conversion power supply, and the magnetic inductor A, the magnetic inductor B, the magnetic inductor C, the buzzer and the LED lamp beads are connected with the conversion power supply in a series connection mode; the input end of the programmable controller is connected with the ultrasonic ranging sensor, and the output end of the programmable controller is connected with the LED lamp beads. The training instrument is simple in design structure, and can help beginners to quickly master the training of strip conveying and feeding actions at different welding positions.

Description

Magnetic induction type manual electric arc welding simulation training instrument
Technical Field
The invention relates to a magnetic induction type manual electric arc welding simulation training instrument.
Background
Manual arc welding is a welding method in which a metal and a base material are melted to form a weld by using arc heat between a welding rod and a workpiece. According to the difference of the relative position of the workpiece, the welding position can be divided into four welding positions, namely horizontal welding, vertical welding, horizontal welding and overhead welding. Chinese patent ZL201420792688.7 discloses an auxiliary training device for manual arc welding, which basically only considers the training of the flat welding mode. The Chinese patent ZL200910023097.7 discloses a simulation training device for manual arc welding strip conveying operation and an arc welding strip conveying detection method, and the simulation training device is mainly used for training a beginner to horizontally weld a strip conveying method and does not consider more strip conveying training of various welding positions including vertical welding, horizontal welding and overhead welding. In addition, the beginner needs to master the feeding speed of the welding rods with different diameters when the welding rods generate different burning speeds under different welding currents.
In addition, the operator needs to pay attention to the size of the weld pool at all times during the operation of the strip. A good quality weld is formed by the solidification of numerous continuous molten pools of consistent size. Therefore, the level of skill of the manual arc welding operation is considered by related professionals, and the final result is the concrete embodiment of the 'bar-moving capability' and the 'molten pool observation capability' in the existing level and the development level. The beginners often have the phenomenon of considering out of coordination of operation actions in the actual operation training, and the problem of easily neglecting to observe the size of a molten pool to adjust the welding action to ensure the welding quality is solved.
Disclosure of Invention
The invention aims to provide a magnetic induction type manual electric arc welding simulation training instrument which can quickly assist a beginner to master common welding rod conveying methods of different welding positions such as horizontal welding, vertical welding, horizontal welding, overhead welding and the like in welding, master corresponding feeding action rhythms at different welding rod combustion speeds, and learn and observe the size of a molten pool in the rod conveying process to adjust welding action postures and movement speeds and the like so as to ensure welding quality.
In order to achieve the purpose, the magnetic induction type manual electric arc welding simulation training instrument comprises a simulation welding workpiece group, a simulation welding rod group and a simulation electric welding machine, wherein the simulation welding workpiece group comprises a positioning frame, a magnetic strip mounting box, a magnetic strip, an ultrasonic distance measuring sensor, a power line and a power socket, three straight grooves are arranged on the positioning frame, the two straight grooves are arranged on one side of the positioning frame in a crossed manner, one straight groove is arranged at the top of the positioning frame, the size of the straight groove is matched with that of the magnetic strip mounting box, the magnetic strip mounting box is detachably connected and fixed in the straight groove, and the magnetic strip is mounted and connected in the magnetic strip mounting box; the ultrasonic ranging sensor arranged at one end of the magnetic stripe mounting box is connected with a power socket through a power line arranged at the bottom of the magnetic stripe mounting box;
the simulated electrode assembly comprises: the test induction head is provided with a magnetic inductor A, a magnetic inductor B, a magnetic inductor C, a buzzer and an LED lamp bead, the magnetic inductor A, the magnetic inductor B and the magnetic inductor C are respectively arranged at different heights in the magnetic induction head, and the LED lamp bead is fixedly connected to the front end of the test induction head;
the simulation electric welding includes: the pneumatic triplet, the two-position three-way manual reversing valve, the two-position five-way electromagnetic reversing valve and the single-rod double-acting air cylinder are sequentially connected, the one-way throttle valve is further connected between the two-position five-way electromagnetic reversing valve and the single-rod double-acting air cylinder, and the power switch is connected with the conversion power supply;
the power socket is connected with a conversion power supply, and the magnetic inductor A, the magnetic inductor B, the magnetic inductor C, the buzzer and the LED lamp beads are connected with the conversion power supply in a series connection mode; the input end of the programmable controller is connected with the ultrasonic ranging sensor, and the output end of the programmable controller is connected with the LED lamp beads.
Further, the simulation welding workpiece group further comprises a bolt, two through holes are formed in the bottom of the straight groove, two nuts are installed at the bottom of the magnetic stripe installation box, and the magnetic stripe installation box penetrates through the through holes and the nuts in a matched mode and is fixedly connected with the straight groove through the bolt.
Further, the simulation welding workpiece group still includes the stationary blade, and the magnetic stripe mounting box openly is connected with the straight flute on locating rack top through the stationary blade down.
Further, the stationary blade is provided with four through-holes, and per two through-holes are a set of, and the stationary blade passes a set of through-hole and straight flute fixed connection through the bolt, and the magnetic stripe mounting box openly passes another set of through-hole connection through the bolt and fixes on the stationary blade downwards.
Further, the height distance between the magnetic inductor B and the magnetic inductor C is 2mm-4 mm.
Furthermore, the LED lamp beads are light-scattering high-brightness red lamp beads, and the aperture size and the brightness of the LED lamp beads are variable.
Further, the LED lamp bead is provided with a lampshade outside.
The substantive characteristics and the progress of the invention are as follows:
the magnetic induction type manual electric arc welding simulation training instrument has the following advantages:
1. the design structure is simple, the manufacturing cost is low, and the training of the conveying and feeding actions of different welding positions can be mastered by a beginner quickly.
2. The simulation training that the beginner can master and adjust the welding action to guarantee the welding quality through observing the darkness (namely the molten bath size) of the lamp pearl can be helped.
3. The training instrument is divided into three parts, is designed by completely referring to the components of actual welding equipment, and can create a relatively real simulated training environment for beginners so as to be convenient for adapting to and mastering the technical requirements of relevant actions more quickly during actual computer operation.
Drawings
Fig. 1 is a schematic structural view of the present invention.
FIG. 2 is a schematic diagram of a simulated electrode assembly.
Fig. 3 is a schematic structural diagram of a test head.
FIG. 4 is a schematic structural diagram of a horizontal welding and vertical welding station for simulating workpiece groups.
FIG. 5 is a rear view of a simulated work piece set flat welding and vertical welding station structure.
FIG. 6 is a schematic diagram of the structure of the horizontal and overhead welding stations of the simulated workpiece set.
FIG. 7 is a schematic diagram of an analog welder.
Fig. 8 is a circuit schematic of a programmable controller.
Part numbers and names in the figures:
the device comprises a simulation welding rod group I, a simulation electric welding machine II and a simulation welding workpiece group III;
11-a positioning frame, 12-a magnetic strip mounting box, 13-a magnetic strip, 14-a fixing sheet, 15-a bolt, 16-an ultrasonic ranging sensor, 17-a power line and 18-a power socket;
21-box body, 22-pneumatic triplet, 23-two-position five-way electromagnetic reversing valve, 24-one-way throttle valve, 25-two-position three-way manual reversing valve, 26-power switch, 27-programmable controller and 28-switching power supply;
31-single-rod double-acting cylinder, 32-grab handle, 33-test induction head, 33-1 magnetic inductor A, 33-2 magnetic inductor B, 33-3 magnetic inductor C, 34-buzzer, 35-LED lamp bead and 36-lampshade.
Detailed Description
The following describes an implementation structure of the present invention with reference to the drawings.
Referring to fig. 1-8, the magnetic induction type manual arc welding simulation training instrument comprises a simulation welding workpiece group III, a simulation welding rod group I and a simulation welding machine II.
Be provided with three straight flutes on simulation welding tool group III's the locating rack 11, two straight flutes are the cross setting in one side of locating rack 11, and a straight flute setting is at the top of locating rack 11, the size and the magnetic stripe mounting box 12 looks adaptation of straight flute, and magnetic stripe mounting box 12 can be dismantled to connect and fix at the straight flute, and magnetic stripe 13 erection joint is in magnetic stripe mounting box 12. The ultrasonic distance measuring sensor 16 installed at one end of the magnetic strip installation box 12 is connected with a power socket 18 through a power line 17 installed at the bottom of the magnetic strip installation box 12, and the power socket 18 is connected with a conversion power supply 28.
The simulation welding workpiece group III further comprises a bolt 15, two through holes are formed in the bottom of the straight groove, two nuts are installed at the bottom of the magnetic stripe installation box 12, and the magnetic stripe installation box 12 penetrates through the through holes and the nut in a matched mode and is fixedly connected with the straight groove through the bolt 15. Through the bolt 15 and the mode of nut complex, magnetic stripe mounting box 12 is respectively in three straight flute fixed connection.
The cooperation through bolt 15 and nut makes magnetic stripe mounting box 12 openly up be connected with the straight flute on locating rack 11 top, can also make magnetic stripe mounting box 12 openly down be connected with the straight flute on locating rack 11 top through stationary blade 14. The fixing piece 14 is provided with four through holes, every two through holes are in a group, the fixing piece 14 penetrates a group of through holes through a bolt 15 and is fixedly connected with the straight groove, and the front face of the magnetic stripe mounting box 12 downwards penetrates another group of through holes through a bolt 15 and is fixedly connected on the fixing piece 14.
A grab handle 32 of the simulation welding rod group I is provided with a single-rod double-acting cylinder 31, a test induction head 33 is arranged at the head of a piston rod of the single-rod double-acting cylinder 31, the test induction head 33 is provided with a magnetic inductor A33-1, a magnetic inductor B33-2, a magnetic inductor C33-3, a buzzer 34 and an LED lamp bead 35, the magnetic inductor A33-1, the magnetic inductor B33-2 and the magnetic inductor C33-3 are respectively arranged at different heights inside the magnetic induction head, and the height distance between the magnetic inductor B33-2 and the magnetic inductor C33-3 is 2mm-4 mm. LED lamp pearl 35 fixed connection is in the front end of test inductive head 33, and LED lamp pearl 35 is astigmatic type highlight red lamp pearl, and LED lamp pearl 35's light ring size and light and darkness are variable. The LED lamp bead 35 is also provided with a lampshade 36 on the outside, and the lampshade 36 is provided with a tip.
The magnetic strip 13 arranged in the magnetic strip mounting box 12 is matched with the magnetic inductor A33-1, the magnetic inductor B33-2 and the magnetic inductor C33-3. The magnetic force of the magnetic strip 13 is selected to be adaptively adjusted according to the distance between the tip of the lamp housing 36 and the surface of the magnetic strip mounting case 12 and the distances between the magnetic strip 13 and the magnetic sensor a33-1, the magnetic sensor B33-2 and the magnetic sensor C33-3. When the distance between the tip of the lampshade 36 and the surface of the magnetic strip mounting box 12 is 2mm-4mm, the magnetic inductor A33-1 is triggered, and when the distance is less than 2mm, the magnetic inductor B33-2 is triggered; when the distance is more than 4mm, the magnetic inductor C33-3 is triggered.
In the simulation electric welding machine II, a pneumatic triplet 22, a two-position three-way manual reversing valve 25, a two-position five-way electromagnetic reversing valve 23 and a single-rod double-acting air cylinder 31 are sequentially connected, a one-way throttle valve 24 is further connected between the two-position five-way electromagnetic reversing valve 23 and the single-rod double action, and a power switch 26 is connected with a conversion power supply 28.
The magnetic inductor A33-1, the magnetic inductor B33-2, the magnetic inductor C33-3, the buzzer 34 and the LED lamp bead 35 are connected with the conversion power supply 28 in series; the input end of the programmable controller 27 is connected with the ultrasonic ranging sensor 16, and the output end of the programmable controller 27 is connected with the LED lamp bead 35.
The working principle of the invention is described below with reference to the accompanying drawings and examples:
(1) and (5) preparing before starting up.
Firstly, one welding position, namely one of horizontal welding, vertical welding, transverse welding and overhead welding, is selected, and the magnetic strip mounting box 12 is fixedly connected with the straight groove. Wherein, the straight flute fixed connection on magnetic stripe mounting box 12 openly up and 11 tops of locating rack is the butt weld, and the straight flute fixed connection on magnetic stripe mounting box 12 openly down through stationary blade 14 and 11 tops of locating rack is for welding on the back, and magnetic stripe mounting box 12 is the horizontal welding with establishing the straight flute fixed connection parallel with ground in 11 sides of locating rack, and magnetic stripe mounting box 12 is the vertical welding with establishing in 11 sides of locating rack and perpendicular to ground straight flute fixed connection.
The operator holds the handle 32 with one hand and rotates the nut of the one-way throttle valve 24 on the simulated welding machine II to the "0" position with the other hand, which represents the slowest burning motion speed of the simulated welding rod. When an operator turns on the power switch 26 and manually rotates the switch of the two-position three-way manual reversing valve 25 to the on position, the pneumatic circuit is switched on, the piston rod of the single-rod double-acting air cylinder 31 does rapid extending movement and stops after extending to the maximum stroke, and the welding gun is in a standby working state, which is equivalent to a state that a new welding rod is clamped on the welding gun to be ready for working.
The movement speed of the piston rod can be adjusted by rotating a nut of the one-way throttle valve 24 in the analog welding machine II (which is equivalent to adjusting the welding current of the welding machine in actual operation).
(2) And (5) arc striking operation training.
The arc striking refers to a process of striking an arc by welding materials (welding rods, welding wires and the like) in welding, and the technical requirement of the industry field is that the distance between the welding rod or the electrode of a welding gun and a workpiece is kept between 2mm and 4mm in the welding process.
The training instrument simulates the arc striking process, when an operator needs to start training, a nut of the one-way throttle valve 24 on the simulated electric welding machine II is rotated to a proper gear, and a beginner can select a lower gear first. At this point, the operator can start striking the arc, and the operator holds the handle 32 to make the test induction head 33 pass over the surface of the magnetic strip mounting box 12, so that the magnetic strip 13 is matched with the magnetic inductor in the test induction head 33. The magnetic strip mounting box 12 is provided with fixed detection points, the tip of the lampshade 36 of the test induction head 33 is rapidly raised by 2-4mm when passing through the detection points, and then the magnetic inductor A33-1 can be triggered, meanwhile, the circuit is switched on to light the astigmatic high-brightness red LED lamp bead 35, and the electromagnet coil circuit of the two-position five-way electromagnetic directional valve 23 is switched on to switch the working position, so that the piston rod of the single-rod double-acting cylinder 31 does retraction motion, which represents that the arc striking operation is successfully completed.
After the piston rod is completely retracted to the bottom, the air path and the electric circuit can be cut off and the equipment returns to the initial state only by twisting the power switch 26 to the 'off' position and manually rotating the switch of the two-position three-way manual reversing valve 2525 to the 'off' position. When the work needs to be done again, the action process can be repeated.
(3) And (5) carrying out fortune training.
In the operation training process, in order to reflect the size of a welding pool, an astigmatic high-brightness red LED lamp bead 35 is arranged on a test induction head 33, and the simulation is realized by utilizing the change of the aperture size and the brightness. The size change of a molten pool in actual welding is mainly related to two parameters, namely, the space distance between a welding rod and a workpiece is large when the distance is small, and the distance is small when the distance is large; secondly, the moving speed of the welding rod along the welding seam is fast, the molten pool is small, and the molten pool is large when the speed is slow. LED lamp pearl 35 and lamp shade 36 are fixed at test inductive head 33 front end, and test inductive head 33 is close more apart from 12 surfaces of magnetic stripe mounting box, and LED lamp pearl 35's light ring is less, otherwise then the grow, can indirect show the molten bath size because of the change of the spatial distance of welding rod and work piece. The simulation tool set is provided with an ultrasonic ranging sensor 16 for measuring the change of the space distance between the test induction head 33 and the ultrasonic ranging sensor 16, and the moving speed of the test induction head 33, which is equivalent to the welding speed, is obtained through the operation of an internal program of the programmable controller 27. The change rate of the moving speed is calculated by an internal program of the programmable controller 27, and the change of the brightness of the LED lamp bead 35 is adjusted through an analog output end. Only if the brightness of the LED lamp bead 35 is basically kept unchanged, the size of the welding molten pool is basically consistent, otherwise, the size of the welding molten pool is increased or decreased, namely, the influence of the moving speed of the welding rod along the welding seam on the size of the molten pool is reflected.
The circuit schematic diagram of the programmable controller 27 is shown in fig. 8, and it is easy for those skilled in the art to design and program the programmable controller according to the requirement.
The specific training process is as follows: after completing the arc striking operation, the operator still holds the handle 32 to start the bar transporting action, and the operation is divided into three parts: feeding the welding rod, moving the welding rod to the welding direction and transversely swinging the welding rod. During the strip conveying process, the tip of the lampshade 36 of the test induction head 33 is required to be kept at a space distance of 2mm-4mm from the surface of the simulation workpiece. If the spatial distance is less than 2mm, the magnetic inductor B33-2 in the test induction head 33 can immediately detect that the distance is less than a set value, the circuit is disconnected, the buzzer 34 sends out a prompt alarm sound to prompt an operator, the LED lamp bead 35 is extinguished, and arc striking operation needs to be restarted. If the spatial distance is larger than 4mm, the magnetic inductor C33-3 in the test induction head 33 immediately detects that the distance is larger than a set value, the circuit is disconnected, the buzzer 34 sends out a prompt alarm sound to prompt an operator, the LED lamp bead 35 is extinguished, and arc striking operation needs to be restarted.
An operator should keep the distance between the tip of the lampshade 36 of the test induction head 33 and the surface of the simulation workpiece within the range of 2-4mm in the strip conveying training process, and pay attention to whether the size of the aperture of the LED lamp bead 35 is consistent or not, and if the size is large, corresponding adjustment should be made immediately. If the speed of the operator moving the simulation welding rod is too fast or too slow, the brightness of the red LED lamp bead 35 on the simulation welding rod can be changed immediately, namely the size of a welding pool is changed, and at the moment, the operator should adjust the welding speed immediately to ensure the consistency of the welding moving speed.
(4) And (5) training in different projects.
The beginners often have unsmooth movements of hands, eyes and brain when starting training due to the incoordination. The method can consider that the training of different items, namely arc striking training, feeding training, welding speed training, welding operation comprehensive training and molten pool size control training, can be carried out in the state of the flat welding position, and when the item is skilled, the related training of different welding positions of vertical welding, horizontal welding and overhead welding can be respectively carried out.

Claims (7)

1. The utility model provides a magnetic induction formula manual arc welding simulation training appearance which characterized in that: the device comprises a simulation welding workpiece group (III), a simulation welding rod group (I) and a simulation electric welding machine (II), wherein the simulation welding workpiece group (III) comprises a positioning frame (11), a magnetic strip mounting box (12), a magnetic strip (13), an ultrasonic distance measuring sensor (16), a power line (17) and a power socket (18), three straight grooves are formed in the positioning frame (11), the two straight grooves are arranged on one side of the positioning frame (11) in a cross mode, one straight groove is arranged at the top of the positioning frame (11), the size of the straight groove is matched with that of the magnetic strip mounting box (12), the magnetic strip mounting box (12) is detachably connected and fixed in the straight groove, and the magnetic strip (13) is installed and connected in the magnetic strip mounting box (12); an ultrasonic ranging sensor (16) arranged at one end of the magnetic strip mounting box (12) is connected with a power socket (18) through a power line (17) arranged at the bottom of the magnetic strip mounting box (12); the simulated welding rod group (I) comprises: the device comprises a single-rod double-acting cylinder (31), a grab handle (32) and a test induction head (33), wherein the single-rod double-acting cylinder (31) is installed on the grab handle (32), the test induction head (33) is installed at the head part of a piston rod of the single-rod double-acting cylinder (31), the test induction head (33) is installed with a magnetic inductor A (33-1), a magnetic inductor B (33-2), a magnetic inductor C (33-3), a buzzer (34) and LED lamp beads (35), the magnetic inductor A (33-1), the magnetic inductor B (33-2) and the magnetic inductor C (33-3) are respectively installed at different heights inside the test induction head (33), and the LED lamp beads (35) are fixedly connected to the front end of the test induction head (33); the simulated electric welder (II) comprises: the pneumatic three-way valve (22), the two-position five-way electromagnetic reversing valve (23), the one-way throttle valve (24), the two-position three-way manual reversing valve (25), the power switch (26), the programmable controller (27) and the conversion power supply (28) are arranged in the box body (21), the pneumatic three-way valve (22), the two-position three-way manual reversing valve (25), the two-position five-way electromagnetic reversing valve (23) and the single-rod double-acting cylinder (31) are sequentially connected, the one-way throttle valve (24) is further connected between the two-position five-way electromagnetic reversing valve (23) and the single-rod double-acting cylinder (31), and the power switch (26) is connected with the conversion power supply (28; the power socket (18) is connected with the conversion power supply (28), and the magnetic inductor A (33-1), the magnetic inductor B (33-2), the magnetic inductor C (33-3), the buzzer (34) and the LED lamp beads (35) are connected with the conversion power supply (28) in a series connection mode; the input end of the programmable controller (27) is connected with the ultrasonic ranging sensor (16), and the output end of the programmable controller (27) is connected with the LED lamp beads (35).
2. The magnetic induction type manual arc welding simulation training instrument according to claim 1, wherein: the simulation welding workpiece group (III) further comprises a bolt (15), two through holes are formed in the bottom of the straight groove, two nuts are installed at the bottom of the magnetic stripe installation box (12), and the magnetic stripe installation box (12) penetrates through the through holes and the nut in a matched mode and is fixedly connected with the straight groove through the bolt (15).
3. The magnetic induction type manual arc welding simulation training instrument according to claim 2, wherein: the simulation welding workpiece group (III) further comprises a fixing sheet (14), and the magnetic strip installation box (12) is connected with the straight groove in the top end of the positioning frame (11) through the fixing sheet (14) downwards in the front face.
4. The magnetic induction type manual arc welding simulation training instrument according to claim 3, wherein: the fixing piece (14) is provided with four through holes, every two through holes are in one group, the fixing piece (14) penetrates through a group of through holes and straight groove fixed connection through bolts (15), and the magnetic stripe mounting box (12) penetrates through another group of through holes through bolts (15) and is connected and fixed on the fixing piece (14) with the front face facing downwards.
5. The magnetic induction type manual arc welding simulation training instrument according to claim 1, wherein: the height distance between the magnetic inductor B (33-2) and the magnetic inductor C (33-3) is 2mm-4 mm.
6. The magnetic induction type manual arc welding simulation training instrument according to claim 1, wherein: the LED lamp beads (35) are light-scattering high-brightness red lamp beads, and the aperture size and the brightness of the LED lamp beads (35) are variable.
7. The magnetic induction type manual arc welding simulation training instrument according to claim 1, wherein: and a lampshade (36) is also arranged outside the LED lamp bead (35).
CN201711032603.XA 2017-10-30 2017-10-30 Magnetic induction type manual electric arc welding simulation training instrument Expired - Fee Related CN107644579B (en)

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US9011154B2 (en) * 2009-07-10 2015-04-21 Lincoln Global, Inc. Virtual welding system
KR101523015B1 (en) * 2011-04-07 2015-05-26 링컨 글로벌, 인크. Virtual testing and inspection of a virtual weldment
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US8992226B1 (en) * 2014-07-15 2015-03-31 Lincoln Global, Inc. Unicoupon for virtual reality welding simulator
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