CN109807423B - Welding closed-loop monitoring system and welding method - Google Patents
Welding closed-loop monitoring system and welding method Download PDFInfo
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- CN109807423B CN109807423B CN201910131196.0A CN201910131196A CN109807423B CN 109807423 B CN109807423 B CN 109807423B CN 201910131196 A CN201910131196 A CN 201910131196A CN 109807423 B CN109807423 B CN 109807423B
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- 238000003466 welding Methods 0.000 title claims abstract description 209
- 238000012544 monitoring process Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 37
- 239000000463 material Substances 0.000 claims abstract description 70
- 230000007246 mechanism Effects 0.000 claims abstract description 36
- 238000005476 soldering Methods 0.000 claims description 27
- 238000006243 chemical reaction Methods 0.000 claims description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims 4
- 229910052742 iron Inorganic materials 0.000 claims 2
- 238000001514 detection method Methods 0.000 claims 1
- 230000008569 process Effects 0.000 abstract description 17
- 229910000679 solder Inorganic materials 0.000 description 6
- 238000004458 analytical method Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000012217 deletion Methods 0.000 description 1
- 230000037430 deletion Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Abstract
The invention discloses a welding closed-loop monitoring system and a welding method. The welding closed-loop monitoring system comprises a welding mechanism (1) and an information acquisition and monitoring mechanism (2); the welding mechanism (1) comprises a first terminal (11), a second terminal (12), a welding material (13) and a welding head (14); the voltage acquisition and monitoring mechanism (2) is used for acquiring and monitoring information between the first terminal (11) and the second terminal (12), between the first terminal (11) and the welding material (13), between the first terminal (11) and the welding head (14) and between the welding material (13) and the welding head (14). The welding closed-loop monitoring system can effectively monitor the welding process. The welding method is based on the welding closed-loop monitoring system, the welding material quantity required by the welding point is calculated in advance, the waveform and the contact time of the control electric signal are set, and the welding closed-loop monitoring system is used for monitoring and analyzing, so that the quality of the welding point is improved, and the welding cost is reduced.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a welding closed-loop monitoring system and a welding method.
Background
By welding, the two separated materials can be spliced in a seamless manner, and the service plasticity of the materials is improved. Welding technology is very wide in industrial application, especially in the field of machining, and is an indispensable technical means, providing technical support for the production of various mechanical equipment.
In the existing welding technology, the quality of welding in the welding process is generally judged according to the experience of a welder, an objective monitoring system is not provided, subjectivity is high, overselding or missing welding is easy to occur, and therefore produced products are easy to have uneven quality and uneven distribution; moreover, depending on manual judgment, considerable experience is required, which is unfavorable for novice operation, and thus, flexible scheduling of production and reduction of production cost are unfavorable. In addition, in the existing welding process, due to the fact that no corresponding monitoring means exists, in the empirical welding process, the welding material consumption of the welding seam with the same size is more and less, the control of the welding quality is not facilitated, and meanwhile the saving of the welding cost is not facilitated.
Disclosure of Invention
The invention aims at overcoming the defects of the prior art and provides a welding method. The welding method is characterized in that the welding material quantity required by the welding point is calculated in advance, the comparison of the electric signal waveform and the contact time is set, the electric signal waveform and the contact time in the welding process are monitored in real time through the welding closed-loop monitoring system, and the comparison analysis is carried out between the electric signal waveform and the contact time and the comparison of the electric signal waveform and the contact time, so that the actual welding material quantity at the welding point is monitored, the welding point quality is monitored, the welding material quantity is effectively saved, the welding cost is reduced, and the welding quality is effectively improved.
The invention also aims to provide a welding closed-loop monitoring system for realizing the welding method.
The aim of the invention is achieved by the following technical scheme.
A welding closed-loop monitoring system comprises a welding mechanism and an information acquisition and monitoring mechanism; the welding mechanism comprises a first terminal, a second terminal, a welding material and a welding head;
The information acquisition and monitoring mechanism is used for acquiring and monitoring information between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the welding head and between the welding material and the welding head.
Preferably, the information acquisition and monitoring mechanism comprises a PLC (programmable logic controller) and a singlechip; the PLC controller is connected with the singlechip through a circuit.
More preferably, the first terminal, the second terminal, the welding material and the soldering bit are respectively connected with the information acquisition port of the singlechip through wires.
Still more preferably, the information acquisition port of the singlechip is provided with an analog-to-digital conversion module.
Still more preferably, the welding material and the soldering bit are respectively and independently connected with a grounding circuit.
More preferably, the information acquisition and monitoring mechanism further comprises a touch display screen; and the touch display screen is connected with the PLC controller through a circuit.
Preferably, the information includes an electrical signal and a contact time; the electrical signal comprises a voltage signal or a current signal.
A welding method based on the welding closed loop monitoring system of any one of the above, comprising the steps of:
(1) The welding material quantity required by welding spots between the first terminal and the second terminal to be welded is calculated in advance;
(2) Simulating welding of the first terminal and the second terminal based on the welding material amount in the step (1), and storing electric signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the soldering bit and between the welding material and the soldering bit in an information acquisition and monitoring mechanism as comparison data;
(3) And the actual welding of the first terminal and the second terminal is carried out, the information acquisition and monitoring mechanism is used for acquiring electric signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the welding tip and between the welding material and the welding tip, and comparing and analyzing the electric signals and the contact time with control data stored in the information acquisition and monitoring mechanism, so that the actual consumption of the welding material of the welding spot between the first terminal and the second terminal is monitored, and the quality of the welding spot is monitored.
Preferably, in the information acquisition and monitoring mechanism, the electrical signal and the contact time are displayed in the form of a waveform chart of the electrical signal changing with the contact time.
Compared with the prior art, the invention has the following advantages and beneficial effects:
(1) The welding closed-loop monitoring system can effectively monitor and collect information between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the welding head and between the welding material and the welding head; wherein, the singlechip is arranged to efficiently and accurately collect the electric signal information and the time information, the PLC is arranged to display and monitor the acquired information in a waveform mode and the like in real time; meanwhile, the PLC can be connected with the welding machine, receives a welding output signal of the welding machine, and combines information acquired by the singlechip to perform feedback automatic control on the welding process, so that high-quality welding control is realized;
(2) The welding method of the invention calculates the amount of the welding material needed by the welding point in advance, sets the comparison electric signal waveform and the contact time, monitors the electric signal waveform and the contact time in the welding process in real time by the welding closed-loop monitoring system, compares and analyzes the electric signal waveform and the contact time with the comparison electric signal waveform and the contact time to monitor the amount of the welding material actually on the welding point, thereby monitoring the quality of the welding point, effectively saving the amount of the welding material, reducing the welding cost and effectively improving the welding quality.
Drawings
FIG. 1 is a schematic diagram of a welding closed-loop monitoring system according to the present invention in embodiment 1;
FIG. 2 is a schematic view showing a welding process structure for welding in embodiment 2;
FIG. 3a is a graph showing the voltage between the tip and the tin bar over time during the welding process monitored by the welding closed loop monitoring system of example 1 in example 2;
FIG. 3b is a graph showing the voltage between the first and second terminals over time during the welding process according to embodiment 2 using the welding closed loop monitoring system of embodiment 1;
FIG. 3c is a graph showing the voltage between the first terminal and the tin bar over time during the welding process monitored by the welding closed loop monitoring system of embodiment 1 according to embodiment 2;
FIG. 3d is a graph of voltage versus time for a welding tip and a first terminal during a welding process using the welding closed loop monitoring system of example 1 of example 2;
the drawings are marked: the welding device comprises a welding mechanism 1, a terminal I, a terminal II, a welding material 13, a welding head 14, an information acquisition and monitoring mechanism 2, a PLC controller 21, a singlechip 22, a 23-touch display screen, a 24-switching power supply and a welding machine 3.
Detailed Description
The technical scheme of the present invention is described in further detail below with reference to specific examples and drawings, but the scope and embodiments of the present invention are not limited thereto.
Example 1
A welding closed-loop monitoring system of the present embodiment, as shown in fig. 1, includes a welding mechanism 1 and an information collecting and monitoring mechanism 2. The welding mechanism 1 comprises a first terminal 11, a second terminal 12, a welding material 13 and a soldering bit 14.
The information collecting and monitoring mechanism 2 is used for collecting and monitoring information between the first terminal 11 and the second terminal 12, between the first terminal 11 and the welding material 13, between the first terminal 11 and the soldering bit 14 and between the welding material 13 and the soldering bit 14. The monitored information electrical signals and contact times are collected and, in particular, the electrical signals include voltage signals or current signals.
Specifically, the information acquisition and monitoring mechanism 2 comprises a PLC controller 21 and a singlechip 22. The PLC controller 21 is connected with the singlechip 22 through a line, and the singlechip 22 transmits collected data to the PLC controller 21 for processing. Meanwhile, the PLC controller 21 may also transmit an edit control signal to the singlechip 22 to adjust or switch the comparison analysis parameters.
And the first terminal 11, the second terminal 12, the welding material 13 and the soldering bit 14 are respectively connected with the information acquisition port of the singlechip 22 through wires. The information acquisition port of the singlechip 22 is provided with an analog-to-digital conversion module, and the analog-to-digital conversion module can compare and analyze the received information such as the electric signal and the like with the analog quantity and then convert the information.
The welding material 13 and the soldering bit 14 are respectively and independently connected with a grounding circuit, and the grounding circuit of the welding material 13 is connected with a resistor R 1 in series. In this embodiment, the circuits of the first terminal 11, the second terminal 12 and the welding material 13, which are connected with the singlechip 22, are respectively connected with an external port circuit in parallel, and resistors R 2、R3 and R 4 are respectively connected with the external port circuit in series.
Further, the information collecting and monitoring mechanism 2 further includes a touch display screen 23. The touch display screen 23 is connected with the PLC controller 21 through a circuit, and the PLC controller 21 can analyze and transmit the collected information to the touch display screen 23 for display. Meanwhile, the control signal outputted by the touch display 23 through the touch may also be transmitted to the PLC controller 21 for editing, analyzing and adjusting.
Further, in this embodiment, referring to fig. 1, the singlechip 22 in the information acquisition and monitoring mechanism 2 is externally connected to a 220V power supply through the switching power supply 24; meanwhile, the PLC controller 21 is directly connected with a 220V power supply through a circuit.
Further, in this embodiment, referring to fig. 1, a PLC controller 21 is connected to the welding machine 3, receives a welding output signal of the welding machine 3, and performs feedback automatic control on the welding process by combining information collected by a singlechip 22, so as to realize high-quality welding control.
Example 2
In this embodiment, the first terminal 11 and the second terminal 12 are welded, and the welding process is shown in fig. 2, firstly, at t 0, the first terminal 11, the second terminal 12, the welding material 13 and the soldering bit 14 are all in a separated state and are not in contact; when welding is carried out, at t 1, the soldering bit 14 is contacted with the first terminal 11; when welding is continued, at t 2, the welding material 13 is contacted with the soldering bit 14 and simultaneously contacted with the first terminal 11, and heating welding is started; after the welding material 13 melts and welds the first terminal 11 and the second terminal 12, the first terminal 11 and the second terminal 12 are connected through the spot welding material, and at t 3, the welding material 13 is separated from the soldering bit 14, and the soldering bit 14 is still in contact with the first terminal 11; finally, at t 4, the soldering bit 14 is separated from the first terminal 11, the welding material 13 and the soldering bit 14 are all in a separated state, and the first terminal 11 and the second terminal 12 are connected through the spot welding material. Thus, the welding is completed.
The welding process adopts the welding closed-loop monitoring system of the embodiment 1 to carry out welding monitoring, and comprises the following steps:
(1) The amount of welding material required for the welding spot between the first terminal and the second terminal to be welded is calculated in advance.
(2) And (3) simulating voltage signals and contact time between the first terminal (T1) and the second terminal (T2), between the first terminal (T1) and the welding material (S), between the first terminal (T1) and the soldering bit (H) and between the welding material (S) and the soldering bit (H) in the welding process based on the welding material quantity of the step (1). In addition, in the information collection and monitoring mechanism, the collected voltage signals and the contact time are displayed in the form of a waveform diagram of the change of the voltage signals along with the contact time, and specifically, the waveform diagram of the change of the collected voltage along with the time is shown in fig. 3 a-3 b.
As can be seen from fig. 3a, at t 0、t1、t3 and t 4, since there is no contact relationship between the welding material (S) and the soldering bit (H), at t 0、t1、t3 and t 4, the resistance between the welding material (S) and the soldering bit (H) is high, resulting in a high voltage between the welding material (S) and the soldering bit (H); at t 2, the welding material (S) is in contact with the tip (H), so that at t 2, the resistance between the welding material (S) and the tip (H) is small, and the voltage between the welding material (S) and the tip (H) is reduced.
As can be seen from fig. 3b, at T 0 and T 1, there is no contact relationship between the first terminal (T1) and the second terminal (T2), so that at T 0 and T 1, the resistance between the first terminal (T1) and the second terminal (T2) is large, resulting in a higher voltage between the first terminal (T1) and the second terminal (T2); at T 2, since the first terminal (T1) and the second terminal (T2) are in contact and welded together after T 3, the resistance between the first terminal (T1) and the second terminal (T2) is small at T 2 and later, resulting in a voltage drop between the first terminal (T1) and the second terminal (T2).
As can be seen from fig. 3c, at T 0、t1、t3 and T 4, there is no contact relationship between the first terminal (T1) and the solder (S), so that at T 0、t1、t3 and T 4, the resistance between the first terminal (T1) and the solder (S) is high, resulting in a high voltage between the first terminal (T1) and the solder (S); at T 2, since the terminal one (T1) is in contact with the solder (S), at T 2, the resistance between the terminal one (T1) and the solder (S) is small, resulting in a voltage drop between the terminal one (T1) and the solder (S).
As can be seen from fig. 3d, at T 0 and T 4, there is no contact between the first terminal (T1) and the tip (H), so that at T 0 and T 4, the resistance between the first terminal (T1) and the tip (H) is high, resulting in a high voltage between the first terminal (T1) and the tip (H); at T 1、t2 and T 3, the contact between the first terminal (T1) and the tip (H) makes the resistance between the first terminal (T1) and the tip (H) small at T 1、t2 and T 3, resulting in a decrease in the voltage between the first terminal (T1) and the tip (H).
Meanwhile, the acquired information is used as control data to be stored in an information acquisition and monitoring mechanism.
(3) And the actual welding of the first terminal and the second terminal is carried out, voltage signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the welding tip and between the welding material and the welding tip are acquired through the information acquisition and monitoring mechanism, and the comparison analysis is carried out with comparison data stored in the information acquisition and monitoring mechanism, so that the actual consumption of the welding material of the welding spot between the first terminal and the second terminal is monitored, and the quality of the welding spot is monitored.
Therefore, the welding material quantity required by the welding point is calculated in advance, the comparison electric signal waveform and the contact time are set, the voltage signal waveform and the contact time in the welding process are monitored in real time through the welding closed-loop monitoring system, and the comparison analysis is carried out between the voltage signal waveform and the contact time, so that the actual welding material quantity at the welding point is monitored, the welding point quality is monitored, the welding material quantity is effectively saved, the welding cost is reduced, and meanwhile, the welding quality is effectively improved.
The above embodiments are merely preferred embodiments of the present invention and only the technical solutions of the present invention will be described in further detail, but the scope and embodiments of the present invention are not limited thereto, and any changes, combinations, deletions, substitutions or modifications made without departing from the spirit and principles of the present invention are included in the scope of the present invention.
Claims (8)
1. A welding method, characterized in that the method is based on a welding closed-loop detection system comprising a welding mechanism (1) and an information acquisition and monitoring mechanism (2); the welding mechanism (1) comprises a first terminal (11), a second terminal (12), a welding material (13) and a welding head (14);
The information acquisition and monitoring mechanism (2) is used for acquiring and monitoring information between the first terminal (11) and the second terminal (12), between the first terminal (11) and the welding material (13), between the first terminal (11) and the soldering iron head (14) and between the welding material (13) and the soldering iron head (14);
the method comprises the following steps:
(1) The welding material quantity required by welding spots between the first terminal and the second terminal to be welded is calculated in advance;
(2) Simulating welding of the first terminal and the second terminal based on the welding material amount in the step (1), and storing electric signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the soldering bit and between the welding material and the soldering bit in an information acquisition and monitoring mechanism as comparison data;
(3) And the actual welding of the first terminal and the second terminal is carried out, the information acquisition and monitoring mechanism is used for acquiring electric signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the welding tip and between the welding material and the welding tip, and comparing and analyzing the electric signals and the contact time with control data stored in the information acquisition and monitoring mechanism, so that the actual consumption of the welding material of the welding spot between the first terminal and the second terminal is monitored, and the quality of the welding spot is monitored.
2. The welding method according to claim 1, characterized in that the information acquisition and monitoring mechanism (2) comprises a PLC controller (21) and a single chip microcomputer (22); the PLC (21) is connected with the singlechip (22) through a line.
3. The welding method according to claim 2, wherein the first terminal (11), the second terminal (12), the welding material (13) and the soldering bit (14) are respectively connected with the information acquisition port of the single chip microcomputer (22) through wires.
4. A welding method according to claim 3, characterized in that the information acquisition port of the single-chip microcomputer (22) is provided with an analog-to-digital conversion module.
5. A welding method according to claim 3, characterized in that the welding material (13) and the soldering tip (14) are each also connected independently to a ground line.
6. The welding method according to any one of claims 2 to 5, wherein the information acquisition and monitoring mechanism (2) further comprises a touch display screen (23); the touch display screen (23) is connected with the PLC (21) through a circuit.
7. The welding method of claim 1, wherein the information comprises an electrical signal and a contact time; the electrical signal comprises a voltage signal or a current signal.
8. A welding method according to claim 1, wherein at the information collecting and monitoring means, the electrical signal and the contact time are displayed in the form of a waveform of the electrical signal as a function of the contact time.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910131196.0A CN109807423B (en) | 2019-02-22 | 2019-02-22 | Welding closed-loop monitoring system and welding method |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910131196.0A CN109807423B (en) | 2019-02-22 | 2019-02-22 | Welding closed-loop monitoring system and welding method |
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| Publication Number | Publication Date |
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| CN109807423A CN109807423A (en) | 2019-05-28 |
| CN109807423B true CN109807423B (en) | 2024-04-23 |
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| CN115781087B (en) * | 2023-01-05 | 2023-04-28 | 扬州太平洋新能源有限公司 | Welding device for boiler evaporation tube |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10248110A1 (en) * | 2002-07-30 | 2004-02-12 | Ruf Electronics Gmbh | System to obtain reproducible conditions when soldering contact points on an electronic circuit board uses voltage and temperature measurements |
| JP2011212705A (en) * | 2010-03-31 | 2011-10-27 | Taiyo Denki Sangyo Kk | Apparatus for melting solder |
| CN103949744A (en) * | 2014-01-15 | 2014-07-30 | 中冶宝钢技术服务有限公司 | Instantaneous temperature control electric iron |
| CN209811398U (en) * | 2019-02-22 | 2019-12-20 | 仝达科技（惠州）有限公司 | Welding closed loop monitoring system |
-
2019
- 2019-02-22 CN CN201910131196.0A patent/CN109807423B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10248110A1 (en) * | 2002-07-30 | 2004-02-12 | Ruf Electronics Gmbh | System to obtain reproducible conditions when soldering contact points on an electronic circuit board uses voltage and temperature measurements |
| JP2011212705A (en) * | 2010-03-31 | 2011-10-27 | Taiyo Denki Sangyo Kk | Apparatus for melting solder |
| CN103949744A (en) * | 2014-01-15 | 2014-07-30 | 中冶宝钢技术服务有限公司 | Instantaneous temperature control electric iron |
| CN209811398U (en) * | 2019-02-22 | 2019-12-20 | 仝达科技（惠州）有限公司 | Welding closed loop monitoring system |
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