CN110136400B - Electrode cap replacement alarm method and system - Google Patents
Electrode cap replacement alarm method and system Download PDFInfo
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- CN110136400B CN110136400B CN201910248681.6A CN201910248681A CN110136400B CN 110136400 B CN110136400 B CN 110136400B CN 201910248681 A CN201910248681 A CN 201910248681A CN 110136400 B CN110136400 B CN 110136400B
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
- G08B21/18—Status alarms
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
- G08B21/18—Status alarms
- G08B21/182—Level alarms, e.g. alarms responsive to variables exceeding a threshold
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/01—Protocols
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/50—Network services
- H04L67/52—Network services specially adapted for the location of the user terminal
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- Computer Networks & Wireless Communication (AREA)
- Signal Processing (AREA)
- Business, Economics & Management (AREA)
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- General Physics & Mathematics (AREA)
- General Factory Administration (AREA)
- Alarm Systems (AREA)
Abstract
The invention discloses an electrode cap replacement alarm method and system, wherein the method comprises the following steps: detecting the number of spot welding times of the current electrode caps of a plurality of devices according to a detection period; screening out equipment with the spot welding times exceeding an alarm threshold value as first equipment according to the spot welding times of the current electrode caps of the plurality of pieces of equipment; acquiring the position information of all first devices; and sending the position information of all the first devices to the client. According to the invention, the number of spot welding times of the current electrode cap of the equipment is detected according to the detection period, then the equipment exceeding the alarm threshold value is screened out as the first equipment, the positions of all the first equipment are collectively sent to the client, and a maintainer can replace the electrode caps in batches according to the position information of all the first equipment. The invention can be widely applied to the field of automation.
Description
Technical Field
The invention relates to the field of automation, in particular to an electrode cap replacement alarm method and system.
Background
In a welding workshop of an automobile manufacturing factory and a production process of the welding workshop, spot welding is one of the most important process flows in the welding process and is a welding process component for ensuring the stability and durability of an automobile body.
In the process of spot welding, the electrode cap is used as a worn product, the electrode cap needs to be ground after being subjected to spot welding for a plurality of times, and the electrode cap becomes thinner gradually as the grinding times become more, so that the electrode cap needs to be replaced after being ground for a plurality of times.
At present, the main strategies for replacing the electrode cap are divided into two types: the first strategy is to set a threshold value on the equipment, then an alarm is generated once the number of spot welding times of the equipment exceeds the threshold value, and then the equipment maintenance personnel immediately replace the equipment. The second strategy is to replace the electrode caps of the entire plant directly before the start-up every day, but such a strategy implies that some of the electrode caps that are not actually used several times are directly scrapped, which is a very costly strategy.
In summary, the current strategy has the problems of low efficiency or waste of electrode cap.
Disclosure of Invention
To solve the above technical problems, the present invention aims to: the electrode cap replacement alarm method and the electrode cap replacement alarm system are provided, so that the replacement efficiency of the electrode cap is improved under the condition of reducing electrode cap waste.
A first aspect of an embodiment of the present invention provides:
an electrode cap replacement alarm method comprises the following steps:
detecting the number of spot welding times of the current electrode caps of a plurality of devices according to a detection period;
screening out equipment with the spot welding times exceeding an alarm threshold value as first equipment according to the spot welding times of the current electrode caps of the plurality of pieces of equipment;
acquiring the position information of all first devices;
and sending the position information of all the first devices to the client.
Further, the method also comprises the following steps:
acquiring historical spot welding data of a plurality of devices;
and respectively configuring the alarm threshold value of each device according to the historical spot welding data of each device.
Further, the step of respectively configuring the alarm threshold value of each device according to the historical spot welding data of each device specifically includes:
calculating the number of spot welding times of each device per hour according to the historical spot welding data of each device;
and configuring an alarm threshold value of each device according to the number of spot welding times of each device per hour.
Further, the configuring of the alarm threshold value of each device according to the number of spot welding times per hour of each device specifically includes:
acquiring the maximum spot welding times of the electrode cap and the early warning time of each device;
calculating the product of the number of spot welding times of the equipment per hour and the early warning time of the equipment;
and subtracting the product corresponding to each device from the maximum number of spot welding times of the electrode cap to obtain the alarm threshold value of each device.
Further, the position information includes information of a workshop area, a production line and a station.
A second aspect of an embodiment of the present invention provides:
an electrode cap replacement alarm system comprising:
the collector is used for collecting the number of spot welding times of the current electrode caps of a plurality of devices;
the server is used for detecting the number of times of spot welding of the current electrode caps of the plurality of devices according to the detection period; screening out equipment with the spot welding times exceeding an alarm threshold value as first equipment according to the spot welding times of the current electrode caps of the plurality of pieces of equipment; acquiring the position information of all first devices; sending the position information of all first equipment to a client;
and the client is used for receiving and displaying the position information of the first equipment.
Further, the device also comprises a database, wherein the database is used for storing historical spot welding data of each device and position information of each device;
the server is further configured to:
acquiring historical spot welding data of a plurality of devices from a database;
and respectively configuring the alarm threshold value of each device according to the historical spot welding data of each device.
Further, the step of respectively configuring the alarm threshold value of each device according to the historical spot welding data of each device specifically includes:
calculating the number of spot welding times of each device per hour according to the historical spot welding data of each device;
and configuring an alarm threshold value of each device according to the number of spot welding times of each device per hour.
Further, the configuring of the alarm threshold value of each device according to the number of spot welding times per hour of each device specifically includes:
acquiring the maximum spot welding times of the electrode cap and the early warning time of each device;
calculating the product of the number of spot welding times of the equipment per hour and the early warning time of the equipment;
and subtracting the product corresponding to each device from the maximum number of spot welding times of the electrode cap to obtain the alarm threshold value of each device.
Further, the position information includes information of a workshop area, a production line and a station.
The invention has the beneficial effects that: according to the invention, the number of spot welding times of the current electrode cap of the equipment is detected according to the detection period, then the equipment exceeding the alarm threshold value is screened out as the first equipment, the positions of all the first equipment are collectively sent to the client, and a maintainer can replace the electrode caps in batches according to the position information of all the first equipment sent by the client.
Drawings
FIG. 1 is a flow chart of an electrode cap replacement alarm method according to an embodiment of the present invention;
fig. 2 is a block diagram of an electrode cap replacement alarm system according to an embodiment of the present invention.
Detailed Description
The noun explains:
PLC: programmable Logic Controller (Programmable Logic Controller) is a digital arithmetic operation electronic system designed specifically for use in industrial environments. It uses a programmable memory, in which the instructions for implementing logical operation, sequence control, timing, counting and arithmetic operation are stored, and utilizes digital or analog input and output to control various mechanical equipments or production processes.
Electrode caps: the electrode cap is used for welding resistance welding equipment, such as a fixed spot welder, a suspension type spot welder, a manipulator spot welder and the like, and is sleeved on an electrode connecting rod, so that the electrode cap is called. The material is mostly chromium zirconium copper, and also has dispersed copper. After welding for a certain number of times (generally 3000-.
The invention is further described with reference to the drawings and the specific examples.
Referring to fig. 1, the present embodiment discloses an electrode cap replacement alarm method, and the method of the present embodiment may be applied to a server or a controller networked with a spot welding device. The spot welding apparatus includes a spot welding robot or the like.
The embodiment comprises the following steps:
and S101, detecting the number of times of spot welding of the current electrode caps of a plurality of devices according to a detection period. The service life of one electrode cap of the spot welding equipment is generally 3000-5000 times, the spot welding speed of each equipment is different due to different stations or models, some equipment performs spot welding for 200 times per hour, and some equipment performs spot welding for 20 times per hour. Typically, one electrode cap can be used for at least several hours.
S102, screening out the equipment with the spot welding times exceeding the alarm threshold value according to the spot welding times of the current electrode caps of the plurality of equipment as first equipment. In the present embodiment, the detection period may be set to 2 hours. Therefore, in the present embodiment, the electrode cap replacement is performed only once every two hours. The embodiment should give the electrode cap at least one advance of the detection period when setting the alarm threshold. For example, the maximum service life of an electrode cap is 5000 times, the spot welding speed of the equipment with the highest spot welding speed on the current production line is 200 times per hour, and then the alarm threshold value of each equipment can be set to 4600 times, so that the electrode cap needing to be replaced cannot be missed to be detected in the detection period. Of course, since the spot welding speed is different for each machine, in other embodiments an alarm threshold may be set for each device.
S103, acquiring the position information of all the first devices. In the present embodiment, the location information of all the devices is stored in the database, and therefore, the data can be read from the database. Of course, in other embodiments, the location information may also be reported by the device in real time.
And S104, sending the position information of all the first devices to the client. The client refers to APP, small programs or WEB application and the like. The client may be a device equipped with software for receiving the location information of the first device.
In this embodiment, the information displayed by the client may be in the form of a list. Table 1 shows a list of information acquired by the client in this embodiment.
TABLE 1
| Device numbering | Workshop area numbering | Production line number | Station numbering | Maintenance personnel |
| 001 | 02 | 12 | 05 | Xiaoming and Xiaochen |
| 002 | 05 | 08 | 21 | Xiaoming and Xiaochen |
| 003 | 01 | 04 | 15 | Plum |
The maintenance personnel can obtain the list of the electrode caps needing to be replaced in the period and the positions of the electrode caps corresponding to the equipment in batches according to the information on the client, and the maintenance personnel can quickly replace the electrode caps accordingly. Of course, after each device is replaced with an electrode cap, the current spot welding data of the electrode cap can be cleared.
This embodiment can realize changing in batches under the extravagant condition of reduction electrode cap through rationally setting up detection cycle and alarm threshold value, reduces to change the influence of electrode cap to producing the line, promotes and produces line efficiency.
As a preferred embodiment, the method further comprises the following steps:
s201, acquiring historical spot welding data of a plurality of devices;
s202, respectively configuring an alarm threshold value of each device according to historical spot welding data of each device.
In the present embodiment, the historical spot welding data refers to historical spot welding records of the equipment, and by means of the spot welding records, the present embodiment can acquire the average spot welding speed of each equipment. Since the production conditions of the equipment at different periods may be different, the spot welding speed of the equipment at different periods may also be different, and therefore the alarm threshold value can be updated regularly. For example, only the last two weeks of spot welding records are taken as the basis for setting the alarm threshold.
In addition, this embodiment has all set up the alarm threshold value for every equipment, can avoid unifying the electrode cap utilization ratio that the alarm threshold value caused and be low. For example, for an apparatus in which the spot welding speed is 200 times per hour, the alarm threshold value set in the present embodiment is 4600 times. And for a device with a spot welding speed of 20 times per hour, the alarm threshold may be set to 4960 times. An alarm threshold value is set for each device, so that the utilization rate of the electrode cap can be further improved.
As a preferred embodiment, the step S202 specifically includes:
s2021, calculating the number of spot welding times of each device per hour according to historical spot welding data of each device;
s2022, configuring an alarm threshold value of each device according to the number of spot welding times of each device per hour.
In the present embodiment, a preferable configuration of the alarm threshold is provided, which configures a reasonable alarm threshold according to the spot welding speed of each device.
As a preferred embodiment, the step S2022 specifically includes:
s20221, acquiring the maximum number of the spot welding times of the electrode cap and the early warning time of each device.
S20222, calculating the product of the number of spot welding times per hour of the equipment and the early warning time of the equipment.
S20223, subtracting the product corresponding to each device from the maximum number of spot welding times of the electrode cap to obtain the alarm threshold value of each device.
The advanced alarm time is set in the server by maintenance personnel.
The product corresponding to the equipment refers to the product of the number of spot welding times per hour of the equipment and the early warning time of the equipment. The advanced alarm time is set according to the quality requirement. For example, when the quality requirement is high, the alarm-in-advance time can be set to be a little longer, for example, 5 hours in advance, in order to ensure that the welding spots manufactured by the electrode caps have no quality problem. In essence, the advance alarm time and the number of spot welding times have a corresponding relation, but due to the fact that the spot welding speed of the equipment is different, the alarm threshold value is set through the number of spot welding times, and the alarm threshold value is difficult for maintenance personnel to set by converting the number of spot welding times into time.
The embodiment helps to utilize the electrode cap to the maximum extent on the premise of satisfying the production quality.
As a preferred embodiment, the location information includes information of a workshop area, a production line, and a work station. The position information of the embodiment consists of three parts, and the embodiment can help maintenance personnel to reasonably plan the route for replacing the electrode cap.
As a preferred embodiment, a plurality of alarm thresholds may be set for the apparatus, and then different process steps or different handlers may be selected according to the threshold that is exceeded by the number of spot welds of the electrode cap present in the apparatus. For example, a device may set two alarm thresholds, referred to as a first alarm threshold of 4500 times and a second alarm threshold of 4800 times. In this embodiment, when the number of spot welding times of the electrode cap of the equipment reaches 4500 times, the maintenance personnel is notified through the client. When the number of times of spot welding of the electrode cap of the equipment reaches 4800 times, the leadership of maintenance personnel is informed through the client side, or the alarm is marked as a danger alarm. Therefore, maintenance personnel can be prevented from omitting the electrode caps needing to be replaced, and corresponding emergency measures can be taken for remediation when the second alarm threshold value is reached.
Referring to fig. 2, the present embodiment discloses an electrode cap replacement alarm system, which includes:
and the collector is used for collecting the number of times of spot welding of the current electrode caps of a plurality of devices. In this embodiment, the collector is connected with a plurality of PLCs, and the PLCs can acquire spot welding data from spot welding equipment.
The server is used for detecting the number of times of spot welding of the current electrode caps of the plurality of devices according to the detection period; screening out equipment with the spot welding times exceeding an alarm threshold value as first equipment according to the spot welding times of the current electrode caps of the plurality of pieces of equipment; acquiring the position information of all first devices; and sending the position information of all the first devices to the client.
And the client is used for receiving and displaying the position information of the first equipment.
The server communicates with the client through facilities such as gateways and routing.
Referring to fig. 2, as a preferred embodiment, a database for storing historical spot welding data of each device and position information of each device is further included;
the server is further configured to:
acquiring historical spot welding data of a plurality of devices from a database;
and respectively configuring the alarm threshold value of each device according to the historical spot welding data of each device.
As a preferred embodiment, the configuring the alarm threshold of each device according to the historical spot welding data of each device specifically includes:
calculating the number of spot welding times of each device per hour according to the historical spot welding data of each device;
and configuring an alarm threshold value of each device according to the number of spot welding times of each device per hour.
As a preferred embodiment, the configuring the alarm threshold value of each device according to the number of spot welding times per hour of each device specifically includes:
acquiring the maximum spot welding times of the electrode cap and the early warning time of each device;
calculating the product of the number of spot welding times of the equipment per hour and the early warning time of the equipment;
and subtracting the product corresponding to each device from the maximum number of spot welding times of the electrode cap to obtain the alarm threshold value of each device.
As a preferred embodiment, the location information includes information of a workshop area, a production line, and a work station.
The system embodiment can achieve the same technical effects as the method embodiment.
The step numbers in the above method embodiments are set for convenience of illustration only, the order between the steps is not limited at all, and the execution order of each step in the embodiments can be adapted according to the understanding of those skilled in the art.
While the preferred embodiments of the present invention have been illustrated and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (4)
1. An electrode cap replacement alarm method is characterized by comprising the following steps:
acquiring historical spot welding data of a plurality of devices;
calculating the number of spot welding times of each device per hour according to the historical spot welding data of each device;
acquiring the maximum spot welding times of the electrode cap and the early warning time of each device;
calculating the product of the number of spot welding times of the equipment per hour and the early warning time of the equipment;
subtracting the product corresponding to each device from the maximum spot welding times of the electrode cap to obtain the alarm threshold value of each device;
detecting the number of spot welding times of the current electrode caps of a plurality of devices according to a detection period;
screening out equipment with the spot welding times exceeding an alarm threshold value as first equipment according to the spot welding times of the current electrode caps of the plurality of pieces of equipment;
acquiring the position information of all first devices;
and sending the position information of all the first devices to the client.
2. The electrode cap replacement alarm method according to claim 1, wherein: the position information comprises information of a workshop area, a production line and a station.
3. An electrode cap replacement alarm system, comprising:
the collector is used for collecting the number of spot welding times of the current electrode caps of a plurality of devices;
a database for storing historical spot welding data of each device and position information of each device;
the server is used for acquiring historical spot welding data of a plurality of devices from the database; calculating the number of spot welding times of each device per hour according to the historical spot welding data of each device; acquiring the maximum spot welding times of the electrode cap and the early warning time of each device; calculating the product of the number of spot welding times of the equipment per hour and the early warning time of the equipment; subtracting the product corresponding to each device from the maximum spot welding times of the electrode cap to obtain the alarm threshold value of each device; detecting the number of spot welding times of the current electrode caps of a plurality of devices according to a detection period; screening out equipment with the spot welding times exceeding an alarm threshold value as first equipment according to the spot welding times of the current electrode caps of the plurality of pieces of equipment; acquiring the position information of all first devices; sending the position information of all first equipment to a client;
and the client is used for receiving and displaying the position information of the first equipment.
4. The electrode cap replacement alarm system according to claim 3, wherein: the position information comprises information of a workshop area, a production line and a station.
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| CN113327407B (en) * | 2021-05-08 | 2022-07-26 | 广州明珞装备股份有限公司 | Electrode cap alarm value analysis method, system and device and storage medium |
| CN113409558B (en) * | 2021-05-08 | 2022-09-13 | 广州明珞装备股份有限公司 | Electrode cap batch replacement alarm method, system and device and storage medium |
| CN113362573B (en) * | 2021-05-08 | 2022-11-08 | 广州明珞装备股份有限公司 | Electrode cap alarm threshold optimization method, system and device and storage medium |
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