CN111496356A - Intelligent stud welding machine and intelligent welding method - Google Patents
Intelligent stud welding machine and intelligent welding method Download PDFInfo
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- CN111496356A CN111496356A CN202010360785.9A CN202010360785A CN111496356A CN 111496356 A CN111496356 A CN 111496356A CN 202010360785 A CN202010360785 A CN 202010360785A CN 111496356 A CN111496356 A CN 111496356A
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- 238000003466 welding Methods 0.000 title claims abstract description 152
- 238000000034 method Methods 0.000 title claims abstract description 13
- 238000006073 displacement reaction Methods 0.000 claims description 48
- 230000006698 induction Effects 0.000 claims description 24
- 230000002159 abnormal effect Effects 0.000 claims description 17
- 238000012544 monitoring process Methods 0.000 claims description 14
- 238000001514 detection method Methods 0.000 claims description 8
- 230000011664 signaling Effects 0.000 claims description 2
- 230000005540 biological transmission Effects 0.000 abstract description 6
- 230000006870 function Effects 0.000 description 4
- 230000004927 fusion Effects 0.000 description 4
- 239000000428 dust Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/20—Stud welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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- Mechanical Engineering (AREA)
- Resistance Welding (AREA)
- Arc Welding Control (AREA)
Abstract
An intelligent stud welding machine comprises a shell, a display screen, a main control board, a channel control board, a plurality of welding gun channel boards and a plurality of welding guns, wherein the main control board, the channel control board, the plurality of welding gun channel boards and the plurality of welding guns are arranged in the shell; the main control board is connected with the channel control board and the display screen, the plurality of welding gun channel boards are connected with the channel control board, and each welding gun is connected with one corresponding welding gun channel board; the shell comprises a plurality of four circumferential side plates, a bottom plate and a top plate, wherein the bottom plate is connected with the bottoms of the four circumferential side plates, and the top plate is connected with the tops of the four circumferential side plates; the display screen is arranged on one of the circumferential side plates; the middle part in the shell is vertically provided with a mounting plate, and the main control board is arranged on the mounting plate; the plurality of welding gun channel plates are arranged on the inner side of one circumferential side plate adjacent to the circumferential side plate provided with the display screen. Therefore, the reliability is increased, the cost is reduced, the data transmission is more stable, and the real-time performance is better. The invention also provides an intelligent welding method.
Description
Technical Field
The invention relates to the technical field of stud welding equipment, in particular to an intelligent stud welding machine and an intelligent welding method.
Background
The existing stud welding equipment does not have an intelligent control function and a data and waveform display function, if the functions of the existing stud welding equipment need to be added, an industrial computer and a display need to be connected externally, so that the industrial computer and the display are unstable in installation and fixation, meanwhile, data such as voltage, current and the like need to be transmitted to the industrial computer through a cable, and the data are displayed by the display after being sorted and analyzed by the industrial computer, so that certain delay exists in data transmission, the real-time performance is poor, the data transmission is unstable, and the cost of the industrial computer is high.
Disclosure of Invention
In view of the above, the present invention provides an intelligent stud welding machine and an intelligent welding method, which have the advantages of increased reliability, reduced cost, more stable data transmission and better real-time performance, so as to solve the above problems.
An intelligent stud welding machine comprises a shell, a display screen arranged on the side face of the shell, and a main control board, a channel control board, a plurality of welding gun channel boards and a plurality of welding guns which are arranged in the shell; the main control board is connected with the channel control board and the display screen, the plurality of welding gun channel boards are connected with the channel control board, and each welding gun is connected with one corresponding welding gun channel board; the shell comprises a plurality of four circumferential side plates, a bottom plate and a top plate, wherein the bottom plate is connected with the bottoms of the four circumferential side plates, and the top plate is connected with the tops of the four circumferential side plates; the display screen is arranged on one of the circumferential side plates; the middle part in the shell is vertically provided with a mounting plate, and the main control board is arranged on the mounting plate; the welding gun channel plates are arranged on the inner side of one circumferential side plate adjacent to the circumferential side plate provided with the display screen; the channel control board is arranged close to the main control board or the welding gun channel board; the intelligent stud welding machine also comprises a plurality of inductors for acquiring induction signals; the main control board is provided with a controller, a memory and a welding monitoring unit; the controller receives the induction signal and calculates calculation data according to the induction signal, and the induction signal and the calculation data are test data; the memory stores preset reference data, current reference waveforms, voltage reference waveforms and welding gun displacement reference waveforms; the welding monitoring unit compares the test data with the reference data and sends out a corresponding alarm signal when the test data exceeds the reference data; the welding monitoring unit correspondingly compares the current waveform, the voltage waveform, the welding gun displacement waveform with the current reference waveform, the voltage reference waveform and the welding gun displacement reference waveform, judges whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal or not, and sends out a corresponding alarm signal if the current waveform, the voltage waveform or the welding gun displacement waveform are abnormal.
Furthermore, a hook is arranged on the outer side of the circumferential side plate below the display screen.
Further, a first cover plate is arranged on the top of the mounting plate, the first cover plate is L-shaped, and the first cover plate covers the main control plate from the upper side and the outer side.
Further, a second cover plate is arranged on the top of the inner side of the circumferential side plate, the second cover plate is L-shaped, and the second cover plate covers the welding gun channel plate from the upper side and the outer side.
Furthermore, the inner sides of the circumferential side plate, the bottom plate and the top plate are also provided with wiring cover plates, and wiring grooves are formed in the wiring cover plates.
Furthermore, the device also comprises a plurality of rollers which are rotatably connected with the bottom plate.
Furthermore, the lifting device also comprises a plurality of lifting hooks, and the lifting hooks are connected with the top plate.
Furthermore, a current detection unit and a voltage detection unit are arranged on the channel control board, and a displacement sensor is arranged on the welding gun.
An intelligent welding method for welding by using the intelligent stud welding machine comprises the following steps: step S1: setting reference data, a current reference waveform, a voltage reference waveform and a welding gun displacement reference waveform; step S2: starting a welding gun for welding; step S3: detecting and calculating to obtain a plurality of test data; step S4: generating a current waveform, a voltage waveform and a welding gun displacement waveform according to the test data; step S5: comparing the test data with the corresponding reference data, and if the test data exceeds the corresponding reference data, entering step S7; step S6: correspondingly comparing the current waveform, the voltage waveform, the welding gun displacement waveform with the current reference waveform, the voltage reference waveform and the welding gun displacement reference waveform, judging whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal, and if the current waveform, the voltage waveform or the welding gun displacement waveform is abnormal, entering the step S7; step S7: and sending out an alarm signal or controlling the welding gun to stop working.
Compared with the prior art, the intelligent stud welding machine comprises a shell, a display screen arranged on the side face of the shell, and a main control board, a channel control board, a plurality of welding gun channel boards and a plurality of welding guns which are arranged in the shell; the main control board is connected with the channel control board and the display screen, the plurality of welding gun channel boards are connected with the channel control board, and each welding gun is connected with one corresponding welding gun channel board; the shell comprises a plurality of four circumferential side plates, a bottom plate and a top plate, wherein the bottom plate is connected with the bottoms of the four circumferential side plates, and the top plate is connected with the tops of the four circumferential side plates; the display screen is arranged on one of the circumferential side plates; the middle part in the shell is vertically provided with a mounting plate, and the main control board is arranged on the mounting plate; the welding gun channel plates are arranged on the inner side of one circumferential side plate adjacent to the circumferential side plate provided with the display screen; the channel control board is arranged close to the main control board or the welding gun channel board; the intelligent stud welding machine also comprises a plurality of inductors for acquiring induction signals; the main control board is provided with a controller, a memory and a welding monitoring unit; the controller receives the induction signal and calculates calculation data according to the induction signal, and the induction signal and the calculation data are test data; the memory stores preset reference data, current reference waveforms, voltage reference waveforms and welding gun displacement reference waveforms; the welding monitoring unit compares the test data with the reference data and sends out a corresponding alarm signal when the test data exceeds the reference data; the welding monitoring unit correspondingly compares the current waveform, the voltage waveform, the welding gun displacement waveform with the current reference waveform, the voltage reference waveform and the welding gun displacement reference waveform, judges whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal or not, and sends out a corresponding alarm signal if the current waveform, the voltage waveform or the welding gun displacement waveform are abnormal. Therefore, the reliability is increased, the cost is reduced, the data transmission is more stable, and the real-time performance is better. The invention also provides an intelligent welding method.
Drawings
Embodiments of the invention are described below with reference to the accompanying drawings, in which:
fig. 1 is a schematic perspective view of an intelligent stud welding machine provided by the invention.
FIG. 2 is an internal schematic view of the intelligent stud welding machine provided by the present invention.
FIG. 3 is a block diagram of a smart stud welder provided by the present invention.
Detailed Description
Specific embodiments of the present invention will be described in further detail below based on the drawings. It should be understood that the description herein of embodiments of the invention is not intended to limit the scope of the invention.
Referring to fig. 1 to 3, the intelligent stud welding machine provided by the present invention includes a housing 10, a display screen 20 disposed on a side surface of the housing 10, a plurality of rollers 30 rotatably disposed at a bottom of the housing 10, a plurality of hooks 40 disposed at a top of the housing 10, and a main control board 110, a channel control board 120, a plurality of welding gun channel boards 130 and a plurality of welding guns disposed in the housing 10.
The main control board 110 is connected to both the channel control board 120 and the display screen 20, and the plurality of welding gun channel boards 130 are connected to the channel control board 120. Each of the welding guns is connected to a corresponding one of the welding gun channel plates 130.
The housing 10 includes a plurality of four circumferential side plates 11, a bottom plate connecting the bottoms of the four circumferential side plates 11, and a top plate 12 connecting the tops of the four circumferential side plates 11.
A plurality of rollers 30 are rotatably connected to the base plate and a plurality of hooks 40 are connected to the top plate 12.
The display screen 20 is disposed on one of the circumferential side plates 11.
A hook 111 is disposed on the outer side of the circumferential side plate 11 below the display screen 20 for hanging an operating handle connected to the main control panel 110.
The main control board 110 is disposed on the mounting plate 50, and the first cover plate 60 is further disposed on the top of the mounting plate 50, the first cover plate 60 is L-shaped and covers the upper side and the outer side of the main control board 110. the first cover plate 60 can prevent dust or foreign materials from being accumulated on the main control board 110.
The plurality of torch path plates 130 are disposed inside one of the circumferential side plates 11 adjacent to the circumferential side plate 11 on which the display screen 20 is mounted.
The passageway control plate 120 may be mounted on the mounting plate 50 or near the torch passageway plate 130.
The second cover plate 70 is provided on the top of the inner side of the circumferential side plate 11, and the second cover plate 70 has a shape of L, and covers the upper and outer sides of the welding torch passageway plate 130. the second cover plate 70 prevents dust or foreign materials from being accumulated on the welding torch passageway plate 130.
The inner sides of the circumferential side plates 11, the bottom plate and the top plate 12 are further provided with wiring cover plates 80, wiring grooves are formed in the wiring cover plates 80, and cables among the electronic components are located in the wiring grooves of the wiring cover plates 80, so that the wiring is simpler and more tidy, and the cables are prevented from being wound.
The torch passageway plate 130 is used to drive the torch.
The channel control board 120 is used for respectively controlling the plurality of welding gun channel boards 130 to work, a current detection unit and a voltage detection unit are arranged on the channel control board 120, and a displacement sensor is arranged on the welding gun.
The main control board 110 is provided with a controller, a memory and a welding monitoring unit. The controller has a timing function.
The memory stores reference data such as a preset current reference value, an average current reference value, a voltage reference value, a short-circuit time reference range, a fusion depth reference range and the like, as well as a current reference waveform, a voltage reference waveform and a welding gun displacement reference waveform.
The controller receives a current induction value of the current detection unit, a voltage induction value of the voltage detection unit and a displacement induction value of the displacement sensor, calculates an average current value, short-circuit welding time and other calculation data according to the induction signals, and the induction signals and the calculation data are test data. The controller also generates a current waveform, a voltage waveform and a welding gun displacement waveform according to the test data.
The welding monitoring unit compares the test data such as the current induction value, the voltage induction value, the displacement induction value, the average current value, the short-circuit welding time and the like with the reference data such as the current reference value, the voltage reference value, the penetration reference range, the average current reference value, the short-circuit time reference range and the like respectively, and if the test data exceeds the reference data, the welding monitoring unit sends out a corresponding alarm signal.
If the current induction value does not reach an initial current reference value in the arc discharge stage, the arc is abnormal; if the voltage induction value does not reach the voltage reference value, the voltage is abnormal; if the average current value does not reach the average current reference value, the current value is lower; if the short-circuit welding time is longer than the upper limit of the short-circuit time reference range, the short-circuit welding is too long, and if the short-circuit welding time is shorter than the lower limit of the short-circuit time reference range, the short-circuit welding is over-end; the sudden drop of the voltage induction value is a voltage drop; and if the displacement induction value is lower than the lower limit of the fusion depth reference range, the fusion depth is too shallow.
The welding monitoring unit compares the current waveform, the voltage waveform and the welding gun displacement waveform with a current reference waveform, a voltage reference waveform and a welding gun displacement reference waveform respectively to judge whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal. And if the current waveform, the voltage waveform or the welding gun displacement waveform is abnormal, the welding monitoring unit sends out a corresponding alarm signal.
The display screen 20 displays test data, reference data, current waveforms, voltage waveforms, torch displacement waveforms, and alarm signals.
The invention also provides an intelligent welding method, which comprises the following steps:
step S1: and setting reference data such as a current reference value, an average current reference value, a voltage reference value, a short-circuit time reference range, a fusion depth reference range and the like, as well as a current reference waveform, a voltage reference waveform and a welding gun displacement reference waveform.
Step S2: and starting a welding gun for welding.
Step S3: in the welding process, sensing signals such as a current sensing value, a voltage sensing value and a displacement sensing value are detected, and calculation data such as an average current value and short-circuit welding time are calculated according to the sensing signals, wherein the sensing signals and the calculation data are test data.
Step S4: and generating a current waveform, a voltage waveform and a welding gun displacement waveform according to the test data.
Step S5: the test data and the reference data are correspondingly compared, and if the test data exceeds the corresponding reference data, the process proceeds to step S7.
Step S6: and correspondingly comparing the current waveform, the voltage waveform, the welding gun displacement waveform with the current reference waveform, the voltage reference waveform and the welding gun displacement reference waveform, judging whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal, and if the current waveform, the voltage waveform or the welding gun displacement waveform is abnormal, entering the step S7. Whether the waveform is abnormal or not is generally determined according to the deformation of the actual waveform relative to the reference waveform, and the waveform determination is well known in the art and will not be described herein.
Step S7: sending out an alarm signal to remind a user; and the welding gun can be controlled to stop working.
Compared with the prior art, the intelligent stud welding machine comprises a shell 10, a display screen 20 arranged on the side surface of the shell 10, and a main control board 110, a channel control board 120, a plurality of welding gun channel boards 130 and a plurality of welding guns which are arranged in the shell 10; the main control board 110 is connected with both the channel control board 120 and the display screen 20, a plurality of welding gun channel boards 130 are connected with the channel control board 120, and each welding gun is connected with a corresponding welding gun channel board 130; the shell 10 comprises a plurality of four circumferential side plates 11, a bottom plate connected with the bottoms of the four circumferential side plates 11 and a top plate 12 connected with the tops of the four circumferential side plates 11; the display screen 20 is arranged on one of the circumferential side plates 11; a mounting plate 50 is vertically arranged in the middle of the inside of the shell 10, and the main control plate 110 is arranged on the mounting plate 50; the plurality of welding gun channel plates 130 are arranged on the inner side of one circumferential side plate 11 adjacent to the circumferential side plate 11 on which the display screen 20 is mounted; the passageway control board 120 is disposed adjacent to the main control board 110 or the torch passageway board 130. Therefore, the reliability is increased, the cost is reduced, the data transmission is more stable, and the real-time performance is better. The invention also provides an intelligent welding method.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the scope of the present invention, and any modifications, equivalents or improvements that are within the spirit of the present invention are intended to be covered by the following claims.
Claims (9)
1. The utility model provides an intelligence stud welding machine which characterized in that: the welding gun device comprises a shell, a display screen arranged on the side surface of the shell, and a main control board, a channel control board, a plurality of welding gun channel boards and a plurality of welding guns which are arranged in the shell; the main control board is connected with the channel control board and the display screen, the plurality of welding gun channel boards are connected with the channel control board, and each welding gun is connected with one corresponding welding gun channel board; the shell comprises a plurality of four circumferential side plates, a bottom plate and a top plate, wherein the bottom plate is connected with the bottoms of the four circumferential side plates, and the top plate is connected with the tops of the four circumferential side plates; the display screen is arranged on one of the circumferential side plates; the middle part in the shell is vertically provided with a mounting plate, and the main control board is arranged on the mounting plate; the welding gun channel plates are arranged on the inner side of one circumferential side plate adjacent to the circumferential side plate provided with the display screen; the channel control board is arranged close to the main control board or the welding gun channel board; the intelligent stud welding machine also comprises a plurality of inductors for acquiring induction signals; the main control board is provided with a controller, a memory and a welding monitoring unit; the controller receives the induction signal and calculates calculation data according to the induction signal, and the induction signal and the calculation data are test data; the memory stores preset reference data, current reference waveforms, voltage reference waveforms and welding gun displacement reference waveforms; the welding monitoring unit compares the test data with the reference data and sends out a corresponding alarm signal when the test data exceeds the reference data; the welding monitoring unit correspondingly compares the current waveform, the voltage waveform, the welding gun displacement waveform with the current reference waveform, the voltage reference waveform and the welding gun displacement reference waveform, judges whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal or not, and sends out a corresponding alarm signal if the current waveform, the voltage waveform or the welding gun displacement waveform are abnormal.
2. The smart stud welder of claim 1, wherein: and a hook is arranged on the outer side of the circumferential side plate below the display screen.
3. The intelligent stud welding machine according to claim 1, wherein a first cover plate is arranged on the top of the mounting plate, the first cover plate is L-shaped, and the first cover plate covers the main control plate from the upper side and the outer side.
4. The intelligent stud welder according to claim 1, wherein a second cover plate is arranged on the top of the inner side of the circumferential side plate, the second cover plate is L-shaped, and the second cover plate covers the welding gun channel plate from the upper side and the outer side.
5. The smart stud welder of claim 1, wherein: the inner sides of the circumferential side plates, the bottom plate and the top plate are also provided with wiring cover plates, and wiring grooves are formed in the wiring cover plates.
6. The smart stud welder of claim 1, wherein: the device also comprises a plurality of rollers which are rotatably connected with the bottom plate.
7. The smart stud welder of claim 1, wherein: the lifting hook is connected with the top plate.
8. The smart stud welder of claim 1, wherein: the channel control board is provided with a current detection unit and a voltage detection unit, and the welding gun is provided with a displacement sensor.
9. An intelligent welding method for welding by using the intelligent stud welding machine according to any one of claims 1-8, characterized in that: the method comprises the following steps:
step S1: setting reference data, a current reference waveform, a voltage reference waveform and a welding gun displacement reference waveform;
step S2: starting a welding gun for welding;
step S3: detecting and calculating to obtain a plurality of test data;
step S4: generating a current waveform, a voltage waveform and a welding gun displacement waveform according to the test data;
step S5: comparing the test data with the corresponding reference data, and if the test data exceeds the corresponding reference data, entering step S7;
step S6: correspondingly comparing the current waveform, the voltage waveform, the welding gun displacement waveform with the current reference waveform, the voltage reference waveform and the welding gun displacement reference waveform, judging whether the current waveform, the voltage waveform and the welding gun displacement waveform are abnormal, and if the current waveform, the voltage waveform or the welding gun displacement waveform is abnormal, entering the step S7;
step S7: and sending out an alarm signal or controlling the welding gun to stop working.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010360785.9A CN111496356B (en) | 2020-04-30 | 2020-04-30 | Intelligent stud welding machine and intelligent welding method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010360785.9A CN111496356B (en) | 2020-04-30 | 2020-04-30 | Intelligent stud welding machine and intelligent welding method |
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| CN111496356A true CN111496356A (en) | 2020-08-07 |
| CN111496356B CN111496356B (en) | 2024-08-02 |
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| Publication number | Publication date |
|---|---|
| CN111496356B (en) | 2024-08-02 |
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