CN111975169A - Automatic intelligent control welding process and intelligent control system thereof - Google Patents
Automatic intelligent control welding process and intelligent control system thereof Download PDFInfo
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- CN111975169A CN111975169A CN201910429000.6A CN201910429000A CN111975169A CN 111975169 A CN111975169 A CN 111975169A CN 201910429000 A CN201910429000 A CN 201910429000A CN 111975169 A CN111975169 A CN 111975169A
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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
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0953—Monitoring or automatic control of welding parameters using computing means
Abstract
The invention relates to an automatic intelligent control welding process and a welding control system. The intelligent touch screen type man-machine interface operation mode is adopted, so that the intelligent functions of one-to-one binding of welding parameters and welding seam information, real-time display of process parameter curves, authorized operation of workers, parameter alarm, shutdown and the like are realized, and the absolute control of the welding process is ensured. Therefore, the welding process is effectively controlled within reasonable technical parameters in real time, the qualification rate of products is effectively ensured, potential safety hazards are eliminated to a great extent, and site construction accidents are prevented.
Description
Technical Field
The invention relates to the field of workpiece welding, in particular to an automatic intelligent control welding process and an intelligent control system thereof.
Background
The wind power tower barrel is a tower pole of wind power generation, and mainly plays a supporting role in a wind generating set and absorbs the vibration of the set. The wind power tower cylinder is composed of tower sections, and each tower section is formed by welding rolled steel plates. In the production process of the wind power tower, the welding accuracy and the quality directly affect the quality and the service life of the wind power tower.
Welding, also known as fusion, is a manufacturing process and technique for joining metals or other thermoplastic materials, such as plastics, by means of heat, high temperature or pressure. The traditional welding process is controlled by a mechanical operation panel, the functions of matching issuing of welding process parameters, identity recognition, welding seam information binding and the like cannot be carried out, and only the basic welding function can be realized. The actions of field constructors are not controlled, and partial field operators change posts privately for convenience, so that unqualified operators enter a field to operate and control a welding process, unqualified products can be produced, and field construction safety accidents can be caused even. Most importantly, in order to improve the working efficiency, a plurality of field operators can privately accelerate the welding process by increasing the welding temperature and the welding speed, and even the work piece is not preheated to a certain temperature, the work is started. Although the welded seam has no difference on the surface and can be detected by a conventional nondestructive detection means, after the product is put into production, the welded seam is easy to generate fatal destructive defects such as cracks. The reason is as follows: in the welding process, welding is not carried out according to welding process parameters, so that the microstructure of a welding line has metal defects of coarse grains, hardening groups and the like, and the welding effect cannot meet the design requirement. Particularly for the welding of thick plates, delayed cracks are easy to generate on welding seams of products produced by welding operation without set parameters after the products are put into operation, and serious hidden troubles are caused for the structural safety of the products.
For example: a batch of offshore wind power single tubular pile products produced by a certain domestic company are found to have tiny delayed cracks during nondestructive testing retest of a construction process after delivery to a client, and the reason is that when field construction personnel carry out welding operation, welding construction is not carried out according to the set welding temperature and the welding speed, but the welding process is accelerated by increasing the welding temperature and the welding speed privately. The produced product has poor gold body structure of martensite, widmanstatten and the like at the defect position under the sampling inspection of a microscope, and thus delayed cracks are caused.
Therefore, in view of the above problems in the prior art, it is an object of the present invention to provide a welding method and a welding system capable of ensuring an absolutely controlled welding process and effectively ensuring welding quality.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides an automatic intelligent control welding process and an intelligent control system thereof, which can effectively solve the problems in the prior art.
The technical scheme of the invention is as follows:
an automatic intelligent control welding process comprises the following steps:
s1, installing a speed measuring device on a roller frame for rolling the workpiece, and arranging an infrared thermometer for detecting the temperature of the workpiece at a position 75mm away from the center of the welding bead and parallel to the welding spot; adding a plurality of peripheral devices on welding equipment, and respectively connecting the welding equipment and the peripheral devices to a PLC (programmable logic controller) through communication cables, wherein the PLC is connected to a man-machine operation system;
S2, placing the welding workpiece on a roller frame, and storing welding process parameters required by the corresponding category of the welding workpiece as preparation parameters into a man-machine operation system for recording according to a welding process;
s3, judging whether the worker is authorized by the peripheral equipment, and after the worker is authorized by the peripheral equipment, inputting the type of the workpiece to be welded by the worker through a man-machine operation system, and issuing corresponding welding preparation parameters by the man-machine operation system according to the type of the workpiece to be welded;
s4, according to the preparation parameters sent by the PLC, the staff adjusts the parameters of the welding equipment and prepares for welding, and before welding, the workpiece to be welded is preheated for 1 hour to reach more than 100 ℃;
s5, manually operating welding equipment to weld corresponding workpieces, and transmitting real-time parameters actually generated in the welding process to a PLC (programmable logic controller) by peripheral equipment in the welding process;
s6, the PLC receives real-time parameters of the welding process in real time, compares and analyzes the real-time parameters with the welding parameters issued correspondingly in real time, if the real-time parameters exceed the range values of the preparation parameters issued correspondingly, the PLC controls the welding equipment to stop the welding process, and sends an alarm instruction to prompt an operator to adjust the parameters of the welding equipment again until the parameters detected by the peripheral equipment in real time accord with the preparation parameter values issued by the PLC, and then continues the welding process;
And S7, repeating the steps S5-6 until the welding operation of the workpieces is finished, and sending the workpieces for inspection.
Further, the peripheral equipment contains temperature sensor, speedtransmitter, identification device, temperature sensor, speedtransmitter set up on the welder's welder, identification device can be one of them for face recognition device, fingerprint identification device, RFID electronic tags identification device.
Further, the speed measuring device comprises a speed measuring wheel connected to the roller frame, the speed measuring wheel is provided with an encoder, and the encoder is connected to the man-machine operation system.
Further, the preliminary parameters in step S2-4 correspond to the welding workpiece type by the following relationship: when the thickness of the workpiece is 10-30 mm, the temperature is controlled at 100-200 ℃, the welding current is 500-600 amperes, the arc voltage is 28-34 volts, the welding speed is 350-500mm/min, and the welding frequency is 2-10 times; when the thickness of the workpiece is 30-150mm, the temperature is controlled at 100-200 ℃, the welding current is 500-700 amperes, the arc voltage is 28-35 volts, the welding speed is 350-1000m m/min, and the welding frequency is more than 10 times.
The welding equipment is provided with a plurality of peripheral equipment, the peripheral equipment is connected to the PLC through the corresponding controller, and the PLC is connected to the corresponding human-machine operation system through a network.
Further, the welding equipment comprises a welding machine for welding a workpiece and a power supply for driving the welding machine, wherein the welding machine and the power supply are respectively connected to the PLC.
Further, the peripheral equipment comprises a temperature sensor, a speed sensor and an identity recognition device, wherein the temperature sensor and the speed sensor are arranged on a welding gun of the welding machine.
Further, the identification device may be one of a face recognition device, a fingerprint recognition device, and an RFID tag recognition device.
Further, the human-machine operation system comprises an industrial tablet computer running software communicating with the peripheral device and the PLC controller.
The invention has the advantages that:
the intelligent touch screen type man-machine interface operation mode is adopted, so that the intelligent functions of one-to-one binding of welding parameters and welding seam information, real-time display of process parameter curves, authorized operation of workers, parameter alarm, shutdown and the like are realized, and the absolute control of the welding process is ensured. Therefore, the welding process is effectively controlled within reasonable technical parameters in real time, the qualification rate of products is effectively ensured, potential safety hazards are eliminated to a great extent, and site construction accidents are prevented.
Drawings
Fig. 1 is a schematic structural diagram of a system according to a third embodiment of the present invention.
Detailed Description
To facilitate understanding of those skilled in the art, the structure of the present invention will now be described in further detail by way of examples in conjunction with the accompanying drawings:
the first embodiment is as follows:
the production date of the wind power tower cylinder produced by me department is as follows: 2018-10.26-2018.12.9, and the thickness of the workpiece is as follows: 21-64 mm.
An automatic intelligent control welding process comprises the following steps:
s1, installing a speed measuring device on a roller frame for rolling the workpiece, and arranging an infrared thermometer for detecting the temperature of the workpiece at a position 75mm away from the center of the welding bead and parallel to the welding spot; adding a plurality of peripheral devices on welding equipment, and respectively connecting the welding equipment and the peripheral devices to a PLC (programmable logic controller) through communication cables, wherein the PLC is connected to a man-machine operation system;
s2, placing the welding workpiece on a roller frame, and storing welding process parameters required by the corresponding category of the welding workpiece as preparation parameters into a man-machine operation system for recording according to a welding process;
s3, judging whether the worker is authorized by the peripheral equipment, and after the worker is authorized by the peripheral equipment, inputting the type of the workpiece to be welded by the worker through a man-machine operation system, and issuing corresponding welding preparation parameters by the man-machine operation system according to the type of the workpiece to be welded;
S4, according to the preparation parameters sent by the PLC, the staff adjusts the parameters of the welding equipment and prepares for welding, and before welding, the workpiece to be welded is preheated for 1 hour to reach more than 100 ℃;
s5, manually operating welding equipment to weld corresponding workpieces, and transmitting real-time parameters actually generated in the welding process to a PLC (programmable logic controller) by peripheral equipment in the welding process;
s6, the PLC receives real-time parameters of the welding process in real time, compares and analyzes the real-time parameters with the welding parameters issued correspondingly in real time, if the real-time parameters exceed the range values of the preparation parameters issued correspondingly, the PLC controls the welding equipment to stop the welding process, and sends an alarm instruction to prompt an operator to adjust the parameters of the welding equipment again until the parameters detected by the peripheral equipment in real time accord with the preparation parameter values issued by the PLC, and then continues the welding process;
and S7, repeating the steps S5-6 until the welding operation of the workpieces is finished, and sending the workpieces for inspection.
Further, the peripheral equipment contains temperature sensor, speedtransmitter, identification device, temperature sensor, speedtransmitter set up on the welder's welder, identification device can be one of them for face recognition device, fingerprint identification device, RFID electronic tags identification device.
Further, the speed measuring device comprises a speed measuring wheel connected to the roller frame, the speed measuring wheel is provided with an encoder, and the encoder is connected to the man-machine operation system.
Further, the preliminary parameters in step S2-4 correspond to the welding workpiece type by the following relationship: when the thickness of the workpiece is 10-30 mm, the temperature is controlled at 100-200 ℃, the welding current is 500-600 amperes, the arc voltage is 28-34 volts, the welding speed is 350-500mm/min, and the welding frequency is 2-10 times; when the thickness of the workpiece is 30-150mm, the temperature is controlled at 100-200 ℃, the welding current is 500-700 amperes, the arc voltage is 28-35 volts, the welding speed is 350-1000m m/min, and the welding frequency is more than 10 times.
Through the above operation steps, the abnormal number of the wind power tower barrels of the batch number produced by me department is 2, and the qualification rate is 99.5%:
example two:
the production date of the wind power tower cylinder produced by me department is as follows: 2018.9.12-2018.12.13, the workpiece thickness is: 22-65 mm.
An automatic intelligent control welding process comprises the following steps:
s1, installing a speed measuring device on a roller frame for rolling the workpiece, and arranging an infrared thermometer for detecting the temperature of the workpiece at a position 75mm away from the center of the welding bead and parallel to the welding spot; adding a plurality of peripheral devices on welding equipment, and respectively connecting the welding equipment and the peripheral devices to a PLC (programmable logic controller) through communication cables, wherein the PLC is connected to a man-machine operation system;
S2, placing the welding workpiece on a roller frame, and storing welding process parameters required by the corresponding category of the welding workpiece as preparation parameters into a man-machine operation system for recording according to a welding process;
s3, judging whether the worker is authorized by the peripheral equipment, and after the worker is authorized by the peripheral equipment, inputting the type of the workpiece to be welded by the worker through a man-machine operation system, and issuing corresponding welding preparation parameters by the man-machine operation system according to the type of the workpiece to be welded;
s4, according to the preparation parameters sent by the PLC, the staff adjusts the parameters of the welding equipment and prepares for welding, and before welding, the workpiece to be welded is preheated for 1 hour to reach more than 100 ℃;
s5, manually operating welding equipment to weld corresponding workpieces, and transmitting real-time parameters actually generated in the welding process to a PLC (programmable logic controller) by peripheral equipment in the welding process;
s6, the PLC receives real-time parameters of the welding process in real time, compares and analyzes the real-time parameters with the welding parameters issued correspondingly in real time, if the real-time parameters exceed the range values of the preparation parameters issued correspondingly, the PLC controls the welding equipment to stop the welding process, and sends an alarm instruction to prompt an operator to adjust the parameters of the welding equipment again until the parameters detected by the peripheral equipment in real time accord with the preparation parameter values issued by the PLC, and then continues the welding process;
And S7, repeating the steps S5-6 until the welding operation of the workpieces is finished, and sending the workpieces for inspection.
Further, the peripheral equipment contains temperature sensor, speedtransmitter, identification device, temperature sensor, speedtransmitter set up on the welder's welder, identification device can be one of them for face recognition device, fingerprint identification device, RFID electronic tags identification device.
Further, the speed measuring device comprises a speed measuring wheel connected to the roller frame, the speed measuring wheel is provided with an encoder, and the encoder is connected to the man-machine operation system.
Further, the preliminary parameters in step S2-4 correspond to the welding workpiece type by the following relationship: when the thickness of the workpiece is 10-30 mm, the temperature is controlled at 100-200 ℃, the welding current is 500-600 amperes, the arc voltage is 28-34 volts, the welding speed is 350-500mm/min, and the welding frequency is 2-10 times; when the thickness of the workpiece is 30-150mm, the temperature is controlled at 100-200 ℃, the welding current is 500-700 amperes, the arc voltage is 28-35 volts, the welding speed is 350-1000m m/min, and the welding frequency is more than 10 times.
Example three:
referring to fig. 1, an automatic intelligent control welding control system comprises a PLC controller, a human-machine operation system, and a welding device, wherein a plurality of peripheral devices are disposed on the welding device, the peripheral devices are connected to the PLC controller through corresponding controllers, and the PLC controller is connected to the corresponding human-machine operation system through a network.
Further, the welding equipment comprises a welding machine for welding a workpiece and a power supply for driving the welding machine, wherein the welding machine and the power supply are respectively connected to the PLC.
Further, the peripheral equipment comprises a temperature sensor, a speed sensor and an identity recognition device, wherein the temperature sensor and the speed sensor are arranged on a welding gun of the welding machine.
Further, the identification device may be one of a face recognition device, a fingerprint recognition device, and an RFID tag recognition device.
Further, the human-machine operation system comprises an industrial tablet computer running software communicating with the peripheral device and the PLC controller.
The above description is only a preferred embodiment of the present invention, and all equivalent changes and modifications made in accordance with the claims of the present invention should be covered by the present invention.
Claims (9)
1. An automatic intelligent control welding process is characterized in that: comprises the following steps:
s1, installing a speed measuring device on a roller frame for rolling the workpiece, and arranging an infrared thermometer for detecting the temperature of the workpiece at a position 75mm away from the center of the welding bead and parallel to the welding spot; adding a plurality of peripheral devices on welding equipment, and respectively connecting the welding equipment and the peripheral devices to a PLC (programmable logic controller) through communication cables, wherein the PLC is connected to a man-machine operation system;
S2, placing the welding workpiece on a roller frame, and storing welding process parameters required by the corresponding category of the welding workpiece as preparation parameters into a man-machine operation system for recording according to a welding process;
s3, judging whether the worker is authorized by the peripheral equipment, and after the worker is authorized by the peripheral equipment, inputting the type of the workpiece to be welded by the worker through a man-machine operation system, and issuing corresponding welding preparation parameters by the man-machine operation system according to the type of the workpiece to be welded;
s4, according to the preparation parameters sent by the PLC, the staff adjusts the parameters of the welding equipment and prepares for welding, and before welding, the workpiece to be welded is preheated for 1 hour to reach more than 100 ℃;
s5, manually operating welding equipment to weld corresponding workpieces, and transmitting real-time parameters actually generated in the welding process to a PLC (programmable logic controller) by peripheral equipment in the welding process;
s6, the PLC receives real-time parameters of the welding process in real time, compares and analyzes the real-time parameters with the welding parameters issued correspondingly in real time, if the real-time parameters exceed the range values of the preparation parameters issued correspondingly, the PLC controls the welding equipment to stop the welding process, and sends an alarm instruction to prompt an operator to adjust the parameters of the welding equipment again until the parameters detected by the peripheral equipment in real time accord with the preparation parameter values issued by the PLC, and then continues the welding process;
And S7, repeating the steps S5-6 until the welding operation of the workpieces is finished, and sending the workpieces for inspection.
2. The automated and intelligently controlled welding process of claim 1, wherein: the peripheral equipment comprises a temperature sensor, a speed sensor and an identity recognition device, wherein the temperature sensor and the speed sensor are arranged on a welding gun of the welding machine, and the identity recognition device can be one of a face recognition device, a fingerprint recognition device and an RFID electronic tag recognition device.
3. The automated and intelligently controlled welding process of claim 2, wherein: the speed measuring device comprises a speed measuring wheel connected to the roller frame, the speed measuring wheel is provided with an encoder, and the encoder is connected to the man-machine operation system.
4. The automated and intelligently controlled welding process of claim 1, wherein: the correspondence relationship between the preparatory parameters and the welding workpiece type in step S2-4 is: when the thickness of the workpiece is 10-30 mm, the temperature is controlled at 100-200 ℃, the welding current is 500-600 amperes, the arc voltage is 28-34 volts, the welding speed is 350-500mm/min, and the welding frequency is 2-10 times; when the thickness of the workpiece is 30-150mm, the temperature is controlled at 100-200 ℃, the welding current is 500-700 amperes, the arc voltage is 28-35 volts, the welding speed is 350-1000m m/min, and the welding frequency is more than 10 times.
5. The utility model provides an automatic intelligent control welding control system which characterized in that: the welding system comprises a PLC (programmable logic controller), a man-machine operation system and welding equipment, wherein a plurality of peripheral equipment are arranged on the welding equipment, the peripheral equipment is connected to the PLC through a corresponding controller, and the PLC is connected to the corresponding man-machine operation system through a network.
6. The automated intelligent control welding control system of claim 5, wherein: the welding equipment comprises a welding machine for welding a workpiece and a power supply for driving the welding machine, wherein the welding machine and the power supply are respectively connected to the PLC.
7. The automated intelligent control welding control system of claim 5, wherein: the peripheral equipment comprises a temperature sensor, a speed sensor and an identity recognition device, wherein the temperature sensor and the speed sensor are arranged on a welding gun of the welding machine.
8. The automated intelligent control welding control system of claim 7, wherein: the identity recognition device can be one of a face recognition device, a fingerprint recognition device and an RFID electronic tag recognition device.
9. The automated intelligent control welding control system of claim 5, wherein: the human-machine operation system comprises an industrial tablet computer, and the industrial tablet computer runs software which is communicated with the peripheral equipment and the PLC.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910429000.6A CN111975169A (en) | 2019-05-22 | 2019-05-22 | Automatic intelligent control welding process and intelligent control system thereof |
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| CN201910429000.6A CN111975169A (en) | 2019-05-22 | 2019-05-22 | Automatic intelligent control welding process and intelligent control system thereof |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113245667A (en) * | 2021-05-12 | 2021-08-13 | 兰州兰石集团有限公司 | Dynamic control method for welding technological parameters of pressure vessel |
| CN114012211A (en) * | 2021-10-13 | 2022-02-08 | 无锡金田电子有限公司 | High-altitude automatic welding equipment and method |
-
2019
- 2019-05-22 CN CN201910429000.6A patent/CN111975169A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113245667A (en) * | 2021-05-12 | 2021-08-13 | 兰州兰石集团有限公司 | Dynamic control method for welding technological parameters of pressure vessel |
| CN114012211A (en) * | 2021-10-13 | 2022-02-08 | 无锡金田电子有限公司 | High-altitude automatic welding equipment and method |
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