CN112427776B - Hull welding man-hour measuring device and method - Google Patents
Hull welding man-hour measuring device and method Download PDFInfo
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- CN112427776B CN112427776B CN202011262549.XA CN202011262549A CN112427776B CN 112427776 B CN112427776 B CN 112427776B CN 202011262549 A CN202011262549 A CN 202011262549A CN 112427776 B CN112427776 B CN 112427776B
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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
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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Abstract
The invention discloses a device and a method for measuring welding hours of a ship body, comprising the following steps: a plurality of field devices for calculating weld hours, the field devices comprising: the signal reading unit reads real-time welding process parameters in a wired transmission mode; a bus module; the signal processing unit is connected with an edge side Internet of things gateway, the edge side Internet of things gateway is connected with the MQTT server through a wireless transceiving module, the signal processing unit is connected with the bus module through a GPIO port, and the edge side Internet of things gateway is in wired connection with the signal reading unit through the bus module; the signal reading unit transmits the real-time welding process parameters to the edge side internet of things gateway through the first signal line, and the signal reading unit converts the real-time welding process parameters into high-level signals in an interruption mode, wherein the high-level signals comprise transient values of parameters such as current and voltage. The invention improves the accuracy and the working efficiency of the actual welding working hour measurement of ship manufacturing enterprises.
Description
Technical Field
The invention relates to the field of welding of hulls, which is applied to the process of manufacturing ships, in particular to a device and a method for measuring welding hours of a hull.
Background
Large metal structural products, such as intermediate products of ship hull sections, occupy a very important position in ship manufacturing. In the production and construction of the products, the electric welder mainly welds all parts by various types of electric welders to form a whole finally, so that the welding becomes the main process of manufacturing the ship body.
When a welder is measured, a signal acquisition device is usually arranged in an area near or inside the electric welder, and a server is arranged to be connected with the electric welder, so that the server can conveniently collect and manage the working conditions of all the electric welders. In the prior art, the electric welding machines are connected with the signal acquisition devices and the server in a wireless mode, the wireless connection has the advantage of being convenient for a welder to operate, but for a ship body with a large and complex size, any construction site is required to be covered with a wireless network, and otherwise data can be lost due to network interruption. Moreover, in the prior art, the working parameters of the electric welding machine are usually acquired in real time, and the process parameters of the electric welding machine during working are more, which mainly comprises: the device comprises a processing module, an information reading module, a signal transmission module, a protection gas flow rate, a welding wire feeding speed and the like, so that the information reading module is required to quickly transmit a large amount of data acquired in real time to the processing module, and higher requirements are provided for the signal transmission speed and the information processing speed of the processing module.
On the other hand, when the welding working hours of the ship body are collected, the current and the voltage of the electric welding machine are measured by a singlechip generally; transmitting the acquired data to a desktop computer through a cable; and estimating actual working hours by the desktop computer according to the wave crest and the wave trough, and storing the actual working hours in the database server for a subsequent information system to use. In the actual use process, the acquisition method needs to modify the existing electric welding machine, and a measurement circuit and an equipment protection circuit are added, so that the problems of long modification period, high cost, poor reusability and difficult maintenance and debugging exist (about 10000 pieces of equipment with different models are available in medium-sized ship enterprises);
communication cables need to be laid on a construction site, and the requirements on the site electrical use environment are high and the usability is poor; the acquisition process is not cooperated with the design and the process (workers need to adjust current and voltage according to the process requirements), and the error of an estimation result is large; when the working hours are estimated, the welding needs to be waited for to be completed, and a third-party software system needs to query a database in a polling mode to acquire the states (starting, shutting down, processing and waiting) of the electric welding machine, so that the efficiency is low.
At present, the on-site electric welding machine layout is more dispersed, and in order to realize the signal acquisition of electric welding machine, use wireless transmission mode to carry out man-hour analysis with the signal transmission who gathers usually to the server, nevertheless at the electric welding machine during operation, the outer discharge current is great, causes very big interference to wireless signal's transmission for the signal of telecommunication distortion that the server received can't effective analysis restore out true electric welding machine operating current, leads to man-hour calculation deviation.
Disclosure of Invention
The invention aims to solve the problem that in the prior art, the electric welding machine is wirelessly connected with a signal acquisition device, and when the electric welding machine works in an uncovered area of a wireless network, the signal acquisition device cannot acquire welding parameters in real time, so that the statistics of welding working hours are inaccurate.
The invention also aims to solve the problems of large real-time data acquisition quantity and high requirements on the signal transmission speed and the information processing speed of the processing module in the prior art, and provides a device and a method for measuring the welding working hours of the ship body.
The invention also aims to reduce the interference of the electric welding machine on wireless signal transmission during working and improve the accuracy of signal transmission.
To achieve these objects and other advantages in accordance with the present invention, there is provided a ship hull welding man-hour measuring device, including: a field device for calculating welding man-hours, be provided with one on every electric welding machine field device, its characterized in that field device includes:
the signal reading unit reads real-time welding process parameters in a wired transmission mode;
the bus module is provided with a TTL interface and a USB interface, and the TTL interface of the bus module is connected with the signal reading unit;
the edge side Internet of things gateway is provided with a wireless transceiving module and a GPIO port, the edge side Internet of things gateway is connected with an MQTT server through the wireless transceiving module, the signal processing unit is connected with the bus module through the GPIO port, and the edge side Internet of things gateway is in wired connection with the signal reading unit through the bus module;
the signal reading unit transmits real-time welding process parameters to the edge side Internet of things gateway through a first signal wire, the signal reading unit converts the real-time welding process parameters into high-level signals in an interruption mode, the high-level signals comprise transient values of current and voltage parameters, and the signal processing unit improves wireless transmission power of the edge side Internet of things gateway according to the size of the real-time welding process parameters.
Preferably, the edge side internet of things gateway uploads production and processing information from the MQTT server and generates a smooth level signal, and the signal processing unit matches the real-time high level signal with the smooth level signal to generate welding operation time.
Preferably, the signal reading unit reads real-time welding process parameters at a period of 0.1 second, the signal reading unit is an acquisition board, an STM32 chip is integrated on the acquisition board, and the STM32 chip sends the high level signal to the edge side physical connection gateway through a pin.
Preferably, the field device further includes a power module, which is a 220V to 6V switching power supply, the output terminal of the power module is connected to a voltage stabilizing protection circuit, the voltage stabilizing protection circuit is used for realizing overvoltage or overcurrent protection, and the voltage stabilizing protection circuit includes: the power supply comprises a fuse, a clamping diode and an LDO chip, wherein the LDO chip converts the 6V voltage output by the power supply module into a first output circuit and a second output circuit.
Preferably, the first output circuit is a 5V/2A linear circuit, and the first output circuit is used for supplying power to the signal reading unit;
the second output circuit is a 3.3V/2A direct current circuit and is used for supplying power to the signal processing unit.
Preferably, the field device is integrated in a package having dimensions of 15cm by 10cm by 5 cm;
the packaging body carrying the welding real-time working hour signal is in wireless relay connection with the adjacent packaging body at the nearby position, or the welding real-time working hour signal is directly uploaded to the MQTT server through a wireless network.
Preferably, the outer part of the electric welding machine is connected with a welding gun through a cable, and the cable is detachably connected with a pincerlike Hall current sensor.
Preferably, the output end of the pincerlike hall current sensor is in wired connection with the signal reading unit in the packaging body through a second signal wire, the pincerlike hall current sensor calculates real-time current and voltage by measuring the magnetic field change of the hall effect when the electric welding machine works, and the measuring frequency of the pincerlike hall current sensor is 0-100 KHz.
Preferably, the measuring process of the measuring device for the welding man-hour of the ship body is as follows: the electric welding machine drives the welding gun to work through a cable, the clamp-shaped Hall current sensor on the cable is detachably mounted to collect real-time current and voltage when the electric welding machine works at the measuring frequency of 0-100KHz, the signal reading unit is in wired connection with the clamp-shaped Hall current sensor through a second signal line and reads real-time signals at the period of 0.1 second, meanwhile, an STM32 chip on the signal reading unit sends instantaneous high-level signals to the signal processing unit in an interruption mode, the signal reading unit is in wired connection with the signal processing unit through a bus module, the signal processing unit matches pre-downloaded smooth level signals with received high-level signals, and after calculation, welding practical working hours are obtained and are actively pushed to the MQTT server through a release mode.
A ship hull welding man-hour measuring method comprises the following steps:
reading a real-time working current signal in the welding real-time working hour signal through a signal reading unit, and transmitting the acquired real-time working current to a signal processing unit of an electric welding machine;
setting a reference current corresponding to the reference transmitting power of the wireless transceiver module, inputting the welding machine working current signal and the reference current into a differential current-voltage converter as input signals to obtain a differential pressure signal between the welding machine working current signal and the reference current, and transmitting the differential pressure signal to the signal processing unit;
step three, the signal processing unit transmits the differential pressure signal to a first power compensation module, and the first power compensation module provides first compensation transmitting power for the wireless transceiver module according to the differential pressure signal;
in the second step, the reference current is connected to the first input terminal of the differential current-voltage converter through a first preamplifier, the real-time working current signal is connected to the second input terminal of the differential current-voltage converter through a second preamplifier, and the output terminal of the differential current-voltage converter is connected to the input terminal of the signal processing unit through a post-amplifier.
The invention at least comprises the following beneficial effects:
1. the clamp-on Hall current sensor used for collecting welding process parameters is detachably arranged on the electric welding machine, the clamp-on Hall current sensor is connected with the signal reading unit in a wired mode, and the signal reading unit is connected with the signal processing unit through the bus module. And on the other hand, the wired connection reduces the interference to the signal acquisition and transmission process in the working process of the electric welding machine, increases the integrity and accuracy of the signal acquisition and transmission, and finally improves the accuracy of the measurement in the welding practical working hours.
2. The signal reading unit transmits the real-time welding process parameters to the edge side Internet of things gateway through the first signal line, the signal reading unit converts the real-time welding process parameters into high-level signals in an interruption mode, the high-level signals comprise transient values of parameters such as current and voltage, the signal processing unit can subscribe production and processing information such as a welding process, a processing area, a dispatching receipt and associated BOM from the MQTT server and generate smooth level signals corresponding to the high-level signals. The signal acquisition unit transmits the high level signal obtained in an interruption mode to the signal processing unit in a wired mode, namely, only the high level signal is received on the signal processing unit, which is equivalent to screening out data or other interference data when the electric welding machine is in a non-welding state by the signal acquisition unit, so that on one hand, the data transmission efficiency between the signal acquisition unit and the signal processing unit is improved, on the other hand, the signal processing unit is convenient to quickly match the high level signal with the processed smooth level signal, the working hours of the welding operation are quickly calculated and generated, and the working efficiency of field equipment is improved.
3. The transmitting power of the wireless receiving and transmitting module is compensated according to the real-time working current of the electric welding machine, so that the interference of the working current of the electric welding machine on wireless transmission signals is reduced, the accuracy of signal receiving of a server is improved, and the accuracy of man-hour supervision and calculation is improved; each electric welding machine is provided with a relay power compensation module, so that wireless signal distortion caused by long-distance transmission is reduced, and the accuracy of receiving signals by a server is further improved.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention.
Drawings
FIG. 1 is a schematic view of the connection structure of the apparatus of the present invention;
FIG. 2 is a general principle schematic of the present invention;
FIG. 3 is a schematic workflow of the method of the present invention.
Detailed Description
The present invention is further described in detail below with reference to the attached drawings so that those skilled in the art can implement the invention by referring to the description text.
Example one
The invention provides a ship hull welding man-hour measuring device, and figure 1 shows an implementation form according to the invention, which comprises the following components: a plurality of field devices for calculating welding hours, the field devices comprising: the system comprises a signal reading unit, a bus module and a signal processing unit, wherein the signal reading unit reads real-time welding process parameters in a wired transmission mode, so that the probability of missed reading and misreading of the real-time welding process parameters is reduced, the bus module is provided with a TTL (transistor-transistor logic) interface and a USB (universal serial bus) interface, and the TTL interface of the bus module is connected with the signal reading unit; the signal processing unit is connected with an edge side Internet of things gateway, the edge side Internet of things gateway is provided with a wireless transceiving module and a GPIO port, the edge side Internet of things gateway is connected with an MQTT server through the wireless transceiving module, the signal processing unit is connected with a bus module through the GPIO port, the edge side Internet of things gateway is in wired connection with a signal reading unit through the bus module, the signal reading unit and the signal processing unit in the field device are connected through the bus module, the interference to the signal acquisition and transmission process in the working process of the electric welding machine is reduced, the integrity and the accuracy of the signal acquisition and transmission are increased, and finally the accuracy of the measurement of the welding real-time is improved.
The signal reading unit transmits the real-time welding process parameters to the edge side internet of things gateway through the first signal line, and the signal reading unit converts the real-time welding process parameters into high-level signals in an interruption mode, wherein the high-level signals comprise transient values of parameters such as current and voltage. The edge side Internet of things gateway can upload production and processing information from the MQTT server and generate a smooth level signal, and the signal processing unit matches the real-time high level signal with the smooth level signal to generate welding actual working hours. The signal acquisition unit transmits the high level signal obtained in an interruption mode to the signal processing unit in a wired mode, namely, only the high level signal is received on the signal processing unit, which is equivalent to screening out data or other interference data when the electric welding machine is in a non-welding state by the signal acquisition unit, so that on one hand, the data transmission efficiency between the signal acquisition unit and the signal processing unit is improved, on the other hand, the signal processing unit is convenient to quickly match the high level signal with the processed smooth level signal, the working hours of the welding operation are quickly calculated and generated, and the working efficiency of field equipment is improved.
Specifically, the signal reading unit reads real-time welding process parameters with 0.1 second period, and the signal reading unit is an acquisition board, and the integration has the STM32 chip on the acquisition board, and the STM32 chip passes through the pin and sends high level signal to edge side thing and allies oneself with the gateway.
To ensure continuous, stable operation of the field device, the field device is integrated in a package having dimensions of 15cm x 10cm x 5 cm. The field device also comprises a power supply module, the power supply module is a 220V-to-6V switching power supply, the output end of the power supply module is connected with a voltage-stabilizing protection circuit, the voltage-stabilizing protection circuit is used for realizing overvoltage or overcurrent protection, and the voltage-stabilizing protection circuit comprises: fuse, clamping diode and LDO chip, the LDO chip converts the 6V voltage of power module output into first output circuit and second output circuit. The first output circuit is a 5V/2A linear circuit and is used for supplying power to the signal reading unit; the second output circuit is a 3.3V/2A direct current circuit and is used for supplying power to the signal processing unit.
The packaging body is arranged in an electric welding machine, the packaging body carrying the welding real-time working hour signal is in wireless relay connection with the adjacent packaging body at the nearby position, or the welding real-time working hour signal is directly uploaded to the MQTT server through a wireless network. Specifically, when the distance between the electric welding machine and the server is larger than the distance between the electric welding machine and an adjacent electric welding machine, the signal carrying the welding real time is relayed and enhanced through the adjacent electric welding machine signal power and then is forwarded to the server, and the signal transmission accuracy is improved; otherwise, the data can be directly sent to the server wirelessly.
When the electric welding machine works, an operator changes the position of the electric welding machine along with the change of a welding station, so that field equipment in the electric welding machine can read welding process parameters in real time, and the information reading module converts the read parameter information into a high-level signal and sends the high-level signal to the information processing unit.
The information processing unit matches the received high level signal with a smooth level signal carried by the information processing unit, and generates welding actual working hours after calculation. When the electric welder is located in the coverage range of the wireless network, the field device and the server are in a wireless network connection state, namely, the edge side Internet of things gateway on the information processing unit and the server can wirelessly transmit, so that the information processing unit sends the working hours of welding reality generated by calculation to the server; when the electric welding machine is not in the coverage range without the wireless network, the field device and the server are in a wireless network disconnection state, at the moment, the field device can still independently complete information reading and processing work, the information processing unit stores the working hours of welding reality generated by calculation, and data transmission is performed when the field device is communicated with the server, so that the phenomenon that the welding process parameters are missed in a wireless network disconnection area is avoided, the field device can independently work and operate, and the influence of the network state is avoided.
The outer part of the electric welding machine is connected with a welding gun through a cable, and the cable is detachably connected with a pincerlike Hall current sensor. Can dismantle the nimble use of being convenient for sensor of connection on the one hand, on the other hand can in time dismantle, accomodate when the electric welding is not used, is favorable to the maintenance of sensor. The output end of the pincerlike Hall current sensor is in wired connection with a signal reading unit in the packaging body through a second signal wire, the pincerlike Hall current sensor calculates real-time current and voltage by measuring the magnetic field change of the Hall effect of the electric welding machine during working, and the measuring frequency of the pincerlike Hall current sensor is 0-100 KHz.
According to the invention, under the condition of network interruption of the electric welding machine, the clamp-shaped Hall current sensor can still acquire welding process data in real time, and after the signal reading unit and the signal processing unit which are integrated in the field equipment transmit and process the welding process data in real time, the welding real-time working hours can be obtained and stored until the electric welding machine is wirelessly connected with the server, the welding real-time working hours can be sent to the server, so that the real-time acquisition of the welding process data is ensured, the conditions of information missing and non-acquisition are avoided, and the accuracy of the measurement of the welding real-time working hours is improved. And on the other hand, the wired connection reduces the interference to the signal acquisition and transmission process in the working process of the electric welding machine, increases the integrity and accuracy of the signal acquisition and transmission, and finally improves the accuracy of the measurement in the welding practical working hours.
The measuring process and the working principle of the measuring device for the welding working hours of the ship body are as follows: the electric welding machine drives the welding gun to work through a cable, the clamp-on Hall current sensor which is detachably mounted on the cable collects real-time current and voltage when the electric welding machine works at the measuring frequency of 0-100KHz, the signal reading unit is in wired connection with the clamp-on Hall current sensor through a second signal wire, the wired connection reduces interference on signal collection in the working process of the electric welding machine, the integrity and the accuracy of signal collection are improved, and the accuracy of measurement in real welding work time is further improved. The signal reading unit reads real-time signals in a period of 0.1 second, simultaneously, the signal reading unit converts real-time welding process parameters into high-level signals in an interruption mode, the high-level signals comprise transient values of parameters such as current and voltage, pins on an SMT chip on the signal reading unit are connected with a TTL interface of a bus module, the bus module is connected with a signal processing unit, the signal reading unit is connected with the signal processing unit through the bus module in a wired mode, the signal reading unit further sends the instantaneous high-level signals to the signal processing unit through the pins and the bus module, the signal processing unit matches pre-downloaded smooth level signals with received high-level signals, welding real-time is obtained after calculation, and the collection, reading and processing programs of the welding process parameters can be independently completed because field equipment and a clamp-shaped Hall current sensor are not influenced by network states, when the electric welder is connected with the server through a wireless network, the field equipment in the electric welder can actively push the welding real-time working hours generated by calculation to the MQTT server in real time through a publishing mode; when the wireless network of the electric welding machine and the service device is disconnected, the field device in the electric welding machine can store the generated welding real-time working hours, and when the network is connected, the data can be sent to the MQTT server.
Example two
In order to improve the signal anti-interference capability of the electric welding machine in the wireless transmission process of the welding man-hour data and improve the signal transmission accuracy, as shown in fig. 2-3, the invention also provides a measuring method of the hull welding man-hour, in particular to a method for improving the monitoring accuracy of the welding man-hour of the electric welding machine, which comprises the following steps:
reading a real-time working current signal of an electric welding machine through a signal reading unit 110, wherein the real-time working current signal is contained in a real-time welding process parameter, in the embodiment, the signal reading unit 110 adopts a pincerlike hall current sensor to acquire a signal, and transmits the acquired real-time working current to a signal processing unit 100 of the electric welding machine;
and step two, setting a reference current corresponding to the reference transmitting power of the wireless transceiver module 140, wherein the reference current is 20% of the maximum working current of the electric welding machine, so that the electric welding machine generally cannot work under the reference current and does not substantially interfere with the signal transceiving of the wireless transceiver module 140 even when working under the reference current. When the working current of the electric welding machine exceeds the reference current, the electric welding machine is generally in a normal working state, the collection and transmission of current signals are affected by the external discharge current and current fluctuation, the accuracy of the signals received by the server is interfered, and the working hour calculation accuracy is caused.
The welding machine working current signal and the reference current are input into a differential current-voltage converter 120 as input signals, so as to obtain a differential signal between the welding machine working current signal and the reference current, and the differential signal is transmitted to the signal processing unit 100.
Specifically, the reference current is connected to a first input terminal of the differential current-voltage converter 120 through a first preamplifier, the real-time operating current signal is connected to a second input terminal of the differential current-voltage converter 120 through a second preamplifier, and an output terminal of the differential current-voltage converter 120 is connected to an input terminal of the signal processing unit 100 through a post-amplifier. The two preamplifiers are used for amplifying two current input signals so as to facilitate detection and analysis of the differential current-voltage converter, reduce signal interference influence and improve detection precision, and the post amplifier amplifies the output signal of the differential current-voltage converter, further reduces signal interference influence and improves the accuracy of a calculated differential pressure signal.
Step three, the signal processing unit 100 transmits the differential pressure signal to a first power compensation module 130, specifically, only when the real-time operating current is greater than the reference current, the first power compensation module 130 is triggered to operate, and the first power compensation module 130 provides a first compensation transmitting power for the wireless transceiver module 140 according to the differential pressure signal.
The first compensation transmitting power is in direct proportion to the differential pressure signal, and the larger the differential pressure signal is, the larger the interference caused by the working current of the electric welding machine to signal acquisition and transmission is, so that the transmission intensity of the intrinsic signal needs to be improved, and the interference of the working current to signal transmission needs to be reduced. When the working current of the welding machine is larger, the first compensation transmitting power provided by the first power compensation module 130 to the wireless transceiver module 140 is larger, so as to counteract interference of the working outgoing current of the welding machine on signal transmission.
It is ensured that the sum of the first compensation transmission power and the rated transmission power of the wireless transceiver module 140 is less than the maximum transmission power of the wireless transceiver module 140, so as to avoid the damage of the wireless transceiver module 140.
In the technical scheme, the electric welding machine sequentially passes through the wireless transceiver module 140, the on-site wireless receiving device and the switch to transmit the real-time working current signal to the server, and the server determines the effective working hours through the real-time working current. The invention mainly optimizes and improves the intermediate signal transmission link, and particularly reduces the distortion caused by signal interference and long distance by a mode of improving the wireless transmitting power of the wireless transmitting and receiving module 140.
Further, a first filter 111 is arranged on the bus module, specifically, the real-time working current signal collected by the signal reading unit 110 is connected to the signal processing unit 100 after passing through the first filter 111, and the first filter 111 is a conventional analog filter and is used for filtering an interference source signal in the collected analog current signal.
When the wireless signal processing device is used on site, a plurality of welding machines generally work at the same time, and the server receives wireless signals transmitted by the welding machines at the same time and independently calculates the effective working hours of each welding machine. Therefore, in the present technical solution, a positioning module 150 is further included, and is configured to determine distances between the welding bugs and between the welding bugs and the on-site wireless receiving device.
The sending signal of the wireless transceiver module 140 includes a welding machine number, a real-time working current signal, a distance signal between the welding machines, and a distance signal between the welding machines and the on-site wireless receiving device. The welding bug number is used by the adjacent welding bugs and the server to distinguish which welding bug is, and thereby determine the real-time operating current signal of the welding bug, the distance between the welding bug and the adjacent welding bug, and the distance between the welding bug and the on-site wireless receiving device.
Specifically, the embodiment further includes a second filter 160, and the current welding machine receives the transmission signal of the adjacent welding machine, filters the transmission signal through the second filter 160, and then transmits the filtered transmission signal to the signal processing unit 100. The second filter 160 may be a conventional band-pass filter, and functions to filter interference signals in other bands in the acquired wireless signals.
The wireless transceiver further comprises a second power compensation module 170, an input end of the second power compensation module 170 is connected to the signal processing unit 100, and an output end of the second power compensation module 170 is connected to the wireless transceiver module 140; if the distance between the adjacent electric welding machine and the current electric welding machine, sent by the current electric welding machine and received by the adjacent electric welding machine, is smaller than the distance between the adjacent electric welding machine and the on-site wireless receiving equipment, the wireless signal received by the adjacent electric welding machine is strengthened by the second power compensation module 170 and then is continuously transmitted;
the second power compensation module 170 provides a second compensation transmission power for the wireless transceiver module 140 according to the distance signal between the adjacent welding machine and the current welding machine, so as to eliminate transmission energy loss caused by long-distance transmission and interference of external signals.
In the above technical solution, the second compensation transmitting power is in direct proportion to the magnitude of the distance signal between the current welding machines, and the sum of the first compensation transmitting power, the second compensation transmitting power and the rated transmitting power of the wireless transceiver module 140 is smaller than the maximum transmitting power of the wireless transceiver module 140.
According to the invention, the transmission power of the wireless transceiver module 140 is compensated according to the real-time working current of the electric welding machine, so that the interference of the working current of the electric welding machine on wireless transmission signals is reduced, the accuracy of signal receiving of a server is improved, and the accuracy of man-hour supervision and calculation is improved; meanwhile, each electric welding machine is provided with a relay power compensation module, wireless signal distortion caused by long-distance transmission is reduced, and the accuracy of receiving signals by the server is further improved.
While embodiments of the invention have been disclosed above, it is not intended that they be limited to the applications set forth in the specification and examples. It can be applied to all kinds of fields suitable for the present invention. Additional modifications will readily occur to those skilled in the art. It is therefore intended that the invention not be limited to the exact details and illustrations described and illustrated herein, but fall within the scope of the appended claims and equivalents thereof.
Claims (10)
1. A ship hull welding man-hour measuring device comprises: a field device for calculating man-hour of welding is provided with one on every electric welding machine field device, its characterized in that, field device includes:
the signal reading unit reads real-time welding process parameters in a wired transmission mode; reading a real-time working current signal of the electric welding machine through a signal reading unit;
the bus module is provided with a TTL interface and a USB interface, and the TTL interface of the bus module is connected with the signal reading unit;
the signal processing unit is connected with an edge-side Internet of things gateway, the edge-side Internet of things gateway is provided with a wireless transceiving module and a GPIO port, the edge-side Internet of things gateway is connected with an MQTT server through the wireless transceiving module, the signal processing unit is connected with the bus module through the GPIO port, the edge-side Internet of things gateway is in wired connection with the signal reading unit through the bus module, and the signal processing unit receives the real-time working current signal;
the signal reading unit transmits real-time welding process parameters to the edge side Internet of things gateway through a first signal wire, the signal reading unit converts the real-time welding process parameters into high-level signals in an interruption mode, the high-level signals comprise transient values of current and voltage parameters, and the signal processing unit improves wireless transmitting power of the edge side Internet of things gateway according to the real-time welding process parameters; setting a reference current corresponding to the reference transmitting power of the wireless transceiver module, inputting the working current signal of the electric welding machine and the reference current into a differential current-voltage converter as input signals to obtain a differential signal between the working current signal of the electric welding machine and the reference current, and transmitting the differential signal to the signal processing unit; the reference current is connected to a first input end of the differential current-voltage converter through a first preamplifier, the real-time working current signal is connected to a second input end of the differential current-voltage converter through a second preamplifier, and an output end of the differential current-voltage converter is connected with an input end of the signal processing unit through a post-amplifier; the signal processing unit transmits the differential pressure signal to a first power compensation module, and the first power compensation module provides first compensation transmitting power for the wireless transceiving module according to the differential pressure signal.
2. The ship hull welding man-hour measuring device according to claim 1, characterized in that the edge side internet of things gateway uploads production processing information from the MQTT server and generates a smooth level signal, and the signal processing unit matches the real-time high level signal with the smooth level signal to generate a welding real man-hour signal.
3. The ship hull welding man-hour measuring device of claim 2, characterized in that the signal reading unit reads real-time welding process parameters at a period of 0.1 second, the signal reading unit is an acquisition board, an STM32 chip is integrated on the acquisition board, and the STM32 chip sends the high-level signal to the edge side physical connection gateway through a pin.
4. The device for measuring welding man-hour of ship hull according to claim 3, characterized in that said field device further comprises a power module which is a 220V to 6V switching power supply, said power module output terminal is connected with a voltage stabilizing protection circuit, said voltage stabilizing protection circuit is used for realizing overvoltage or overcurrent protection, said voltage stabilizing protection circuit comprises: the power supply comprises a fuse, a clamping diode and an LDO chip, wherein the LDO chip converts the 6V voltage output by the power supply module into a first output circuit and a second output circuit.
5. The ship hull welding man-hour measuring device according to claim 4, wherein the first output circuit is a 5V/2A linear circuit, and the first output circuit is used for supplying power to the signal reading unit;
the second output circuit is a 3.3V/2A direct current circuit and is used for supplying power to the signal processing unit.
6. The hull weld man-hour measuring device of claim 5, wherein the field device is integrated in a package having dimensions of 15cm by 10cm by 5 cm;
the packaging body carrying the welding real-time working hour signal is in wireless relay connection with the adjacent packaging body at the nearby position, or the welding real-time working hour signal is directly uploaded to the MQTT server through a wireless network.
7. The hull welding man-hour measuring device according to claim 6, wherein a welding gun is connected to the exterior of the welding machine through a cable, and a clamp-type Hall current sensor is detachably connected to the cable.
8. The device for measuring the welding man-hour of the ship hull as claimed in claim 7, wherein the output end of the pincer-shaped Hall current sensor is in wired connection with the signal reading unit in the packaging body through a second signal wire, the pincer-shaped Hall current sensor calculates the real-time current and voltage by measuring the magnetic field change of the Hall effect when the electric welder works, and the measuring frequency of the pincer-shaped Hall current sensor is 0-100 KHz.
9. The hull welding man-hour measuring device according to claim 8, wherein a measuring process of the hull welding man-hour measuring device is: the electric welding machine drives the welding gun to work through a cable, the clamp-shaped Hall current sensor on the cable is detachably mounted to collect real-time current and voltage when the electric welding machine works at the measuring frequency of 0-100KHz, the signal reading unit is in wired connection with the clamp-shaped Hall current sensor through a second signal line and reads real-time signals at the period of 0.1 second, an STM32 chip on the signal reading unit sends instantaneous high-level signals to the signal processing unit in an interruption mode, the signal reading unit is in wired connection with the signal processing unit through a bus module, the signal processing unit matches the pre-downloaded smooth level signals with the received high-level signals, and the welding actual working time is obtained after calculation and is actively pushed to the MQTT server through a publishing mode.
10. A ship welding man-hour measuring method is characterized by comprising the following steps:
reading a real-time working current signal in a welding real-time working hour signal through a signal reading unit, and transmitting the acquired real-time working current signal to a signal processing unit of an electric welding machine;
setting a reference current corresponding to the reference transmitting power of the wireless transceiver module, inputting the welding machine working current signal and the reference current into a differential current-voltage converter as input signals to obtain a differential pressure signal between the welding machine working current signal and the reference current, and transmitting the differential pressure signal to the signal processing unit;
step three, the differential pressure signal is transmitted to a first power compensation module by the signal processing unit, and the first power compensation module provides first compensation transmitting power for the wireless transceiving module according to the differential pressure signal;
in the second step, the reference current is connected to the first input terminal of the differential current-voltage converter through a first preamplifier, the real-time working current signal is connected to the second input terminal of the differential current-voltage converter through a second preamplifier, and the output terminal of the differential current-voltage converter is connected to the input terminal of the signal processing unit through a post-amplifier.
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| CN202011262549.XA CN112427776B (en) | 2020-11-12 | 2020-11-12 | Hull welding man-hour measuring device and method |
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| CN202011262549.XA CN112427776B (en) | 2020-11-12 | 2020-11-12 | Hull welding man-hour measuring device and method |
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| DE4339526A1 (en) * | 1993-11-19 | 1995-05-24 | Philips Patentverwaltung | Radio with transmission power control |
| US5740165A (en) * | 1996-02-29 | 1998-04-14 | Lucent Technologies Inc. | Wireless TDMA transmitter with reduced interference |
| US7783263B2 (en) * | 2006-12-14 | 2010-08-24 | Texas Instruments Incorporated | Simplified digital predistortion in a time-domain duplexed transceiver |
| CN102941395B (en) * | 2012-11-27 | 2015-03-25 | 上海工业自动化仪表研究院 | Welding process parameter recording and welding quality analysis system |
| CN104749977A (en) * | 2015-02-11 | 2015-07-01 | 上海广为焊接设备有限公司 | Control circuit of integrated electric welding machine based on wireless transmission |
| CN204465010U (en) * | 2015-04-03 | 2015-07-08 | 山东哈雷电力科技有限公司 | Be easy to the Intelligent reactive power compensation device safeguarded |
| CN107813070B (en) * | 2016-09-12 | 2020-07-31 | 中国科学院沈阳自动化研究所 | Wireless detection device and method for online monitoring and working hour statistics of welding quality |
| CN109885002A (en) * | 2019-03-04 | 2019-06-14 | 江苏科技大学 | A kind of welding machine networking intelligent monitor system and monitoring method |
| CN210413152U (en) * | 2019-06-06 | 2020-04-28 | 南宁嘉昌机电设备有限责任公司 | Informationized welding management control system |
| CN211840523U (en) * | 2019-09-24 | 2020-11-03 | 武汉华海通用电气有限公司 | Ship body welding parameter monitoring system |
| CN110640266A (en) * | 2019-10-24 | 2020-01-03 | 贵州民族大学 | Electric welding remote monitering system |
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