CN112529367A - Welding process evaluation system and method - Google Patents
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Abstract
The invention relates to a welding process evaluation method and an evaluation system, wherein the evaluation method comprises the following steps: and (3) calculating the coverage area: obtaining the evaluated welding condition parameters, calculating the corresponding coverage range according to the welding condition parameters, and inputting the obtained coverage range into a coverage range summarizing base; evaluation-free determination: obtaining welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation; if not, performing a welding process evaluation test; judging whether the test result of the welding process evaluation test is qualified or not, and if so, storing the test result as the evaluated welding condition parameters into a range summary library; if not, the welding process evaluation test is carried out again. The system or the method is convenient to operate, easy to manage and time-saving.
Description
Technical Field
The present disclosure relates to systems and methods for evaluating welding processes, and particularly to a system and a method for evaluating a welding process.
Background
"china manufacturing 2025" definitely ranks intelligent manufacturing as the development direction of future manufacturing industry, and one of the most commonly used processes in the mechanical manufacturing industry is welding, and because of the complexity of the welding process, the control of welding quality is very important. The evaluation of the welding process is an indispensable process for evaluating and determining whether the welding process meets the requirements before welding production, and each welding manufacturing enterprise expends much energy, resources and cost on the evaluation of the welding process every year.
The main purpose of the welding process evaluation is to determine the welding process specification and the welding materials matched with the base metal and the plate thickness, so as to obtain the welding joint performance meeting the use requirement. Because the workload of the welding process evaluation test is heavy, in order to improve the efficiency and avoid repetition, it is necessary to use the coverage calculation and the avoidance of the evaluation rule in the welding process evaluation standard to reasonably reduce the workload of the test, and fig. 1 is a welding process evaluation workflow.
At present, the research of the domestic computer-aided welding technology mainly focuses on the aspects of welding simulation, welding production management, welding process data management and the like. These systems are all a single study on welding process design, welding production management and process assessment data management, but when relevant parameters change in the process assessment process, the calculation of relevant factor coverage is required to be carried out strictly according to the specification in the ISO15614-1 standard so as to determine whether a welding process assessment test needs to be carried out again. This process requires accurate understanding of the standard content by process raters and calculation of the coverage of the relevant factors. As the number of tests increases, the number of data recorded increases, and the work of determining that retesting is not necessary becomes more complicated. Managing the records and the data required for the query is also more cumbersome.
Disclosure of Invention
The invention provides a welding process evaluation system and an evaluation method for realizing automatic calculation and judgment-free coverage of welding process evaluation parameters.
The technical scheme adopted by the invention is as follows: a welding process assessment and evaluation method comprises the following steps of S01 coverage calculation: obtaining the evaluated welding condition parameters, calculating the corresponding coverage range according to the welding condition parameters, and inputting the obtained coverage range into a coverage range summarizing base;
s02 exempt assessment: obtaining welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation;
if not, performing a welding process evaluation test;
s03, judging whether the test result of the welding process evaluation test is qualified, if so, returning to the step S01 as the evaluated welding condition parameter; if not, the welding process evaluation test is carried out again.
Further, the welding condition parameters comprise base material group, mechanization degree category, welding method, welding position, joint details, welding filling material and current type.
Further, in step S03, if the test result of the welding process evaluation test is not qualified, the welding process is adjusted and then the test is performed again.
The invention also provides a welding process evaluation system, which comprises
A coverage calculation module: the device is used for acquiring the evaluated welding condition parameters and calculating the corresponding coverage range according to the welding condition parameters;
coverage summary library: the device is used for storing the welding condition parameter coverage range acquired by the coverage range calculation module; a judgment-free module: the coverage area summarizing library is used for acquiring welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation;
if not, prompting to perform a welding process evaluation test;
a welding process evaluation test result processing module: obtaining a welding process evaluation test result, judging whether the welding process evaluation test result is qualified, and if so, transmitting the welding process evaluation test result to the coverage area calculation module as an evaluated welding condition parameter; if not, the welding process evaluation test is prompted to be carried out again.
Furthermore, the welding condition parameters comprise a plurality of welding condition parameters, and the coverage summary database records the coverage of the welding condition parameters, the coverage of each factor and the corresponding relationship between the coverage of the other factors.
Further, the welding condition parameters comprise base material group, mechanization degree category, welding method, welding position, joint details, welding filling material and current type.
Further, in step S03, if the test result of the welding process evaluation test is not qualified, the welding process is adjusted and then the test is performed again.
The beneficial effects produced by the invention comprise: integrating all process parameters of all welding process evaluation records by using a coverage area calculation module, synchronously calculating the coverage areas of different parameters of all factors, and storing the coverage areas into a coverage area summary library; and meanwhile, the necessity of carrying out a test on the project to be evaluated is rapidly judged and evaluated. The method is convenient to operate, the difficulty of standard reference and process evaluation necessity judgment during manual operation is obviously reduced, the burden of welding process personnel is reduced, the welding process evaluation efficiency and accuracy are improved, the competitiveness of an enterprise is enhanced, and meanwhile, a foundation is laid for future digital and intelligent development of the enterprise.
Drawings
FIG. 1 is a flow chart of the interaction between modules of the present invention.
Detailed Description
The present invention is explained in further detail below with reference to the drawings and the specific embodiments, but it should be understood that the scope of the present invention is not limited to the specific embodiments.
Example 1
A welding process assessment method comprises
S01 coverage calculation: obtaining the evaluated welding condition parameters, calculating the corresponding coverage range according to the welding condition parameters, and inputting the obtained coverage range into a coverage range summarizing base;
s02 exempt assessment: obtaining welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation;
if not, performing a welding process evaluation test;
s03, judging whether the test result of the welding process evaluation test is qualified, if so, returning to the step S01 as the evaluated welding condition parameter; if not, the welding process evaluation test is carried out again. And in the step S03, if the test result of the welding process evaluation test is unqualified, the welding process is adjusted and then the test is carried out again.
The welding condition parameters comprise base material group, mechanization degree category, welding method, welding position, joint detail, welding filling material and current type.
Example 2
An evaluation system for executing the evaluation method for evaluating the welding process of embodiment 1 includes
A coverage calculation module: the device is used for acquiring the evaluated welding condition parameters and calculating the corresponding coverage range according to the welding condition parameters;
coverage summary library: the device is used for storing the welding condition parameter coverage range acquired by the coverage range calculation module; a judgment-free module: the coverage area summarizing library is used for acquiring welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation;
if not, prompting to perform a welding process evaluation test;
a welding process evaluation test result processing module: obtaining a welding process evaluation test result, judging whether the welding process evaluation test result is qualified, and if so, transmitting the welding process evaluation test result to the coverage area calculation module as an evaluated welding condition parameter; if not, the welding process evaluation test is prompted to be carried out again.
The welding condition parameters comprise a plurality of welding condition parameters, and the coverage area summary database records the coverage area of each welding condition parameter and the corresponding relation between the coverage area of each factor and the coverage area of other factors.
The welding condition parameters comprise base material group, mechanization degree category, welding method, welding position, joint detail, welding filling material and current type.
And if the welding process evaluation test result is unqualified, the welding process is adjusted and then the test is carried out again.
Specific examples are:
a welding process assessment self-evaluation system comprising:
(1) the welding condition parameter module is created according to ISO15614-1 standard, and specifically comprises a base material group, a mechanization degree category, a welding method, a welding position, a joint detail, a welding filling material, a current type and the like, different levels of relevant welding condition parameters are defined in all the parameters, a coverage calculation method is provided, and a basis is provided for data reference of the coverage calculation in the step (2).
(2) A coverage calculation module: the module carries out coverage calculation on welding condition parameters in the welding condition parameter module according to the ISO15614-1 standard, and comprises the steps of inputting welding qualified process parameters (qualified welding condition parameters after evaluation tests are carried out) and automatically calculating the parameter coverage. The welding condition parameters mainly comprise welding material information (base metal type and material thickness), general rules of welding processes (welding method, welding position, joint type, welding material, current type, heat input, preheating temperature, interlayer temperature, dehydrogenation treatment and heat treatment), special requirements of different welding methods (submerged arc welding, gas metal arc welding, non-gas metal arc welding, plasma arc welding, oxyacetylene welding, back shielding gas) and the like; and (4) inputting and recording process parameters, inputting the process parameters of qualified welding process evaluation items, automatically calculating and analyzing the specific coverage range of each factor, storing the calculation results into a coverage range summarizing base, and synchronously displaying the calculation results in automatic coverage range calculation. The coverage calculation results are shown in table 1:
TABLE 1
TABLE 1 continuation
(3) A judgment-free module: after welding condition parameters to be evaluated are input, in an evaluation-free judging module, the coverage range of all factors of a qualified welding process evaluation item in a coverage range calculating module is automatically called, the coverage range and the welding condition parameters in evaluation-free calculation are subjected to matching analysis one by one, and finally whether the welding process to be evaluated can be evaluated or not is determined through comprehensive judgment of matching results of all parameters, and if the welding process not to be evaluated needs to be evaluated, an evaluation test is carried out on the welding process. The results of the non-evaluation are shown in Table 2:
TABLE 2
TABLE 2 continuation
Example of coverage calculation:
1. in the "overlay calculation" module, the evaluated welding condition parameters are input
(1) Inputting the brand number 'Q550' of the base material A, selecting the brand number '2.2' of the base material A, selecting the brand number 'Q345' of the base material B, selecting the brand number '1.2' of the base material B, and obtaining the covered base material combination '2.2-1.2, 2.1-1.2,1.4-1.2,1.3-1.2,1.2-1.2,2.2-1.1,1.4-1.1,1.3-1.1, 1.2-1.1, 1.1-1.1' through a coverage calculation module;
(2) inputting the thickness of the butt joint base metal into 10 mm, and obtaining the coverage range of the multi-pass welding thickness of 3-20 mm through a coverage range calculation module;
(3) the mechanization degree is selected to be manual, and the coverage range is obtained to be manual;
(4) selecting 135 consumable electrode non-inert gas shielded welding (MAG) as a welding method, and automatically obtaining a coverage area of the 135 consumable electrode non-inert gas shielded welding (MAG);
(5) selecting 'flat welding' at the welding position, and automatically obtaining the 'flat welding' in the coverage range;
(6) selecting a full penetration butt weld according to the joint type, and automatically obtaining a coverage range of the full penetration butt weld, a partial penetration butt weld and a fillet weld;
(7) selecting 'single-sided welding lines with the liners' for the liners, and obtaining a coverage 'single-sided welding lines with the liners and double-sided welding lines';
(8) selecting 'no back gouging' for back gouging, and automatically obtaining a coverage 'no back gouging, back gouging';
(9) inputting the model number of the welding filling material into 'ER 50-6', selecting a group 'ER 50-6', and automatically obtaining a coverage range 'ER 50-6, replaceable manufacturer';
(10) selecting 'direct current reverse connection' for the current type, and automatically obtaining the coverage 'direct current reverse connection';
(11) inputting welding voltage of 23V, inputting welding current of 220A, inputting welding speed of 4 mm/s, selecting 135 consumable electrode non-inert gas shielded arc welding (MAG) by a welding method, and automatically calculating the covering range of welding heat input to be 0.759-1.265 KJ/mm;
(12) the preheating temperature is selected from the preheating temperature, the preheating temperature is input to 150 ℃, and the preheating temperature coverage range is automatically calculated to be larger than 150 ℃;
(13) the highest inter-road temperature is input to be 250 ℃, and the coverage range from preheating temperature to 300 ℃ is automatically calculated.
2. In the 'evaluation-free' module, a coverage summarizing library is called, if welding condition parameters to be evaluated are in the coverage summarizing library, matching is displayed, and if the welding condition parameters are not in the coverage summarizing library, mismatching is displayed:
(1) inputting the brand number 'Q890' of the base material A, selecting the brand number '3.2' of the base material A, selecting the brand number 'Q345' of the base material B and selecting the brand number '1.2' of the base material B, then planning to carry out welding process evaluation, and if the matching of the welding condition parameters and the data in the coverage range summary library on the base material category is 'unmatched', the method cannot be covered;
(2) inputting the thickness of the butt joint parent metal to be 15 mm, and covering the butt joint parent metal if the matching performance on the thickness of the parent metal is matched;
(3) the mechanization degree is selected to be manual, and the matching property on the mechanization degree is matching, namely covering;
(4) the welding method selects 135 consumable electrode non-inert gas shielded welding (MAG), and shows matching, namely covering;
(5) if the welding position is selected to be ' flat welding ', the matching ' is displayed, namely the covering is carried out;
(6) the joint type is selected from 'full penetration butt weld', and 'matching' is displayed, namely covering is realized;
(7) if the liner selects the single-sided no-liner welding seam, the non-matching is displayed, namely the covering cannot be carried out;
(8) selecting 'back chipping', displaying 'matching', namely covering;
(9) inputting the model number of the welding filling material into 'ER 50-6', selecting a group 'ER 50-6', displaying 'matching', namely covering;
(10) if the current type is selected to be direct current positive connection, the display is not matched, namely the display cannot be covered;
(11) the welding voltage is input to be 26V, the welding current is input to be 280A, the welding speed is input to be 4 mm/s, the welding method is selected to be 135 consumable electrode non-inert gas shielded arc welding (MAG), and mismatch is displayed, namely covering cannot be carried out;
(12) the preheating temperature is selected from the preheating temperature, 80 ℃ is input, and mismatching is displayed, namely the cover cannot be carried out;
(13) inputting the highest inter-road temperature of 200 ℃, and displaying matching, namely covering;
(14) finally, the WPQR match condition shows a "mismatch," i.e., the welding process evaluation test needs to be re-developed.
The invention has been described with reference to a few embodiments. However, it will be apparent to those skilled in the art that other embodiments of the invention disclosed above are equally possible within the scope of the invention, as defined by the appended patent claims.
As will be appreciated by one skilled in the art, embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks. These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solutions of the present invention and not for limiting the same, and although the present invention is described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: modifications and equivalents may be made to the embodiments of the invention without departing from the spirit and scope of the invention, which is to be covered by the claims.
Claims (7)
1. A welding process evaluation method is characterized in that: comprises that
S01 coverage calculation: obtaining the evaluated welding condition parameters, calculating the corresponding coverage range according to the welding condition parameters, and inputting the obtained coverage range into a coverage range summarizing base;
s02 exempt assessment: obtaining welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation;
if not, performing a welding process evaluation test;
s03, judging whether the test result of the welding process evaluation test is qualified, if so, returning to the step S01 as the evaluated welding condition parameter to obtain a coverage range summary library; if not, the welding process evaluation test is carried out again.
2. The welding process assessment evaluation method according to claim 1, wherein: the welding condition parameters comprise base material group, mechanization degree category, welding method, welding position, joint detail, welding filling material and current type.
3. The welding process assessment evaluation method according to claim 1, wherein: and in the step S03, if the test result of the welding process evaluation test is unqualified, the welding process is adjusted and then the test is carried out again.
4. A welding process evaluation system is characterized in that: comprises that
A coverage calculation module: the device is used for acquiring the evaluated welding condition parameters and calculating the corresponding coverage range according to the welding condition parameters;
coverage summary library: the device is used for storing the welding condition parameter coverage range acquired by the coverage range calculation module;
a judgment-free module: the coverage area summarizing library is used for acquiring welding condition parameters to be evaluated, calling the coverage area summarizing library, judging whether the welding condition parameters to be evaluated are in the coverage area summarizing library, and if so, avoiding evaluation;
if not, prompting to perform a welding process evaluation test;
a welding process evaluation test result processing module: obtaining a welding process evaluation test result, judging whether the welding process evaluation test result is qualified, and if so, transmitting the welding process evaluation test result to the coverage area calculation module as an evaluated welding condition parameter; if not, the welding process evaluation test is prompted to be carried out again.
5. The welding process assessment evaluation system of claim 4, wherein: the welding condition parameters comprise a plurality of welding condition parameters, and the coverage area summary database records the coverage area of each welding condition parameter and the corresponding relation between the coverage area of each factor and the coverage area of other factors.
6. The welding process assessment evaluation system of claim 4, wherein: the welding condition parameters comprise base material group, mechanization degree category, welding method, welding position, joint detail, welding filling material and current type.
7. The welding process assessment evaluation system of claim 4, wherein: and in the step S03, if the test result of the welding process evaluation test is unqualified, the welding process is adjusted and then the test is carried out again.
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Application publication date: 20210319 |