CN112570923A - Online monitoring method for resistance butt welding quality of small-specification chain link chain - Google Patents
Online monitoring method for resistance butt welding quality of small-specification chain link chain Download PDFInfo
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- CN112570923A CN112570923A CN202011184233.3A CN202011184233A CN112570923A CN 112570923 A CN112570923 A CN 112570923A CN 202011184233 A CN202011184233 A CN 202011184233A CN 112570923 A CN112570923 A CN 112570923A
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
- G01N27/04—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance
- G01N27/041—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance of a solid body
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Abstract
The invention discloses a resistance butt welding quality on-line monitoring method of a small-specification ring chain, which is characterized in that welding process characteristics are analyzed based on welding joint forming process data during chain welding, a quality on-line monitoring system is established through corresponding quality judgment standards, welding current, welding voltage, upsetting displacement, upsetting force and main shaft corner parameters are used as characteristic quantities for welding quality judgment, and the method comprises the following steps: deploying sensors required for measuring the parameters on a welding secondary circuit and an upsetting mechanism of a butt welding machine for small-specification chains; a lower computer unit is arranged beside the butt welder controller and connected with the sensor, and welding signals are acquired through data; the welding process data acquired by the lower computer unit is transmitted to the upper computer unit through the Ethernet, the processing module establishes a real-time data model to process, analyze and diagnose the data signals, and the welding quality diagnosis result is displayed on the display module in real time. After the scheme is adopted, the welding quality in the chain production process can be monitored on line in real time.
Description
[ technical field ] A method for producing a semiconductor device
The invention relates to a method for monitoring the quality of resistance welding, in particular to a method for monitoring the quality of resistance butt welding in the production of small-specification chain links on line, belonging to the technical field of resistance butt welding of chain links.
[ background of the invention ]
The chain is used as a basic mechanical part and is widely applied to industries such as mines, ships, petroleum, hoisting machinery and the like. Because the chain is characterized in that the rings are buckled, the quality problem of any chain ring can influence the quality of the whole chain, and serious safety accidents can be caused seriously. Therefore, the problem of quality stability in the production of the endless chain is always a technical focus of attention in the industry.
Welding is the most important processing link in the production of a chain with a ring chain, a small-sized chain (a chain with the diameter of the chain ring between phi 4mm and phi 16 mm) is usually produced by a resistance butt welding method, the resistance butt welding is a complex process with high nonlinearity, multivariable coupling effect and a large number of uncertain factors, the welding time of the resistance butt welding is extremely short, the joint forming process is sealed and invisible, the automation beat is extremely fast, the welding quality monitoring and judging work difficulty is very high, quality inspection is usually realized by methods such as a tensile strength test of a welded finished product and a sampling destructive inspection in the current actual production, and the problems of high hysteresis, much waste, time consumption and labor consumption exist.
[ summary of the invention ]
The invention provides an on-line monitoring method for the resistance butt welding quality of a small-specification chain, aiming at the problem of hysteresis quality of the existing small-specification chain in the resistance butt welding production process, and the on-line monitoring method can provide a welding quality judgment result in the chain production process on line.
On the basis, the collected welding data can be uploaded, and the whole process of the resistance butt welding production of the small-specification chain chains can be automatically monitored, displayed and recorded.
Therefore, the invention provides the following technical scheme:
a resistance butt welding quality on-line monitoring method of a small-specification ring chain is characterized in that welding process characteristics are analyzed based on welding joint forming process data during welding of the ring chain, a welding quality on-line monitoring system is established according to corresponding quality judgment standards, parameters such as welding current, welding voltage, upsetting displacement, upsetting force and spindle rotation angle in the welding process are adopted as characteristic quantities for judging the welding quality, and the method comprises the following steps:
s1) deploying sensors required for measuring the parameters on a welding secondary circuit and an upsetting mechanism of the butt welding machine for the small-size chains to be monitored; s2) installing a lower computer unit beside the controller of the butt welding machine, connecting the sensor in the step S1), and acquiring data corresponding to welding signals; s3), the welding process data acquired by the data of the lower computer unit in the step S2) are transmitted to the upper computer unit through Ethernet, a real-time data model is established through a processing module of the upper computer unit to process, analyze and diagnose the data signals, and then the welding quality diagnosis result is displayed in real time through a display module of the upper computer unit.
The welding quality on-line monitoring system comprises a sensor unit, a lower computer unit, a data transmission unit and an upper computer unit, wherein the sensor unit is connected with the lower computer unit, and the upper computer unit is connected with the lower computer unit through the data transmission unit; the butt welding machine head comprises a pair of welding electrode arms, welding electrodes which are respectively arranged at the bottoms of the welding electrode arms, an iron pier positioned below the welding electrodes, and upsetting mechanisms which are respectively arranged at the two outer sides of the iron pier, wherein the two upsetting mechanisms are provided with upsetting shafts which are arranged in a mutually facing manner, and a conveying claw for dragging the endless chain is arranged at the discharge side of the endless chain; the welding electrode arm is provided with a welding current sensor, a welding voltage sensing cable and an upsetting displacement sensor, the upsetting mechanism is provided with an upsetting force sensor, and a spindle rotation angle encoder is arranged on a spindle of a butt welding machine head.
The sensor unit is used for collecting a welding current signal, a welding voltage signal, an upsetting displacement signal, an upsetting force signal and a main shaft corner signal of the chain link in the resistance butt welding production process, the lower computer unit is used for conditioning an original signal collected by the sensor unit into a proper electric signal, the data transmission unit is used for transmitting welding data processed by the lower computer unit to the upper computer unit to complete data management and storage, the upper computer unit is used for processing the welding data, inputting a mathematical model and analyzing the welding quality, and finally, a welding quality diagnosis result is displayed on the display module.
The lower computer unit comprises a power module, a signal conditioning module and a control module which are integrated on a circuit board, wherein the power module supplies power to the control module and the signal conditioning module respectively, the signal conditioning module is connected with a main shaft corner encoder and each sensor of the sensor unit through a lead, a welding voltage sensing cable is directly connected with the signal conditioning module so as to condition the acquired original signals into appropriate electric signals and transmit the electric signals to the control module, and the control module is responsible for receiving and processing welding data and transmitting the data to the data transmission unit.
The data transmission unit comprises a data communication module and a database management module, the data communication module transmits the welding data acquired by the lower computer unit to the upper computer unit in an Ethernet mode, and the database management module realizes processing, storage and query of the acquired data.
The upper computer unit comprises a processing module and a display module, the processing module processes, calculates and analyzes real-time welding data uploaded by data transmission to obtain a real-time diagnosis result of the welding quality of the corresponding chain ring, and the display module displays the welding data curve and the real-time monitoring result.
The invention has at least the following advantages and positive effects:
1. the invention fills the technical blank in the field of on-line monitoring of the welding quality of the resistance butt welding of the chain chains. In the prior art, the on-line monitoring of the welding quality in the field of resistance welding focuses on the direction of resistance spot welding, and the research and the application of resistance to the welding direction are temporarily avoided.
2. The resistance butt welding online monitoring system adopts a modular design, and the sensor unit, the lower computer unit, the data transmission unit and the upper computer unit form the resistance butt welding online monitoring system, can monitor the resistance butt welding production process condition of the chain in real time on line, judge the welding quality of the chain in real time, remind the unqualified welding products to be treated, realize online monitoring diagnosis and predictive maintenance, so that corresponding improvement measures can be taken in time, and the major loss caused by shutdown and production halt can be avoided.
3. The invention transmits the real-time welding monitoring data to the database through the Ethernet through the data transmission unit for processing, analysis, storage and query, can realize long-term storage and management of welding data, realizes traceability of production data and provides reliable data support for improving the welding production management level.
[ description of the drawings ]
FIG. 1 is a block diagram of a welding quality on-line monitoring system for the on-line monitoring method of the present invention;
FIG. 2 is a schematic diagram of the sensor components and mechanical components disposed on the head of a butt welding machine.
[ detailed description ] embodiments
Referring to fig. 1-2, a method for monitoring the resistance butt welding quality of a small-sized chain link on line is disclosed, which analyzes the welding process characteristics based on the data of the welding joint formation process during the welding of the chain link K, establishes a welding quality on-line monitoring system according to the corresponding quality judgment standard, and takes the parameters of welding current, welding voltage, upset displacement, upset force and spindle rotation angle in the welding process as the characteristic quantities for judging the welding quality, and specifically comprises the following steps:
1. and deploying sensors required for measuring the parameters in a welding secondary loop and an upsetting mechanism of the butt welding machine for the small-size chains to be monitored.
2. And (3) installing a lower computer unit 3 beside a controller of the butt welding machine, connecting the sensors in the step (1), and acquiring data corresponding to welding signals during welding production.
3. In the step 2, the welding process data acquired by the lower computer unit 3 is transmitted to the upper computer unit 5 through the Ethernet, a real-time data model is established through the processing module 51 of the upper computer unit 5 to process, analyze and diagnose the data signals, and then the welding quality diagnosis result is displayed in real time through the display module 50 of the upper computer unit 5, so that the welding quality of the small-specification link chain K is monitored on line in real time.
The welding quality on-line monitoring system comprises a sensor unit S, a lower computer unit 3, a data transmission unit 4 and an upper computer unit 5, wherein the sensor unit S is connected with the lower computer unit 3, and the upper computer unit 5 is connected with the lower computer unit 3 through the data transmission unit 4; the butt welding machine head 1 comprises a pair of welding electrode arms 11, a welding electrode 111 which is separately arranged at the bottom of the welding electrode arms, a steel pier 12 which is positioned below the welding electrode 111, and upsetting mechanisms 13 which are respectively arranged at the two outer sides of the steel pier 12, wherein the two upsetting mechanisms are provided with upsetting shafts 131 and 132 which are arranged in a mutually facing way, and a conveying claw 2 for dragging a chain of a ring chain is arranged at the discharge side of the chain of the ring chain K; the right-hand welding electrode arm shown in fig. 2 is provided with a welding current sensor S1, a welding voltage sensing cable S2 and an upset displacement sensor S4 are respectively provided on the two welding electrode arms 11, an upset force sensor S3 is provided on the right-hand upset mechanism, and a spindle rotation angle encoder S5 is provided on a spindle (conventional part not shown) of the butt welder head 1.
The welding electrode 111 is used to deliver a welding current to the links to be welded; the main shaft controls the butt welder head 1 and the upsetting mechanism 13 to move through a cam, wherein the upsetting shaft 131 and the upsetting shaft 132 are used for transmitting upsetting force and an upsetting path to a chain ring to be welded; the transfer claw 2 is used to transport unwelded links to the welding position (top of the pier 12) and to guide welded links out of the welding position after the welding operation; the upsetting displacement sensor S4 is used for measuring the relative displacement of the two upsetting shafts; the iron pier 12 is of a conventional structure, and two side slopes thereof are provided with pits for engagement of the endless chain, and the top thereof is used for welding and positioning the endless chain.
The upsetting mechanism 13 is a conventional structure, and the upsetting shaft 131 is the same as the upsetting shaft 132.
The sensor unit S is used for collecting a welding current signal, a welding voltage signal, an upsetting displacement signal, an upsetting force signal and a main shaft corner signal of the chain K in the resistance butt welding production process, the lower computer unit 3 is used for conditioning an original signal collected by the sensor unit S into a proper electric signal, the data transmission unit 4 is used for transmitting welding data processed by the lower computer unit 3 to the upper computer unit 5 to complete management and storage of the data, the upper computer unit 5 is used for processing the welding data, inputting a mathematical model and analyzing the welding quality, and finally a welding quality diagnosis result is displayed on the display module 50.
The lower computer unit 3 comprises a power supply module 30, a signal conditioning module 31 and a control module 32 which are integrated on a circuit board, the power supply module 30 respectively supplies power to the control module 32 and the signal conditioning module 31, the signal conditioning module 31 is connected with a main shaft corner encoder S5, a welding current sensor S1, an upsetting displacement sensor S4 and an upsetting force sensor S3 of the sensor unit S through conducting wires, a welding voltage sensing cable S2 is directly connected with the signal conditioning module 31 to condition the collected original signals into appropriate electric signals and transmit the electric signals to the control module 32, and the control module 32 is responsible for receiving and processing welding data and transmitting the data to the data transmission unit 4.
The data transmission unit 4 comprises a data communication module 41 and a database management module 42, the data communication module 41 transmits the welding data acquired by the lower computer unit 3 to the upper computer unit 5 in an Ethernet mode, and the database management module 42 realizes processing, storage and query of the acquired data.
The upper computer unit 5 comprises a processing module 51 and a display module 50, the processing module 51 processes, calculates and analyzes real-time welding data transmitted in data transmission to obtain a real-time diagnosis result of the welding quality of the corresponding chain ring, and the display module 50 displays the welding data curve and the real-time monitoring result.
The primary welding process comprises the following steps: the chain K enters from the left lower side to cross over the iron pier 12 and is meshed on the iron pier 12, the conveying claw 2 reciprocates downwards and rightwards to draw the chain K to reach a welding position to finish feeding, the welding electrode arm 11 descends along with the welding electrode 111 and clamps a chain ring, the upsetting mechanism 13 drives an upsetting shaft to draw close inwards to apply upsetting force to clamp the chain ring, the welding machine is electrified and applies upsetting force to finish welding, the conveying claw 2 hooks the chain K to drive the chain K to move downwards and rightwards, welding is carried out once when one chain ring is pulled each time, and discharging is carried out until the whole chain K is welded.
The method can monitor characteristic parameters such as welding current, welding voltage, upsetting displacement, upsetting force and main shaft corner in the welding process to analyze the neural network model on line in real time, and the data model can train and optimize according to the collected parameters in real time to realize the on-line judgment of the welding quality in the production process of the chain link chain.
The invention can also transmit the collected welding current, welding voltage, upsetting displacement, upsetting force and main shaft corner data to the upper computer unit through the Ethernet, thereby realizing the automatic monitoring, displaying and recording of the whole process of the small-specification chain link resistance butt welding production.
The small-size chain is a chain K with chain links with the diameter between phi 4mm and phi 16 mm.
Claims (6)
1. A method for monitoring the resistance butt welding quality of a small-specification chain link chain on line is characterized by comprising the following steps: the method is based on the characteristic of the welding process of analyzing the data of the forming process of a welding joint during the welding of a chain and a chain, establishes an online welding quality monitoring system according to corresponding quality judgment standards, adopts parameters of welding current, welding voltage, upsetting displacement, upsetting force and main shaft rotation angle in the welding process as characteristic quantities for judging the welding quality, and comprises the following steps:
s1) deploying sensors required for measuring the parameters on a welding secondary circuit and an upsetting mechanism of the butt welding machine for the small-size chains to be monitored;
s2) installing a lower computer unit beside the controller of the butt welding machine, connecting the sensor in the step S1), and acquiring data corresponding to welding signals;
s3), the welding process data acquired by the data of the lower computer unit in the step S2) are transmitted to the upper computer unit through Ethernet, a real-time data model is established through a processing module of the upper computer unit to process, analyze and diagnose the data signals, and then the welding quality diagnosis result is displayed in real time through a display module of the upper computer unit.
2. The on-line monitoring method for the resistance butt welding quality of the small-specification chain link chain according to claim 1, characterized in that: the welding quality on-line monitoring system comprises a sensor unit, a lower computer unit, a data transmission unit and an upper computer unit, wherein the sensor unit is connected with the lower computer unit, and the upper computer unit is connected with the lower computer unit through the data transmission unit; the butt welding machine head comprises a pair of welding electrode arms, welding electrodes which are respectively arranged at the bottoms of the welding electrode arms, an iron pier positioned below the welding electrodes, and upsetting mechanisms which are respectively arranged at the two outer sides of the iron pier, wherein the two upsetting mechanisms are provided with upsetting shafts which are arranged in a mutually facing manner, and a conveying claw for dragging the endless chain is arranged at the discharge side of the endless chain; the welding electrode arm is provided with a welding current sensor, a welding voltage sensing cable and an upsetting displacement sensor, the upsetting mechanism is provided with an upsetting force sensor, and a spindle rotation angle encoder is arranged on a spindle of a butt welding machine head.
3. The on-line monitoring method for the resistance butt welding quality of the small-specification chain link chain according to claim 2, characterized in that: the sensor unit is used for collecting a welding current signal, a welding voltage signal, an upsetting displacement signal, an upsetting force signal and a main shaft corner signal of the chain link in the resistance butt welding production process, the lower computer unit is used for conditioning an original signal collected by the sensor unit into a proper electric signal, the data transmission unit is used for transmitting welding data processed by the lower computer unit to the upper computer unit to complete management and storage of the data, the upper computer unit is used for processing the welding data, inputting a mathematical model and analyzing the welding quality, and finally, a welding quality diagnosis result is displayed on the display module.
4. The on-line monitoring method for the resistance butt welding quality of the small-specification loop chain according to claim 2 or 3, characterized in that: the lower computer unit comprises a power module, a signal conditioning module and a control module which are integrated on a circuit board, the power module respectively supplies power to the control module and the signal conditioning module, the signal conditioning module is connected with a main shaft corner encoder and each sensor of the sensor unit through a lead, a welding voltage sensing cable is directly connected with the signal conditioning module so as to condition the acquired original signal into a proper electric signal and transmit the proper electric signal to the control module, and the control module is responsible for receiving and processing welding data and transmitting the data to the data transmission unit.
5. The on-line monitoring method for the resistance butt welding quality of the small-specification loop chain according to claim 2 or 3, characterized in that: the data transmission unit comprises a data communication module and a database management module, the data communication module transmits the welding data acquired by the lower computer unit to the upper computer unit in an Ethernet mode, and the database management module realizes processing, storage and query of the acquired data.
6. The on-line monitoring method for the resistance butt welding quality of the small-specification loop chain according to claim 2 or 3, characterized in that: the upper computer unit comprises a processing module and a display module, the processing module processes, calculates and analyzes real-time welding data uploaded by data transmission to obtain a real-time diagnosis result of the welding quality of the corresponding chain link, and the display module displays the welding data curve and the real-time monitoring result.
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| CN108188560A (en) * | 2017-12-12 | 2018-06-22 | 广州亨龙智能装备股份有限公司 | Hand-held electric resistance welding Quality Monitoring Control System based on linux system |
| CN109108445A (en) * | 2018-11-05 | 2019-01-01 | 南京菲斯特焊接科技有限公司 | A kind of suspension type electric resistance electric arc welder welding process parameter monitor and monitoring method |
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2020
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Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0189805A2 (en) * | 1985-02-01 | 1986-08-06 | Elpatronic Ag | Machine for welding longitudinal seams of rounded sheet metal container borders |
| CN1806992A (en) * | 2006-01-27 | 2006-07-26 | 王洪军 | Full automatic hydraulic flash butt welding method of metal circular ring chain and apparatus thereof |
| CN104690407A (en) * | 2013-12-12 | 2015-06-10 | 佛山安可锚链有限公司 | Automatic recording system for anchor chain flash welding machine and automatic recording method |
| CN204504488U (en) * | 2015-02-15 | 2015-07-29 | 广东省工业技术研究院(广州有色金属研究院) | A kind of steel pipe flash butt welding on-line monitoring system |
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