CN112859733A - Control system based on PLC and welding speed - Google Patents
Control system based on PLC and welding speed Download PDFInfo
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- CN112859733A CN112859733A CN202110088670.3A CN202110088670A CN112859733A CN 112859733 A CN112859733 A CN 112859733A CN 202110088670 A CN202110088670 A CN 202110088670A CN 112859733 A CN112859733 A CN 112859733A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
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- 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
- B23K31/02—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 soldering or welding
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention provides a control method based on a PLC and a welding speed, which comprises a PLC operation module, a PLC signal butt joint module, a transmission speed monitoring module, a welding wire conveying monitoring module, a welding machine monitoring module and a speed matching module. The invention has the beneficial effects that: the PLC program realizes the adjustment of the welding speed, and firstly, the PLC program has strong stability and can realize stable adjustment through pulse signals. The invention relates to a self-feedback system for real-time feedback and real-time adjustment, which can be in a dynamic adjustment mode and constantly keep the welding standard in accordance with the requirement standard.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a control system based on a PLC and a welding speed.
Background
At present, in the welding process, if a large-scale welding processing enterprise performs welding, the welding robot performs welding through a welding robot, and the robot is controlled based on a PLC. The PLC is a circuit editing control device that uses a pulse signal in the control process and then controls the welding based on the physical drive train. However, in the prior art, the PLC system only controls the operation of the welding equipment when controlling the welding, but for the actual welding wire feeding mechanism, the three parts of the equipment for conveying the welding body and the welding main body of the welding robot are controlled to only control the operation of the welding body, and the welding robot cannot control the welding equipment to weld in a state conforming to the welding mark, and cannot realize the accurate and efficient welding. The welding wire is not fed timely, the conveying speed of a welding body exceeds the welding speed, and therefore welding is not standard in some places.
Disclosure of Invention
The invention provides a control system based on a PLC and a welding speed, which is used for solving the problem of low welding operation efficiency caused by too high or too low welding speed.
A PLC and welding speed based control system comprising:
a PLC operation module: the pulse control signal control device is used for generating a pulse control signal through a preset PIC editing program and controlling welding equipment to weld a welding body through the pulse control signal;
PLC signal butt joint module: the welding speed output by the pulse control signal is determined according to the pulse control signal, a corresponding transmission signal is generated and sent to a transmission module;
a transmission module; the transmission adjusting device is used for determining transmission adjusting information according to the transmission signal and adjusting the transmission equipment; wherein,
the transmission apparatus includes: the welding wire conveying mechanism, the welding head moving mechanism and the welding body conveying mechanism;
a transfer speed monitoring module: the device is used for acquiring the conveying speed of the welding body in real time;
a welding wire conveying monitoring module: the device is used for acquiring the welding wire conveying speed of the welding wire conveying device in real time;
the welding machine monitoring module: the real-time scanning device is used for scanning a welding body in real time and determining the real-time welding speed;
a speed matching module: and the PIC editing program is used for matching the welding wire feeding speed, the conveying speed and the real-time welding speed with an actual welding standard, generating a matching value according to a matching result and sending the matching value to the PLC operation module.
As an embodiment of the present invention, the PLC operation module includes:
a program control module: the PLC control system comprises a PLC editor program used for receiving an external user and determining a generation table for generating a pulse control signal in the PLC editor program;
the generating table includes: adjusting the signal generating table and starting the signal generating table;
a start control unit: the device comprises a starting signal generation table, a pulse control signal generation table and a control signal generation unit, wherein the starting signal generation table is used for generating a pulse control signal for starting the welding equipment;
a regulation control unit: and the pulse control unit is used for acquiring the matching value in the operation process of the welding equipment, comparing the matching value with the adjustment signal generation table and outputting a corresponding pulse control signal for adjusting the welding equipment.
As an embodiment of the invention, the welder monitoring module comprises:
an image pickup unit: the real-time welding system is used for acquiring real-time welding images of the welding equipment and a welding body through a camera arranged at the upper part of the welding equipment;
a scanning unit: the real-time welding image is scanned by a laser scanning technology, and the welding speed is determined; wherein
The welding speed determining step includes:
dividing the real-time welding image according to preset time intervals, and determining a region corresponding to each divided preset time interval;
determining the welding distance of each preset time period in the corresponding area of each preset time period through the laser scanning technology, and judging whether the time period with the welding distance of 0 exists or not;
taking the time period when the welding distance is 0 as an invalid time period, and taking the time period when the welding distance is not 0 as an effective time period;
and substituting the welding distance of each effective time period and the total duration of the effective time period into a summation average formula to determine the welding speed.
As an embodiment of the present invention, the PLC signal docking module:
an analysis unit: the pulse control signal is used for receiving the pulse control signal and judging the pulse control signal to be a starting signal or an adjusting control signal;
a welding speed unit: the control device is used for determining the adjustment control parameters of the adjustment control signals when the pulse control signals are the adjustment control signals, determining corresponding execution logic, and generating transmission control instructions according to the execution logic;
a transmission unit: the real-time transmission model generation device is used for acquiring real-time transmission data of a transmission device and generating a real-time transmission model according to the real-time transmission data of the transmission device;
a transmission unit: the transmission control device is used for receiving the transmission control instruction, determining a transmission signal and sending the transmission signal to a transmission mechanism; wherein.
The transmission signal comprises welding wire feeding adjusting parameters, welding head moving adjusting parameters and welding body transmission parameters.
As an embodiment of the present invention, the transmission module includes:
a signal receiving unit: the transmission device is used for receiving the transmission signals and generating an intermediate state matrix of the transmission device;
a judging unit: the device is used for judging whether the standard state matrix is equal to the middle state matrix or not according to the acquired preset standard state matrix; wherein,
if not, the transmission signal is received again;
and if so, updating the intermediate state matrix to the local state matrix.
As an embodiment of the present invention, the transmission module further includes:
a speed model construction unit: the speed balance regulating and controlling module is used for building a speed balance regulating and controlling model according to the real-time welding speed and based on the transmission signal;
a model conversion unit: the system comprises a speed balance regulation model, a tracking analysis function, a hot spot device, a control device and a control device, wherein the speed balance regulation model is used for counting the speed regulation condition of transmission equipment and identifying the hot spot device of high-frequency regulation through functionalization;
a blending module: and the device information acquisition module is used for acquiring the device information of the high-frequency-adjustment hotspot device, detecting the device type according to the device information, determining the adjustment factor of the high-frequency adjustment, and replacing the device according to the adjustment factor.
As an embodiment of the present invention, the transfer speed monitoring module includes:
a monitoring unit: the speed sensor is arranged on the welding body conveying mechanism to acquire the conveying speed of the welding body conveying mechanism in real time;
an analysis unit: the welding body conveying mechanism is used for analyzing the conveying speed of the welding body conveying mechanism, judging whether the conveying speed exceeds a preset standard or not and marking the conveying speed in real time;
an emergency stop unit: for emergency stopping of the transmission when the transmission speed exceeds a preset criterion.
As an embodiment of the present invention, the wire feed monitoring module comprises:
a welding wire monitoring unit: the welding wire changing image acquisition device is used for acquiring a changing image of the welding wire through a camera arranged at the upper part of the welding device:
screening unit: the length change image and the welding wire replacement image of the welding wire are screened out from the change image within a preset time;
a welding wire data processing unit: the length change image before the cutting time point is used as a first calculation image set, and the length change image after the cutting time point is used as a second calculation image set;
a consumption length calculation unit: the first and second calculation image sets are respectively sorted according to time, a first welding wire length difference value of a first length change image and a last length change image in the first calculation image set after sorting is determined, a second welding wire length difference value of the first length change image and the last length change image in the second calculation image set after sorting is determined, and the sum of the first welding wire length difference value and the second welding wire length difference value is used as a welding wire consumption length
A wire feeding speed calculation unit: and the controller is used for determining the welding wire conveying speed according to the welding wire consumption length and the preset time.
As an embodiment of the present invention, the speed matching module includes:
a speed model unit: the speed model is constructed according to the welding wire feeding speed, the conveying speed and the welding speed;
a matching control unit: the system comprises a speed model, a speed fusion module and a control module, wherein the speed model is used for determining fusion speed characteristics according to the speed model, matching the speed fusion characteristics with a preset welding standard and determining a matching value;
a matching value transmitting unit: and the data interface is used for determining the data interface of the PIC editing program and importing the matching value into the PLC editing program through the data interface.
As an embodiment of the present invention, the speed matching module determines the matching value at each time, and includes the following steps:
step 1: acquiring a welding wire feeding speed, a conveying speed and a welding speed, and determining a welding wire feeding speed characteristic, a welding body conveying speed characteristic and a welding speed characteristic:
wherein S represents a wire feed speed characteristic; c represents a weld body conveyance speed characteristic; h represents a welding speed characteristic; x is the number oftRepresents the wire feeding speed at time t; y istRepresents the conveying speed of the welded body at the time t; z is a radical oftRepresents the welding speed at the time t; ε represents the time distribution coefficient; b (x)t) A normal distribution function representing a wire feeding speed; b (y)t) A normal distribution function representing a conveying speed of the welded body; b (z)t) A normal distribution function representing a welding speed; t represents a time; t represents data acquisition time;
step 2: constructing a fusion speed characteristic model according to the welding wire conveying speed characteristic, the welding body conveying speed characteristic and the welding speed characteristic:
wherein,
an average speed representing a wire feed speed;
an average speed representing a conveying speed of the welding body;
an average speed representing a welding speed; ptRepresenting the fusion speed characteristic value at the time t;
and step 3: acquiring a preset welding standard, matching the fusion speed characteristic model with the welding standard, and determining a matching value:
wherein F represents a match value; biRepresents the ith welding standard; 1,2,3 … … n; n represents the total number of welding standards set.
The invention has the beneficial effects that: the PLC program realizes the adjustment of the welding speed, and firstly, the PLC program has strong stability and can realize stable adjustment through pulse signals. The invention relates to a self-feedback system for real-time feedback and real-time adjustment, which can be in a dynamic adjustment mode and constantly keep the welding standard in accordance with the requirement standard.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and drawings.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a system diagram of a control system based on a PLC and a welding speed according to an embodiment of the present invention;
fig. 2 is a block diagram of a PLC operation module according to an embodiment of the present invention.
Detailed Description
The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.
As shown in the attached figure 1, the invention is a control system based on a PLC and a welding speed, and the invention has the function of automatically adjusting the welding speed according to the actual field welding condition so as to achieve the aim of standard welding. The invention comprises the following steps:
a PLC operation module: the pulse control signal control device is used for generating a pulse control signal through a preset PIC editing program and controlling welding equipment to weld a welding body through the pulse control signal;
PLC signal butt joint module: the welding speed output by the pulse control signal is determined according to the pulse control signal, a corresponding transmission signal is generated and sent to a transmission module;
a transmission module; the transmission adjusting device is used for determining transmission adjusting information according to the transmission signal and adjusting the transmission equipment; wherein,
the transmission apparatus includes: the welding wire conveying mechanism, the welding head moving mechanism and the welding body conveying mechanism;
a transfer speed monitoring module: the device is used for acquiring the conveying speed of the welding body in real time;
a welding wire conveying monitoring module: the device is used for acquiring the welding wire conveying speed of the welding wire conveying device in real time;
the welding machine monitoring module: the real-time scanning device is used for scanning a welding body in real time and determining the real-time welding speed;
a speed matching module: and the PIC editing program is used for matching the welding wire feeding speed, the conveying speed and the real-time welding speed, generating a matching value according to a matching result and sending the matching value to the PLC operation module.
The principle of the technical scheme is as follows: the PLC editor program is realized by language-to-language (STL) editing based on statement tables, can automatically reflect the matching data in the form of matching values according to the detected matching data of the welding wire conveying speed, the conveying speed and the welding speed, and generates pulse control signals, a table corresponding to the matching values is preset in the PLC editor program, the number of the matching values and the like correspond to the pulse control signals, and the PLC editor program controls that any welding point can meet the welding standard in the whole welding process. The PLC signal butt-joint module outputs the welding speed to be adjusted when a pulse control signal is provided, then determines how the transmission equipment of the welding device is adjusted according to the welding speed to achieve the welding speed, and then generates a transmission signal according to the adjustment requirement. And controlling the transmission equipment to carry out the welding wire feeding speed which best meets the preset standard based on the transmission signal. The transmission module mainly sends signals to the welding wire conveying mechanism, the welding head moving mechanism and the welding equipment moving mechanism, so that the welding wire conveying speed adjustment, the welding head moving speed adjustment and the welding body conveying mechanism moving speed adjustment are realized. The monitoring device of the present invention comprises three parts. The welding machine monitoring module is based on a laser scanning camera, and determines the real-time welding speed according to the real-time scanning video, wherein the real-time welding speed is the same as the moving speed of a welding head moving structure. A transfer speed monitoring module: a control unit for acquiring a conveying speed of conveying the welded body, that is, a conveying speed of the welded body conveying mechanism, in real time; a welding wire conveying monitoring module: the device is used for acquiring the welding wire conveying speed of the welding wire conveying device in real time; i.e., the speed at which the wire feed mechanism feeds the wire. And finally, generating data for speed adjustment through speed matching, and transmitting the data to a PLC (programmable logic controller) editing program to realize the control of the overall speed and further realize the control of the welding speed.
The invention has the beneficial effects that: the PLC program realizes the adjustment of the welding speed, and firstly, the PLC program has strong stability and can realize stable adjustment through pulse signals. The invention relates to a self-feedback system for real-time feedback and real-time adjustment, which can be in a dynamic adjustment mode and constantly keep the welding standard in accordance with the requirement standard.
As an embodiment of the present invention: as shown in fig. 2, the PLC operation module includes:
a program control unit: the device comprises an editing program, a generation table and a control unit, wherein the editing program is imported by an external user, and the generation table is used for determining a generation pulse control signal in the editing program;
the generating table includes: adjusting the signal generating table and starting the signal generating table;
a start control unit: the device comprises a starting signal generation table, a pulse control signal generation table and a control signal generation unit, wherein the starting signal generation table is used for generating a pulse control signal for starting the welding equipment;
a regulation control unit: and the pulse control unit is used for acquiring the matching value in the operation process of the welding equipment, comparing the matching value with the adjustment signal generation table and outputting a corresponding pulse control signal for adjusting the welding equipment.
The principle of the technical scheme is as follows: the PLC operation module is mainly used for receiving and running a PLC editing program input by a user, wherein a generation comparison table for generating a pulse control signal is automatically arranged in the PLC editing program, and the PLC operation module is also used for generating the pulse control signal. The invention comprises two conditions when the pulse signal is output, namely adjusting the welding equipment and starting the welding equipment. The real-time status of the welding equipment is compared with the start signal generation table (before the welding equipment is not started, all equipment of the welding equipment are required to meet the starting standard, such as the power state, the state of a motor of a transmission mechanism, whether the motor is damaged or not, and the like, and the welding equipment can be started only if all equipment is in a good state. When the welding equipment needs to be regulated and controlled after the welding equipment is started, the matching value is compared with the regulation signal generation table, and the value for generating the pulse control signal in the regulation signal generation table is a regulation value and can generate the pulse control signal specially used for regulation.
The beneficial effects of the above technical scheme are that: the invention can realize the starting and the welding speed regulation of the welding equipment according to the PLC editing program, and can start the welding equipment according to the state of the welding equipment before the welding equipment is started, thereby realizing the advanced detection of the welding equipment.
As an embodiment of the present invention: the welder monitoring module includes:
an image pickup unit: the real-time welding system is used for acquiring real-time welding images of the welding equipment and a welding body through a camera arranged at the upper part of the welding equipment;
a scanning unit: the real-time welding image is scanned by a laser scanning technology, and the welding speed is determined; wherein
The welding speed determining step includes:
dividing the real-time welding image according to preset time intervals, and determining a region corresponding to each divided preset time interval;
determining the welding distance of each preset time period in the corresponding area of each preset time period through the laser scanning technology, and judging whether the time period with the welding distance of 0 exists or not;
taking the time period when the welding distance is 0 as an invalid time period, and taking the time period when the welding distance is not 0 as an effective time period;
and substituting the welding distance of each effective time period and the total duration of the effective time period into a summation average formula to determine the welding speed.
The principle and the beneficial effects of the technical scheme are as follows: the invention calculates the welding speed based on the shot image of the shooting technology and the laser scanning technology. Laser scanning enables accurate calculation of the welding distance, and real-time welding images serve as parameter images of welding. The invention divides the time interval into the effective time interval and the ineffective time interval when calculating the welding speed because the invention is a large welding device, the welding bodies are welded one by one, but the time interval for changing the welding parts generally exists in the welding time between the two welding bodies, and at the moment, the welding time is calculated, but the welding state is not in the welding state, therefore, the invention is ineffective for the time interval and does not carry out calculation. The preset time interval is set manually, and the welding speed is determined according to the actual welding scene and the condition of the welding equipment. This is part of the welding standard set up.
As an embodiment of the present invention: the PLC signal butt-joint module:
an analysis unit: the pulse control signal is used for receiving the pulse control signal and judging the pulse control signal to be a starting signal or an adjusting control signal;
a welding speed unit: the control device is used for determining the adjustment control parameters of the adjustment control signals when the pulse control signals are the adjustment control signals, determining corresponding execution logic, and generating transmission control instructions according to the execution logic;
a transmission unit: the real-time transmission model generation device is used for acquiring real-time transmission data of a transmission device and generating a real-time transmission model according to the real-time transmission data of the transmission device;
a transmission unit: the transmission control device is used for receiving the transmission control instruction, determining a transmission signal and sending the transmission signal to a transmission mechanism; wherein.
The transmission signal comprises welding wire feeding adjusting parameters, welding head moving adjusting parameters and welding body transmission parameters.
The principle and the beneficial effects of the technical scheme are as follows: the invention analyzes the pulse control signal, because the pulse signal is a discrete signal with period, it can dynamically adjust the transmission equipment. In judging the starting signal and the adjusting control signal, the adjusting signal or the starting signal can be judged only by judging whether the waveform is a stable linear waveform or a curve waveform. When the pulse signal is the adjusting signal, because the PLC device simultaneously controls multiple execution steps at the same time, that is, executes the same time, the PLC device has multiple pulse signals sent out, so that the multiple pulse signals received by the same transmission structure can determine their corresponding adjusting control parameters and execute logic, for example: the pulse signal of the moving time of the welding head, the pulse signal of the moving direction and the pulse signal controlled by the motor are simultaneously received by the welding head moving mechanism at the same time.
As an embodiment of the present invention: the transmission module includes:
a signal receiving unit: the transmission device is used for receiving the transmission signals and generating an intermediate state matrix of the transmission device;
a judging unit: the device is used for judging whether the standard state matrix is equal to the middle state matrix or not according to the acquired preset standard state matrix; wherein,
if not, the transmission signal is received again;
and if so, updating the intermediate state matrix to the local state matrix.
The principle and the beneficial effects of the technical scheme are as follows: in order to enable the control signals of the whole transmission equipment to meet the standard during regulation, the control signals of the whole transmission equipment are embodied in a matrix form, the matrix is a time-based matrix, and the intermediate state matrix embodies the matrix of real-time state parameters of a plurality of transmission equipment of the transmission mechanism at each moment of dynamic regulation. The standard state matrix is a preset matrix of real-time state parameters of a plurality of transmission devices of the transmission mechanism at each moment in a state conforming to standard welding (for example, the elements in the standard state matrix are the state parameters of the welding wire feeding mechanism, the welding head moving mechanism and the welding body conveying mechanism at each moment). Therefore, whether the adjusted welding standard is met or not can be judged by comparing the two matrixes. Furthermore, in the case of the standard, execution is performed according to the existing standard, and in the case of the non-standard, the transmission signal is received again, and the transmission signal at this time is already a new signal generated dynamically. The intermediate state matrix is updated to the local state matrix for storage as historical data.
As an embodiment of the present invention: the transmission module further includes:
a speed model construction unit: the speed balance regulating and controlling module is used for building a speed balance regulating and controlling model according to the real-time welding speed and based on the transmission signal;
a model conversion unit: the system comprises a speed balance regulation model, a tracking analysis function, a hot spot device, a control device and a control device, wherein the speed balance regulation model is used for counting the speed regulation condition of transmission equipment and identifying the hot spot device of high-frequency regulation through functionalization;
a blending module: and the device information acquisition module is used for acquiring the device information of the high-frequency-adjustment hotspot device, detecting the device type according to the device information, determining the adjustment factor of the high-frequency adjustment, and replacing the device according to the adjustment factor.
The principle and the beneficial effects of the technical scheme are as follows: when the transmission equipment is adjusted, a speed balance adjustment model is also constructed based on the real-time welding speed and the transmission signal of the equipment, and the speed balance adjustment model embodies that the speed adjustment is carried out at the moment and the equipment is in a balanced state (the speed is the same after each adjustment). The purpose of the functionalization is then to be able to trace each transmission device in the form of data, determining the number of device adjustments, which must be due to damage to a part of the device when the device has been adjusted all the time. Further, the equipment information of the transmission equipment which is adjusted at a high frequency is determined, equipment detection is carried out, and the reason why the equipment needs to be adjusted all the time is judged, so that equipment replacement is carried out. In the process, the real-time online state detection (judging whether the transmission equipment has a fault) of the equipment can be carried out, and the operation of the equipment is not influenced. And for the transmission equipment with low adjusting frequency, the transmission equipment can not be replaced and detected under the condition of not influencing production.
As an embodiment of the present invention: the transfer speed monitoring module includes:
a monitoring unit: the speed sensor is arranged on the welding body conveying mechanism to acquire the conveying speed of the welding body conveying mechanism in real time;
an analysis unit: the welding body conveying mechanism is used for analyzing the conveying speed of the welding body conveying mechanism, judging whether the conveying speed exceeds a preset standard or not and marking the conveying speed in real time;
an emergency stop unit: for emergency stopping of the transmission when the transmission speed exceeds a preset criterion.
The principle and the beneficial effects of the technical scheme are as follows: the present invention controls the welding speed based on the three speeds, the wire feeding speed, the transfer speed of the welded body, and the real-time welding speed, and therefore it is also necessary to acquire the transfer speed of the welded body transfer mechanism. The analysis unit is used for judging whether the speed is too high (the speed is slightly too high or too low and is adjusted by the invention, and the speed is extremely abnormal and needs to be stopped urgently) when the welded body is conveyed, so that the welded body is welded wrongly in the whole welding process. An emergency stop may be possible if the welding is wrong. Thereby reducing welding losses and altering the welding speed.
As an embodiment of the present invention: the welding wire feeding monitoring module comprises:
a welding wire monitoring unit: the welding wire changing image acquisition device is used for acquiring a changing image of the welding wire through a camera arranged at the upper part of the welding device:
screening unit: the length change image and the welding wire replacement image of the welding wire are screened out from the change image within a preset time;
a welding wire data processing unit: the length change image before the cutting time point is used as a first calculation image set, and the length change image after the cutting time point is used as a second calculation image set;
a consumption length calculation unit: the first and second calculation image sets are respectively sorted according to time, a first welding wire length difference value of a first length change image and a last length change image in the first calculation image set after sorting is determined, a second welding wire length difference value of the first length change image and the last length change image in the second calculation image set after sorting is determined, and the sum of the first welding wire length difference value and the second welding wire length difference value is used as a welding wire consumption length
A wire feeding speed calculation unit: and the controller is used for determining the welding wire conveying speed according to the welding wire consumption length and the preset time.
The principle and the beneficial effects of the technical scheme are as follows: the invention aims to obtain the conveying speed of a welding wire. The method comprises the steps of acquiring all length change images of the welding wire in a preset period of time (monitoring) by a camera (the length change is because if the welding wire is replaced, the length of a new welding wire is longer than that of the original welding wire after replacement, but the length of the new welding wire is shortened in a non-replacement period, but the length change images and the welding wire replacement images are consumed), and therefore when the consumed length of the welding wire is calculated, the length change images and the welding wire replacement images of the welding wire are introduced. The wire consumption length is calculated as the total consumption length in the period before and after the wire replacement image, respectively, and then the wire feeding speed is determined based on this period.
As an embodiment of the present invention, the speed matching module includes:
a speed model unit: the speed model is constructed according to the welding wire feeding speed, the conveying speed and the welding speed;
a matching control unit: the system comprises a speed model, a speed fusion module and a control module, wherein the speed model is used for determining fusion speed characteristics according to the speed model, matching the speed fusion characteristics with a preset welding standard and determining a matching value;
a matching value transmitting unit: and the data interface is used for determining the data interface of the PIC editing program and importing the matching value into the PLC editing program through the data interface.
The principle and the beneficial effects of the technical scheme are as follows: the speed model unit is used for constructing a speed model according to the welding wire conveying speed, the conveying speed and the welding speed, is a fusion speed characteristic model, can fuse different speeds into the same model, and can embody the overall fusion characteristics of different devices after parameterization. The fusion characteristics embody the overall characteristics of speed-related factors, and the obtained matching value is the related degree value of the two other objects when the preset welding standard images are matched, and the value is between 0 and 1; after this is percentile, the difference value is obtained by subtracting this value from 1. In the present invention, the comparison table set in the preset PIC editor is directly based on the correlation degree value.
As an embodiment of the present invention, the speed matching module determines the matching value at each time, and includes the following steps:
step 1: acquiring a welding wire feeding speed, a conveying speed and a welding speed, and determining a welding wire feeding speed characteristic, a welding body conveying speed characteristic and a welding speed characteristic:
wherein S represents a wire feed speed characteristic; c represents a weld body conveyance speed characteristic; h represents a welding speed characteristic; x is the number oftRepresents the wire feeding speed at time t; y istRepresents the conveying speed of the welded body at the time t; z is a radical oftRepresents the welding speed at the time t; ε represents the time distribution coefficient; b (x)t) A normal distribution function representing a wire feeding speed; b (y)t) A normal distribution function representing a conveying speed of the welded body; b (z)t) A normal distribution function representing a welding speed; t represents a time; t represents data acquisition time;
step 2: constructing a fusion speed characteristic model according to the welding wire conveying speed characteristic, the welding body conveying speed characteristic and the welding speed characteristic:
wherein,
an average speed representing a wire feed speed;
an average speed representing a conveying speed of the welding body;
an average speed representing a welding speed; ptRepresenting the fusion speed characteristic value at the time t;
and step 3: acquiring a preset welding standard, matching the fusion speed characteristic model with the welding standard, and determining a matching value:
wherein F represents a match value; biRepresents the ith welding standard; 1,2,3 … … n; n represents the total number of welding standards set.
The principle and the beneficial effects of the technical scheme are as follows: the invention calculates the product of the normal distribution function of each moment under the time factor and the ratio of each moment to the total time in turn based on the speed characteristics of the wire feeding speed, the conveying speed and the welding speed to embody the dynamic characteristics of each speed. When the fusion speed characteristic is calculated, the speed mean value and the exponential function are introduced to determine the fusion characteristic of the welding wire conveying speed, the conveying speed and the welding speed at each moment, so that the dynamic adjustment can be performed, and the adjustment at each moment can be realized. And when the matching value is calculated finally, the matching relation is directly calculated through the matching algorithm.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (10)
1. A control system based on PLC and welding speed, comprising:
a PLC operation module: the pulse control signal control device is used for generating a pulse control signal through a preset PIC editing program and controlling welding equipment to weld a welding body through the pulse control signal;
PLC signal butt joint module: the welding speed output by the pulse control signal is determined according to the pulse control signal, a corresponding transmission signal is generated and sent to a transmission module;
a transmission module; the transmission adjusting device is used for determining transmission adjusting information according to the transmission signal and adjusting the transmission equipment; wherein,
the transmission apparatus includes: the welding wire conveying mechanism, the welding head moving mechanism and the welding body conveying mechanism;
a transfer speed monitoring module: the device is used for acquiring the conveying speed of the welding body in real time;
a welding wire conveying monitoring module: the device is used for acquiring the welding wire conveying speed of the welding wire conveying device in real time;
the welding machine monitoring module: the real-time scanning device is used for scanning a welding body in real time and determining the real-time welding speed;
a speed matching module: and the PIC editing program is used for matching the welding wire feeding speed, the conveying speed and the real-time welding speed with an actual welding standard, generating a matching value according to a matching result and sending the matching value to the PLC operation module.
2. The PLC and welding speed based control system of claim 1, wherein the PLC operating module comprises:
a program control unit: the PLC control system comprises a PLC editor program used for receiving an external user and determining a generation table for generating a pulse control signal in the PLC editor program;
the generating of the comparison table comprises: adjusting the signal generating table and starting the signal generating table;
a start control unit: the device comprises a starting signal generation table, a pulse control signal generation table and a control signal generation unit, wherein the starting signal generation table is used for generating a pulse control signal for starting the welding equipment;
a regulation control unit: and the pulse control unit is used for acquiring the matching value in the operation process of the welding equipment, comparing the matching value with the adjustment signal generation table and outputting a corresponding pulse control signal for adjusting the welding equipment.
3. The PLC and weld speed based control system of claim 1, wherein the welder monitoring module comprises:
an image pickup unit: the real-time welding system is used for acquiring real-time welding images of the welding equipment and a welding body through a camera arranged at the upper part of the welding equipment;
a scanning unit: the real-time welding image is scanned by a laser scanning technology, and the welding speed is determined; wherein
The welding speed determining step includes:
dividing the real-time welding image according to preset time intervals, and determining a region corresponding to each divided preset time interval;
determining the welding distance of each preset time period in the corresponding area of each preset time period through the laser scanning technology, and judging whether the time period with the welding distance of 0 exists or not;
taking the time period when the welding distance is 0 as an invalid time period, and taking the time period when the welding distance is not 0 as an effective time period;
and substituting the welding distance of each effective time period and the total duration of the effective time period into a summation average formula to determine the welding speed.
4. The PLC and weld speed based control system of claim 1, wherein the PLC signal docking module:
an analysis unit: the pulse control signal is used for receiving the pulse control signal and judging the pulse control signal to be a starting signal or an adjusting control signal;
a welding speed unit: the control device is used for determining the adjustment control parameters of the adjustment control signals when the pulse control signals are the adjustment control signals, determining corresponding execution logic, and generating transmission control instructions according to the execution logic;
a transmission unit: the real-time transmission model generation device is used for acquiring real-time transmission data of a transmission device and generating a real-time transmission model according to the real-time transmission data of the transmission device;
a transmission unit: the transmission control device is used for receiving the transmission control instruction, determining a transmission signal and sending the transmission signal to a transmission mechanism; wherein
The transmission signal comprises welding wire feeding adjusting parameters, welding head moving adjusting parameters and welding body transmission parameters.
5. The PLC and welding speed based control system of claim 1, wherein the transmission module comprises:
a signal receiving unit: the transmission device is used for receiving the transmission signals and generating an intermediate state matrix of the transmission device;
a judging unit: the device is used for judging whether the standard state matrix is equal to the middle state matrix or not according to the acquired preset standard state matrix; wherein,
if not, the transmission signal is received again;
and if so, updating the intermediate state matrix to the local state matrix.
6. The PLC and welding speed based control system of claim 1, wherein the transmission module further comprises:
a speed model construction unit: the speed balance regulating and controlling module is used for building a speed balance regulating and controlling model according to the real-time welding speed and based on the transmission signal;
a model conversion unit: the system comprises a speed balance regulation model, a tracking analysis function, a hot spot device, a control device and a control device, wherein the speed balance regulation model is used for counting the speed regulation condition of transmission equipment and identifying the hot spot device of high-frequency regulation through functionalization;
a blending module: and the device information acquisition module is used for acquiring the device information of the high-frequency-adjustment hotspot device, detecting the device type according to the device information, determining the adjustment factor of the high-frequency adjustment, and replacing the device according to the adjustment factor.
7. The PLC and welding speed based control system of claim 1, wherein the transfer speed monitoring module comprises:
a monitoring unit: the speed sensor is arranged on the welding body conveying mechanism to acquire the conveying speed of the welding body conveying mechanism in real time;
an analysis unit: the welding body conveying mechanism is used for analyzing the conveying speed of the welding body conveying mechanism, judging whether the conveying speed exceeds a preset standard or not and marking the conveying speed in real time;
an emergency stop unit: for emergency stopping of the transmission when the transmission speed exceeds a preset criterion.
8. The PLC and welding speed based control system of claim 1, wherein the wire feed monitoring module comprises:
a welding wire monitoring unit: the welding wire changing image acquisition device is used for acquiring a changing image of the welding wire through a camera arranged at the upper part of the welding device:
screening unit: the length change image and the welding wire replacement image of the welding wire are screened out from the change image within a preset time;
a welding wire data processing unit: the length change image before the cutting time point is used as a first calculation image set, and the length change image after the cutting time point is used as a second calculation image set;
a consumption length calculation unit: the first and second calculation image sets are respectively sorted according to time, a first welding wire length difference value of a first length change image and a last length change image in the first calculation image set after sorting and a second welding wire length difference value of the first length change image and the last length change image in the second calculation image set after sorting are determined, and the sum of the first welding wire length difference value and the second welding wire length difference value is used as the welding wire consumption length;
a wire feeding speed calculation unit: and the controller is used for determining the welding wire conveying speed according to the welding wire consumption length and the preset time.
9. The PLC and welding speed based control system of claim 1, wherein the speed matching module comprises:
a speed model unit: the speed model is constructed according to the welding wire feeding speed, the conveying speed and the welding speed;
a matching control unit: the system comprises a speed model, a speed fusion module and a control module, wherein the speed model is used for determining fusion speed characteristics according to the speed model, matching the speed fusion characteristics with a preset welding standard and determining a matching value;
a matching value transmitting unit: and the data interface is used for determining the data interface of the PIC editing program and importing the matching value into the PLC editing program through the data interface.
10. The PLC and welding speed based control system of claim 9, wherein the speed matching module determines a match value at each time, comprising the steps of:
step 1: acquiring a welding wire feeding speed, a conveying speed and a welding speed, and determining a welding wire feeding speed characteristic, a welding body conveying speed characteristic and a welding speed characteristic:
wherein S represents a wire feed speed characteristic; c represents a weld body conveyance speed characteristic; h represents a welding speed characteristic; x is the number oftRepresents the wire feeding speed at time t; y istRepresents the conveying speed of the welded body at the time t; z is a radical oftRepresents the welding speed at the time t; ε represents the time distribution coefficient; b (x)t) A normal distribution function representing a wire feeding speed; b (y)t) A normal distribution function representing a conveying speed of the welded body; b (z)t) A normal distribution function representing a welding speed; t represents a time; t represents data acquisition time;
step 2: constructing a fusion speed characteristic model according to the welding wire conveying speed characteristic, the welding body conveying speed characteristic and the welding speed characteristic:
wherein,
an average speed representing a wire feed speed;
an average speed representing a conveying speed of the welding body;
an average speed representing a welding speed; ptRepresenting the fusion speed characteristic value at the time t;
and step 3: acquiring a preset welding standard, matching the fusion speed characteristic model with the welding standard, and determining a matching value:
wherein F represents a match value; biRepresents the ith welding standard; 1,2,3 … … n; n represents the total number of welding standards set.
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| CN113453438A (en) * | 2021-06-11 | 2021-09-28 | 上海美维电子有限公司 | Etching production line speed control method |
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