CN112935604A - Central control system for hardfacing production - Google Patents
Central control system for hardfacing production Download PDFInfo
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- CN112935604A CN112935604A CN201911263747.5A CN201911263747A CN112935604A CN 112935604 A CN112935604 A CN 112935604A CN 201911263747 A CN201911263747 A CN 201911263747A CN 112935604 A CN112935604 A CN 112935604A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 50
- 238000005552 hardfacing Methods 0.000 title claims description 21
- 238000003466 welding Methods 0.000 claims abstract description 25
- 238000001816 cooling Methods 0.000 claims description 10
- 230000005540 biological transmission Effects 0.000 claims description 6
- 238000002955 isolation Methods 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 4
- 238000003908 quality control method Methods 0.000 abstract description 4
- 238000004891 communication Methods 0.000 description 6
- 238000005259 measurement Methods 0.000 description 5
- 238000012544 monitoring process Methods 0.000 description 5
- 238000013461 design Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 230000000750 progressive effect Effects 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 230000008054 signal transmission Effects 0.000 description 2
- 238000007619 statistical method Methods 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009529 body temperature measurement Methods 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000012806 monitoring device Methods 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Classifications
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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
- B23K31/02—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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
Abstract
The invention relates to a welding production quality control system, in particular to a wear-resistant surfacing production central control system, which comprises: the system comprises a headquarter monitoring center and a base website, wherein the headquarter monitoring center is provided with a headquarter computer, a display, a printer and an alarm device which are connected with the headquarter computer, the base website comprises a plurality of work station data acquisition devices, a wireless base station, a router, a base computer, a display, a printer and an alarm device, the work station data acquisition devices are connected with the wireless base station through WiFi, the wireless base station is connected with the base computer through the router, and the base computer is connected with the headquarter computer through the Internet. The automatic collecting and analyzing device can automatically collect and analyze the surfacing parameters of the surfacing production station in real time, remotely monitor and greatly improve the quality management level of enterprises and the quality of surfacing products.
Description
Technical Field
The invention relates to a welding production quality control system, in particular to a wear-resistant surfacing production central control system. The novel wear-resistant surfacing remote control system is a novel practical and progressive design for realizing the remote control of the surfacing by utilizing the Internet technology, and is suitable for wide popularization and application in the industrial field.
Background
A large-scale surfacing enterprise serving for producing and repairing various wear-resistant parts often has a plurality of production bases, and each base is provided with a plurality of production stations. For large wear-resistant parts such as grinding rollers and millstones in coal mills of power plants, and compression rollers in rolling mills of cement plants, in order to reduce transportation, production bases need to be arranged near the periphery of factories and mines with a large number of build-up welding requirements. How to carry out centralized management and control on the overlaying production quality of each scattered base and station is always a problem which needs to be solved urgently by each large-scale overlaying enterprise.
In addition, in the existing welding production field management, various standard parameters are recorded in detail in the production construction process according to the ISO9000 requirements, and the statistical analysis is carried out on the test results, so that not only is a large amount of personnel required to carry out the work, but also the recorded data distortion caused by human factors cannot be avoided. The quality control method for recording production process parameters and carrying out statistical analysis on the inspection results cannot control in time to avoid producing unqualified products in the welding production with multi-factor influence on standard parameters. Particularly, in the automatic welding production, a monitoring system capable of monitoring the welding process in real time and adjusting and controlling in time is urgently needed.
Based on abundant practical experience and professional knowledge for many years of designing and manufacturing of the products, the inventor of the invention actively carries out research and innovation by matching with the application of theories so as to create a wear-resistant surfacing production central control system, realize remote control of the wear-resistant surfacing by utilizing the internet technology and improve the quality management level and the surfacing quality of enterprises. After continuous research and design and repeated trial and improvement, the invention with practical value is finally created.
Disclosure of Invention
The invention mainly aims to overcome the defects in the existing surfacing production quality control and provide a wear-resistant surfacing production central control system based on the Internet +. The novel wear-resistant surfacing remote control system is a novel practical and progressive design for realizing the remote control of the surfacing by utilizing the Internet technology, and is suitable for wide popularization and application in the industrial field.
The purpose of the invention and the technical problem to be solved are realized by adopting the following technical scheme.
The central control system for the hardfacing production comprises a headquarters monitoring center and a base website, wherein the headquarters monitoring center is provided with a headquarters computer, a display, a printer and an alarm device, the display, the printer and the alarm device are connected with the output end of the headquarters computer, the base website comprises a plurality of work station data acquisition devices, a wireless base station, a router, a base computer, a display, a printer and an alarm device, the work station data acquisition devices are connected with the wireless base station through WiFi, the wireless base station is connected with the base computer through the router, and the base computer is connected with the display, the printer and the alarm device and is connected with the headquarters computer through the Internet.
The object of the present invention and the technical problems solved thereby can be further achieved by the following technical measures.
Aforementioned hardfacing production central control system, wherein station data acquisition device include: the device comprises a plurality of parameter sensors, a signal conditioner, a single chip microcomputer and wifi, wherein the parameter sensors are connected with the signal conditioner, the signal conditioner is connected with the single chip microcomputer, and the single chip microcomputer is connected with the wifi.
In the hardfacing production central control system, the plurality of parameter sensors are analog parameter sensors or digital parameter sensors, the signal conditioner is an analog signal conditioner or a digital signal conditioner, and the analog parameter sensors are connected with the analog signal conditioner and connected with the single chip microcomputer through an a/D converter and an isolation chip; the digital parameter sensor is connected with the singlechip through a photoelectric isolator.
The hardfacing production central control system of the foregoing, wherein the plurality of parameter sensors comprises: an arc voltage sensor, a welding current sensor, a wire feeding speed sensor, a workpiece rotating speed sensor, a workpiece temperature sensor and a cooling time sensor.
The main processing chip in the station data acquisition device is an EMW3165 wireless transmission data acquisition module.
The hardfacing production central control system described above, wherein the wireless base station is a 300M outdoor wireless base station.
Compared with the prior art, the invention has obvious advantages and beneficial effects. By means of the technical scheme, the wear-resistant surfacing production central control system can achieve considerable technical progress and practicability, has wide industrial utilization value and at least has the following advantages:
1. the wear-resistant surfacing production central control system enables a headquarter monitoring center to automatically acquire and analyze surfacing parameters of surfacing production stations of websites of all bases in real time through an internet system, so that remote monitoring is realized, and the quality management level of enterprises and the quality of surfacing products are greatly improved.
2. The central control system for the hardfacing production can be used for quality management of a welding production workshop by a base website and can automatically acquire, analyze and control the welding parameters of a welding production station in real time through a computer network system.
3. The wear-resistant surfacing production central control system automatically acquires, analyzes and controls the welding parameters of the welding production stations in real time through the computer network system, not only saves a large amount of manpower, but also avoids the distortion of recorded data caused by human factors.
4. The wear-resistant surfacing production central control system can give an alarm in time once serious fluctuation of welding parameters is found, so that serious quality accidents are prevented.
5. The wear-resistant surfacing production central control system adopts the 'Internet +' and accords with the development direction of national production and manufacturing industry.
In summary, the hardfacing production central control system of the present invention has the advantages and practical values described above, it is a great improvement in the structure or function of the method and apparatus, it is a significant advance in the art, it produces useful and practical effects, it has a wide value of industrial utilization, and it is a novel, progressive, practical new design.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood, the present invention may be implemented in accordance with the content of the description, and in order to make the above and other objects, features, and advantages of the present invention more clearly understood, the following preferred embodiments are described in detail with reference to the accompanying drawings.
Drawings
Fig. 1 is a block diagram of a hardfacing production central control system of the present invention.
Fig. 2 is a block diagram of a base site in a hardfacing production central control system of the present invention.
FIG. 3 is a block diagram of the station data acquisition device in the hardfacing production central control system of the present invention.
Detailed Description
To further illustrate the technical means and effects of the present invention adopted to achieve the predetermined objects, the following detailed description will be made on the specific implementation, structure, features and effects of the hardfacing production central control system according to the present invention with reference to the accompanying drawings and preferred embodiments.
Referring to fig. 1, 2 and 3, the hardfacing production central control system according to the preferred embodiment of the present invention includes a headquarters monitoring center 1 and a base website 2, wherein the headquarters monitoring center 1 is provided with a headquarters computer 11, a display 12, a printer 13 and an alarm device 14 connected to an output end of the headquarters computer 11, the base website 2 includes a plurality of work station data acquisition devices 3, a wireless base station 21, a router 22, a base computer 23, a display 24, a printer 25 and an alarm device 26, the plurality of work station data acquisition devices 3 are connected to the wireless base station 21 through WiFi, the wireless base station 21 is connected to the base computer 23 through the router 22, and the base computer 23 is connected to the display 24, the printer 25 and the alarm device 25 and is connected to the headquarters computer 11 through internet.
The wireless base station is a WiFi module by adopting a network distribution mode combining Ethernet and WiFi. And a wireless WiFi communication mode is adopted between the wireless base station and the station data acquisition device. The wireless base station 21 and the base computer use a wired network (Ethernet) communication mode. A router is configured at a base computer end, a twisted pair shielded wire is used as a communication cable to form a local area network, field devices (namely data acquisition devices on station devices) in the network are fixedly provided with IP addresses, and a central control computer accesses equipment data through the IP addresses and a ModbusTCP protocol. The twisted pair shielded wire is adopted as the communication cable to improve the signal transmission stability.
The radio base station is a 300M outdoor radio base station.
The station data acquisition device 3 comprises: a plurality of parameter sensor, signal conditioner, AD converter 31, isolator, singlechip 32 and wifi33, parameter sensor connects the signal conditioner, the signal conditioner is connected singlechip 32, singlechip 32 connects wifi 33. The parameter sensors are analog parameter sensors or digital parameter sensors, the isolator is a photoelectric isolator 34 or an isolation chip 35, the signal conditioner is an analog signal conditioner 36 or a digital signal conditioner 37, and the analog parameter sensors are connected with the analog signal conditioner 36 and connected with the single chip microcomputer 31 through an A/D converter 31 and the isolation chip 35; the digital parameter sensor is connected with the singlechip 31 through a photoelectric isolator 34.
The plurality of parameter sensors includes: an arc voltage sensor 38, a welding current sensor 39, a wire feed speed sensor 40, a workpiece rotational speed sensor 41, a workpiece temperature sensor 42, and a cooling timing sensor 43.
The main processing chip in the station data acquisition device adopts an EMW3165 wireless transmission data acquisition module. The module comprises an MCU microcontroller and a WiFi communication module. The MCU microcontroller contains a 12-bit A/D converter inside. The module has the characteristics of high performance, strong function, strong anti-interference capability, low power consumption, low price and small volume. The self-contained A/D converter can be used for measuring current and voltage analog quantities. The CPU unit of the module performs functions of sampling control, digital filtering, data preprocessing, data temporary storage, data uploading and the like. Based on the working environment of the workshop, the wiring is difficult, and a wireless data transmission mode is suitable to be adopted. The module is provided with a standard WiFi radio frequency unit and performs wireless transmission functions.
The parameter acquisition part adopts high-precision Hall current and voltage sensors to measure current and voltage parameters. And measuring the temperature of the workpiece by adopting an infrared temperature sensor. In order to match the analog signal output by the sensor with the input range of the A/D converter, the analog signal is conditioned, filtered and protected. The encoder digital pulse signal also needs conditioning to match the digital signal level range of the master control unit. And a control signal for starting and stopping cooling is introduced from the cooling control device and is sent to the main control unit after level adjustment.
The base website can be independently used as a centralized monitoring device of a welding workshop, and is used for collecting, monitoring, recording and analyzing welding parameters (arc voltage, welding current, wire feeding speed, workpiece rotating speed, workpiece temperature and cooling time) of each surfacing (or welding) station in real time. The working process is as follows:
1) circularly collecting six parameters of arc voltage, welding current, wire feeding speed, workpiece rotating speed, workpiece temperature and cooling time of 1-8 surfacing stations;
2) the computer stores, analyzes and gives an alarm to the parameters collected by each station, the first 5 parameters exceeding the welding standard requirements are displayed in a warning way, and a buzzer of the corresponding station is indicated to give an alarm;
3) data are cyclically acquired every 1.1 second;
for the butt welding bases distributed on other places, the hardfacing production central control system can realize remote monitoring through the internet. The headquarter monitoring center is connected with each base website through the Internet to perform parameter acquisition, transmission, recording, analysis and alarm.
The signal transmission uses a point-to-multipoint communication mode. Each station acquisition end is usually in an acquisition command state of a receiving computer, acquires data after receiving an acquisition command, uploads the data to the computer, and returns to the receiving state.
The data are collected by the computer in a unified and timed itinerant mode. Each station is provided with an address, and the computer appoints a certain station to collect data by sending different addresses. Only one workstation uploads data at a time.
In order to improve the measurement precision, digital filtering is performed on current, voltage and temperature measurement data, the measurement is performed once in 2ms, and 25 measurement data are taken to obtain an average value; for the measurement of the rotation speed, the number of pulses of the encoder within 50ms is supposed to be counted.
The computer data processing contents are as follows:
1. manually feeding or changing the diameter and welding parameter specification of workpieces at each station;
2. calculating the A/D data uploaded by each station, the pulse counting data of the encoder and the cooling start-stop switching value data to obtain 6 parameter values, giving the rotating linear speed of the workpiece, and marking 'cooling start' or 'cooling stop' at corresponding time;
3. parameter measurement values of all stations are given according to a date and time sequence list;
4. if the parameter fluctuation is abnormal, instructing the corresponding station to alarm by using a buzzer;
5. drawing a waveform diagram of each parameter;
6. counting and analyzing the acquired data based on the mutual relation of the parameters and the influence on the welding quality;
7. storing data and statistics and analysis results;
8. and the data of each parameter and the statistical and analytical results are displayed or printed under the control of a man-machine dialog box.
Although the present invention has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (6)
1. A hardfacing production central control system, characterized by comprising: the system comprises a headquarter monitoring center and a base website, wherein the headquarter monitoring center is provided with a headquarter computer, a display, a printer and an alarm device which are connected with the headquarter computer, the base website comprises a plurality of work station data acquisition devices, a wireless base station, a router, a base computer, a display, a printer and an alarm device, the work station data acquisition devices are connected with the wireless base station through WiFi, the wireless base station is connected with the base computer through the router, and the base computer is connected with the display, the printer and the alarm device and is connected with the headquarter computer through the Internet.
2. A hardfacing production central control system according to claim 1, wherein said station data acquisition device comprises: the device comprises a plurality of parameter sensors, a signal conditioner, a single chip microcomputer and wifi, wherein the parameter sensors are connected with the signal conditioner, the signal conditioner is connected with the single chip microcomputer, and the single chip microcomputer is connected with the wifi.
3. The hardfacing production central control system of claim 2, wherein the plurality of parameter sensors are analog or digital, the signal conditioner is an analog or digital signal conditioner, the analog parameter sensor is connected to the analog signal conditioner and to the single chip via an a/D converter and an isolation chip; the digital parameter sensor is connected with the singlechip through a photoelectric isolator.
4. A hardfacing production central control system according to claim 2, wherein said plurality of parameter sensors comprises: an arc voltage sensor, a welding current sensor, a wire feeding speed sensor, a workpiece rotating speed sensor, a workpiece temperature sensor and a cooling time sensor.
5. The hardfacing production central control system of claim 1, wherein the processing chip in the station data acquisition device is an EMW3165 wireless transmission data acquisition module.
6. The hardfacing production central control system of claim 1, wherein the wireless base station is a 300M outdoor wireless base station.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911263747.5A CN112935604A (en) | 2019-12-10 | 2019-12-10 | Central control system for hardfacing production |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201911263747.5A CN112935604A (en) | 2019-12-10 | 2019-12-10 | Central control system for hardfacing production |
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| CN112935604A true CN112935604A (en) | 2021-06-11 |
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| CN201911263747.5A Pending CN112935604A (en) | 2019-12-10 | 2019-12-10 | Central control system for hardfacing production |
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| CN207503291U (en) * | 2017-11-30 | 2018-06-15 | 成都优家生活科技有限公司 | A kind of intelligent Community inspection trips system |
| CN109032099A (en) * | 2018-09-04 | 2018-12-18 | 山东建筑大学 | Engineering machinery assemble production line online awareness system |
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2019
- 2019-12-10 CN CN201911263747.5A patent/CN112935604A/en active Pending
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20090120653A (en) * | 2008-05-20 | 2009-11-25 | 한국이엠아이테크놀로지 주식회사 | Web-based monitoring system for incoming transfer facilities |
| CN202351682U (en) * | 2011-11-30 | 2012-07-25 | 北京工业大学 | Wireless network monitoring system used in welding production workshop |
| CN102984821A (en) * | 2011-12-30 | 2013-03-20 | 山东黄金集团有限公司 | Safety monitoring wireless sensor network in factory |
| CN103513638A (en) * | 2013-09-30 | 2014-01-15 | 上海交通大学 | Robot welding manufacturing producing line wireless network monitoring system |
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