CN114131145A - Non-digital welding machine welding process quality monitoring system and method - Google Patents
Non-digital welding machine welding process quality monitoring system and method Download PDFInfo
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- CN114131145A CN114131145A CN202111512603.6A CN202111512603A CN114131145A CN 114131145 A CN114131145 A CN 114131145A CN 202111512603 A CN202111512603 A CN 202111512603A CN 114131145 A CN114131145 A CN 114131145A
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- 238000003466 welding Methods 0.000 title claims abstract description 289
- 238000000034 method Methods 0.000 title claims abstract description 89
- 238000012544 monitoring process Methods 0.000 title abstract description 9
- 238000012545 processing Methods 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 7
- 230000005540 biological transmission Effects 0.000 claims description 6
- 238000007689 inspection Methods 0.000 description 7
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
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- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
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Abstract
The invention discloses a non-digital welding machine welding process quality monitoring system and a non-digital welding machine welding process quality monitoring method. The method comprises the steps of establishing a drawing number and a welding line number of equipment to be welded and a WPS method library corresponding to each welding line, and meanwhile, additionally arranging a current and voltage sensor and an operating device on a non-digital welding machine to acquire working parameters of the welding machine in real time. The on-site welding personnel select the corresponding welding seam number through the operating device in the welding process, the welding and timing can be carried out when clicking, the current monitored numerical value and the welding seam are automatically compared to set current and voltage, the pause button can be clicked in the welding process, the timing and comparison are paused, the end button is clicked after the welding is finished, the whole welding process is automatically recorded and uploaded to the method background, and the management personnel can review and check related information at any time, so that the welding quality of the welding seam is supervised and evaluated.
Description
Technical Field
The invention relates to the technical field of welding quality supervision pipes of non-digital welding machines, in particular to a quality supervision system for a welding process of a non-digital welding machine.
Background
At present, because a digital welding machine can automatically set welding parameters, monitor a welding process in real time and improve welding quality, the digital welding machine is widely accepted by the industry, but the digital welding machine is high in price and limited in use scenes, main welding equipment of a plurality of manufacturing enterprises or a non-digital welding machine still exists, particularly, the digital welding machine is hardly available in some non-assembly line discrete factories, and in the actual welding process of the non-digital welding machine, a welder can automatically adjust the welding parameters due to acceleration of welding speed and does not follow welding process rules, so that poor welding quality of a welding point can be caused, and hidden dangers are buried for equipment use.
Because the non-digital welding machine does not have a parameter monitoring and transmitting module, welding parameters can only be ensured in the welding process mainly by a mode of randomly checking welding points through on-site inspection personnel, however, the inspection personnel has low spot inspection efficiency and certain delay, and the quality of all welding points cannot be ensured.
Disclosure of Invention
The invention aims to: aiming at the problems, the quality supervision system for the welding process of the non-digital welding machine is provided, and the problem that the quality cannot be effectively supervised in the welding process of the non-digital welding machine in the prior art is solved.
The invention is realized by the following scheme:
a non-digital welding machine welding process quality monitoring system pre-alarm module: performing acousto-optic pre-alarm reminding on illegal operation;
an on-site operation device: the system is used for consulting and operating various matters on site;
the background comparison processing module: the welding parameter acquisition module is used for inputting welding information of equipment to be welded, comparing the data acquired by the welding parameter acquisition module with the stored information and judging;
a non-digital welder: the method is used for welding operation, mainly carbon dioxide gas shielded welding;
a welding parameter acquisition module: the device is used for collecting relevant parameters of the welding machine;
a data transmission module: for transmitting welding parameters;
based on the non-digital welding machine welding process quality supervision system, the field operation device is an operation panel; the non-digital welding machine is a manual welding machine or a semi-automatic welding machine.
Based on the non-digital welding machine welding process quality supervision system, the welding parameter acquisition module comprises a current collector, a voltage collector, a flowmeter and a gas pressure collector.
Based on the non-digital welding machine welding process quality monitoring system, the field operation device is a movable touch button-added handheld machine, the connection mode of the field operation device is the same as that of a welding gun, and the field operation device can move together with the welding gun.
Based on the non-digital welding machine welding process quality supervision system, a box for placing the field operation device is additionally arranged on the welding machine body.
The invention provides a quality supervision method for a welding process of a non-digital welding machine, which specifically comprises the following steps:
the method comprises the following steps: inputting relevant information of the welding drawing in a background comparison processing module;
step two: opening the operation panel by a field welder, and looking up welding information of a position to be welded;
step three: the field welding personnel adjust the current and voltage parameters of the welding machine and perform trial welding according to the welding seam process standard information of the corresponding welding seam obtained in the step two;
step four: after the trial welding is completed, a welder clicks a start button of each welding line in the operation panel, and the system starts to time the welding time of the corresponding welding line.
Step five: in the welding process, the background comparison processing module compares and judges real-time welding parameters of the welding machine with the recorded standard welding parameters, sets a corresponding alarm threshold value, and transmits signals to the pre-alarm module for pre-alarming if the fluctuation exceeds the alarm threshold value;
step six: in the welding process, if an emergency occurs and the welding is required to be stopped, a pause button of a corresponding welding line in the operation panel can be clicked, and the timing is stopped;
step seven: after each welding line is finished, the end button of the corresponding welding line is clicked, the operation panel can automatically store welding parameters and welding time of the whole welding process and upload the welding parameters and the welding time to the cloud background system, and relevant personnel can evaluate the welding of workers according to records.
And in the second step, relevant information of the welding drawing, including the type of the welding seam, the welding process, welding materials and the like, is stored in a database in a table form.
In the third step, the obtained welding seam process standard information of the corresponding welding seam is specifically that a welding drawing number is input, a welding seam list corresponding to the drawing is popped up by the system, the welding seam list comprises the type of the welding seam, the WPS number, welding materials and other related information, and for the multi-layer welding seam, layered management is carried out, and the welding information of each layer of welding seam is looked up.
In the fifth step and the seventh step, the welding parameters are voltage values and current values.
In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:
1. by the method, various data in the welding process can be monitored in real time, alarm recording is carried out on illegal welding operation, welding quality can be guaranteed to the maximum extent, working strength of inspection personnel is reduced, the inspection personnel can call out data of each welding line to check at any time, meanwhile, when problems occur in the later period, problems can be conveniently searched, and welding process is improved.
Drawings
FIG. 1 is a schematic diagram of a quality supervision device for a welding process of a non-digital welder according to the present invention;
FIG. 2 is a schematic flow diagram of the invention as a whole;
description of the drawings: 101. a pre-alarm module; 102. a field operation device; 103. a background comparison processing module; 104. a non-digital welder; 105. a welding parameter acquisition module; 106. and a data transmission module.
Detailed Description
All of the features disclosed in this specification, or all of the steps in any method or process so disclosed, may be combined in any combination, except combinations of features and/or steps that are mutually exclusive.
Any feature disclosed in this specification (including any accompanying claims, abstract) may be replaced by alternative features serving equivalent or similar purposes, unless expressly stated otherwise. That is, unless expressly stated otherwise, each feature is only an example of a generic series of equivalent or similar features.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "left", "right", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the referred devices or elements must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
Furthermore, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature.
Example 1
As shown in fig. 1, a quality supervision system for a welding process of a non-digital welder 104 comprises a pre-alarm module 101, a field operation device 102, a background comparison processing module 103, the non-digital welder 104, a welding parameter acquisition module 105 and a data transmission module 106;
the pre-alarm module 101 is used for performing acousto-optic pre-alarm reminding when the real-time monitored data in the welding process deviate from the values set in the background; the pre-alarm module 101 is a wireless sound-light alarm and is connected with the background comparison processing module 103 through a TCP/IP (transmission control protocol/Internet protocol), and the field operation device 102 can be manually closed;
the field operation device 102 is used for consulting and operating various matters on the field; the field operation device 102 is operated by a field welding worker, the operator can check tasks needing to be welded of all equipment after logging in an account password of the operator, after selecting a corresponding equipment drawing number, the method automatically pops up a welding line number corresponding to a drawing and a corresponding welding process parameter list, according to the actual situation of the equipment field, the welding line needing to be welded is selected, after the selection is completed, a start button is clicked, the method automatically carries out welding timing and carries out comparison judgment with real-time monitoring data of a welding machine, and the purpose of monitoring the quality of the welding process is achieved;
the field operation device 102 considers the actual working condition of field welding, an operator wears gloves and can walk back and forth when welding large equipment, the operation device preferentially selects a movable touch button hand-held machine, the connection mode is the same as that of a welding gun, and the operation device can move together with the welding gun.
Further, a box for placing the field operation device 102 is additionally arranged on the welding machine body;
the background comparison processing module 103 is configured to enter welding information of the device to be welded, where the welding information includes drawing information of the device, welding seam information and corresponding welding process rules to form corresponding welding process rules, and compare data acquired by the welding parameter acquisition module 105 with stored information to make a determination; the field welding personnel can check related information by using the operating device without checking a welding process card by coring, so that paperless welding field is realized, and the welding efficiency is improved;
the non-digital welder 104 is used for welding operation and can be a manual welder or a semi-automatic welder;
the welding parameter acquisition module 105 is used for acquiring relevant parameters of the welder, such as acquiring current and voltage values of a non-digital welder and gas pressure and flow of a shielded welder; the device can be a current collector, a voltage collector, a flowmeter and a gas pressure collector.
The data transmission module 106 is configured to send various types of information acquired by the welding parameter acquisition module 105 to the background comparison processing module 103;
in this embodiment, the field operation device 102 may be an operation panel;
in the prior art, when a large-sized workpiece or structure is welded, the length of each welding seam to be welded is different, the technological requirements required by each welding seam are also different, each welding seam is considered at the beginning of design according to comprehensive factors such as a stress structure, a position relation, an environment and the like, the type, the welding mode and the welding material of each welding seam are regulated, and each welding seam is numbered to form a WPS (welding process procedure) number;
when a welder welds a large-scale structure or a key weld, a quality department can enforce the welder to check related welding process requirements of WPS (welding process specification), and strictly require welding according to the WPS number set by the process department. Particularly, when a key welding seam is welded, multilayer welding can be performed, welding parameters need to be changed by referring to the WPS for many times, and the welding time is long;
welding personnel among the prior art can be for save time sometimes, accelerate welding speed, weld violating the regulations, lead to welding quality not to conform to the norm, and under this situation, the personnel of patrolling and examining can't inspect, and the digital welding machine among the prior art also can't solve above-mentioned problem.
Therefore, the inventor of the scheme makes an improvement on the scheme.
Example 2
As shown in fig. 2, based on the foregoing embodiment 1, the present embodiment provides a quality supervision method for a welding process of a non-digital welder 104, which specifically includes the following steps:
the method comprises the following steps: the method comprises the following steps of (1) inputting relevant information of a welding drawing, including a welding seam type, a welding process, a welding material and the like, into a background comparison processing module 103, and storing the relevant information in a database in a table form;
step two: the method comprises the steps that a field welder opens an APP of a system for operating a panel, inputs a number of a welding drawing, and pops up a welding line list corresponding to the drawing, including the type of the welding line, the WPS number, welding materials and other related information, carries out hierarchical management on multiple layers of welding lines, and looks up welding information of each layer of welding line;
step three: the field welding personnel adjust the current and voltage parameters of the welding machine and perform trial welding according to the welding seam process standard information of the corresponding welding seam obtained in the step two;
step four: after the trial welding is finished, a welder clicks a start button of each welding line in the operation panel, and the system starts to time the welding time of the corresponding welding line, so that false alarm caused by the trial welding can be avoided; meanwhile, the welding time of each welding line can be accurately controlled.
Step five: in the welding process, the background comparison processing module 103 compares and judges the real-time current and voltage parameters of the welding machine with the recorded current and voltage parameters, sets a corresponding alarm threshold, and if the fluctuation exceeds the alarm threshold, the background comparison processing module 103 transmits a signal to the pre-alarm module 101 for pre-alarm;
step six: in the welding process, if an emergency occurs and welding needs to be stopped, a pause button of a corresponding welding seam in the operation panel can be clicked, timing is stopped, and the background comparison processing module 103 can accurately record the whole welding time;
step seven: after each welding line is finished, clicking an end button of the corresponding welding line, automatically storing the current voltage and the welding time of the whole welding process by the operation panel, uploading the current voltage and the welding time to the cloud background system, and evaluating the welding of workers according to the record by related personnel;
the method can monitor various data in the welding process in real time, alarm and record illegal welding operation, can ensure the welding quality to the maximum extent, reduce the working strength of inspection personnel, and the inspection personnel can call out the data of each welding line at any time to check and evaluate the welding quality, can conveniently search problem points when problems occur in the later period, improve the welding process, and simultaneously can also be used as an evaluation index of the welding efficiency of the welding personnel to improve the working efficiency of the welding personnel.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (9)
1. The quality supervision system for the welding process of the non-digital welding machine is characterized in that:
the pre-alarm module: performing acousto-optic pre-alarm reminding;
an on-site operation device: the system is used for consulting and operating various matters on site;
the background comparison processing module: the welding parameter acquisition module is used for inputting welding information of equipment to be welded, comparing the data acquired by the welding parameter acquisition module with the stored information and judging;
a non-digital welder: for welding operations;
a welding parameter acquisition module: the device is used for collecting relevant parameters of the welding machine;
a data transmission module: for transmitting welding parameters.
2. The non-digital welder welding process quality supervision system of claim 1, characterized in that: the field operation device is an operation panel; the non-digital welding machine is a manual welding machine or a semi-automatic welding machine.
3. The non-digital welder welding process quality supervision system of claim 2, characterized in that: the welding parameter acquisition module comprises a current collector, a voltage collector, a flowmeter and a gas pressure collector.
4. The non-digital welder welding process quality supervision system of claim 1, characterized in that: the field operation device is a movable touch button-added handset, the connection mode of the field operation device is the same as that of a welding gun, and the field operation device can move together with the welding gun.
5. The non-digital welder welding process quality supervision system of claim 1, characterized in that: the welding machine body is additionally provided with a box for placing the field operation device.
6. A supervision method based on the welding process quality supervision system of the non-digital welding machine of any claim 1-5 is characterized in that: the method specifically comprises the following steps:
the method comprises the following steps: relevant equipment welding drawings and relevant information of welding seam parameters are input into a background comparison processing module;
step two: opening the operation panel by a field welder, and looking up welding information of a position to be welded;
step three: the field welding personnel adjust the current and voltage parameters of the welding machine and perform trial welding according to the welding seam process standard information of the corresponding welding seam obtained in the step two;
step four: after the trial welding is completed, a welder clicks a start button of each welding line in the operation panel, and the system starts to time the welding time of the corresponding welding line.
Step five: in the welding process, the background comparison processing module compares and judges real-time welding parameters of the welding machine with the recorded standard welding parameters, sets a corresponding alarm threshold value, and transmits signals to the pre-alarm module for pre-alarming if the fluctuation exceeds the alarm threshold value;
step six: in the welding process, if an emergency occurs and the welding is required to be stopped, a pause button of a corresponding welding line in the operation panel can be clicked, and the timing is stopped;
step seven: after each welding line is finished, the end button of the corresponding welding line is clicked, the operation panel can automatically count and store welding parameters and welding time of the whole welding process and upload the welding parameters and the welding time to the cloud background system, and relevant personnel can evaluate the welding quality of workers according to records.
7. The method for supervising the welding process quality of the non-digital welding machine as claimed in claim 6, wherein: and in the second step, the relevant information of the welding drawing, including the type of the welding seam, the welding process, the welding materials and the like, is stored in a database in a spreadsheet form, can be checked in real time, and realizes paperless welding operation.
8. The method for supervising the welding process quality of the non-digital welding machine as claimed in claim 6, wherein: in the third step, the obtained welding seam process standard information of the corresponding welding seam is specifically that a welding drawing number is input, a welding seam list corresponding to the drawing is popped up by the system, the welding seam list comprises the type of the welding seam, the WPS number, welding materials and other related information, and for the multi-layer welding seam, layered management is carried out, and the welding information of each layer of welding seam is looked up.
9. The method for supervising the welding process quality of the non-digital welding machine as claimed in claim 6, wherein: in the fifth step and the seventh step, the welding parameters are voltage values and current values.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111512603.6A CN114131145A (en) | 2021-12-08 | 2021-12-08 | Non-digital welding machine welding process quality monitoring system and method |
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| CN202111512603.6A CN114131145A (en) | 2021-12-08 | 2021-12-08 | Non-digital welding machine welding process quality monitoring system and method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116393874A (en) * | 2023-03-14 | 2023-07-07 | 国机智能技术研究院有限公司 | Welding manufacturing control method and control system for pressure vessel |
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