CN205967855U - Real -time weld defects on -line monitoring device - Google Patents
Real -time weld defects on -line monitoring device Download PDFInfo
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- CN205967855U CN205967855U CN201620437547.2U CN201620437547U CN205967855U CN 205967855 U CN205967855 U CN 205967855U CN 201620437547 U CN201620437547 U CN 201620437547U CN 205967855 U CN205967855 U CN 205967855U
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Abstract
The utility model provides a real -time weld defects on -line monitoring device can the butt weld parameter carry out online real time monitoring. And will monitor data and preserve. It to pass judgment on weld quality to reach to contrast through the data that exceed standard value degree of mismatching and defect database through the electrical parameter standard value of setting for simultaneously. The utility model discloses effectual parameter to automatic weld is monitored fast, judgees and improve automatic weld's quality.
Description
Technical field
The utility model is related to the monitoring device in welding process, especially a kind of real-time weld defect on-line monitoring dress
Put.
Background technology
Aluminum alloy materials are lightweight with it, and corrosion resistance is good and is easy to the advantages of be molded using pressing method and becomes communications and transportation
Field mitigates the ideal material of deadweight.But there is substantial amounts of crackle, incomplete fusion, lack of penetration etc. lack in aluminum alloy welding termination process
Fall into.Especially in EMUs aluminum alloy bodywork welding process, because structural member possesses longer length, deposit in welding process
Weld defect hide in welding point, postwelding cannot find, thus causing great potential safety hazard.But also exist
EMUs Welded quality problems take place frequently it is impossible to the defect that welding process is occurred finds in time and detects, afterwards at present
No corresponding data support, analysis difficulty big the problems such as.
For other similar welding processes, there is also identical problem.
Utility model content
The utility model main purpose is to solve the above problems and not enough, provides a kind of real-time weld defect to supervise online
Survey device, realize carrying out monitor in real time to the technological parameter of automatic welding process, realize chased after the first day of the lunar month and the weld defect of data
Prediction.
For achieving the above object, the technical solution of the utility model is：
A kind of real-time weld defect on-Line Monitor Device, including by the source of welding current interconnective welding operation system
System, welding control system and intelligence control system, wherein：
Welding operation system, under the control of welding control system, is subjected to；
Welding control system, one or more electrical quantity in collection welding operation systematic procedure is simultaneously transferred to Based Intelligent Control
According to the signal of intelligence control system feedback, system, controls whether welding operation system is subjected to；
Intelligence control system, the standard value of one or more electrical quantity of setting, set up defect database, system is controlled to welding
System gathers and transmits the electrical quantity coming and carries out contrasting, analyze, assess and judging with standard value, according to result of determination, feeds back signal
To welding control system, thus controlling welding operation, and record electrical quantity and result of determination.
Further, described intelligence control system includes general devicenet and intelligent controller, described general
Devicenet carries out the setting of electrical quantity, is connected with the power supply port of the described source of welding current, and the electrical quantity record by collection
Enter described intelligent controller to preserve and analyze.
Further, the electrical quantity receiving is analyzed and assessed to described intelligence control system by control software, judges electricity ginseng
Whether number is mated and matching degree with described standard value, selects corresponding pre-set control programs according to matching degree, and output control is believed
Number, and signal is fed back to welding control program.
Further, when the electrical quantity collecting and described standard value match or Qu Peidu standard value ± 10% model
When enclosing interior, welding continues.
Further, when the real-time electrical quantity collecting is mismatched with standard value, mismatch degree exceeds the 20% of standard value
Or when -18%, call defect database, real-time electrical quantity change curve is carried out with intelligence real not, in intelligence control system
It is analyzed, obtains prediction and the assessment of current weld defect, record current event, reported to the police by warning device, and stop welding
Connect.
Further, described electrical quantity includes voltage parameter and/or current parameters and/or throughput parameter.
In sum, the utility model provides a kind of real-time weld defect on-line monitoring method and device, in conjunction with dress
Put and method, welding parameters can carry out online monitor in real time.And monitoring data is preserved.Pass through setting simultaneously
Electrical quantity standard value and contrast is carried out by the data beyond standard value mismatch degree and defect database can pass judgment on weldquality.
The utility model can fast and effectively be monitored to the parameter of automatic welding, passes judgment on and improve the quality of automatic welding.
Brief description
Fig. 1：A kind of system composition schematic diagram of real-time weld defect on-Line Monitor Device of the utility model；
Fig. 2：A kind of control flow schematic diagram of real-time weld defect on-line monitoring method of the utility model.
Wherein：General devicenet1, current sensor 2, robot demonstrator 3, robot control cabinet 4, voltage sensor
Device 5, welding operation platform 6, robot base 7, robot 8, welding gun 9, controlling interface 10, intelligent controller 11, warning device
12, protect gas cylinder 13, mass-air-flow sensor 14, power supply port 15, the source of welding current 16, the positive plate of the source of welding current 17, welding electricity
Source negative pole 18.
Specific embodiment
Below in conjunction with the accompanying drawings and specific embodiment is described in further detail to the utility model.
The utility model provides a kind of real-time weld defect on-Line Monitor Device, including mutual by the source of welding current 16
Welding operation system, welding control system and the intelligence control system connecting, wherein：
Welding operation system, under the control of welding control system, is subjected to；
Welding control system, one or more electrical quantity in collection welding operation systematic procedure is simultaneously transferred to Based Intelligent Control
According to the signal of intelligence control system feedback, system, controls whether welding operation system is subjected to；
Intelligence control system, the standard value of one or more electrical quantity of setting, set up defect database, system is controlled to welding
System gathers and transmits the electrical quantity coming and carries out contrasting, analyze, assess and judging with standard value, according to result of determination, selects to control
Program, and control signal is fed back to welding control system, thus controlling welding operation, and record electrical quantity and result of determination.
As shown in figure 1, general devicenet 1 (Devicenet is that the one kind growing up the mid-90 is based on CAN
The style of opening of (Controller Area Network) technology, meet inexpensive, the high performance communication network of global industry standard
Network, initially by the development and application of Rockwell company of the U.S..Devicenet has become international standard IEC62026-3《Low pressure is opened
Pass equipment and control device Control Unit Device Interface》, and it has been listed in European standard, be also setting of actual Asia and America
Standby network mark is accurate.In October, 2002 DeviceNet is approved for CNS GB/T18858.3-2002, and in 2003.4.1
Rise and implement.) electrically connect with the power supply port 15 of the source of welding current 16, output end is electrically connected with robot control cabinet 4, and passes through
Robot demonstrator 3 is carrying out communication and the control of robot 8 and the source of welding current 16.Current sensor 2 and source of welding current negative pole
18 electrical connections, voltage sensor 5 is in series with source of welding current negative pole 18, and electrically connects with welding operation platform 6, protects gas cylinder 13
It is electrically connected with source of welding current control port 15 after connecing mass-air-flow sensor 14.Current sensor 2, voltage sensor 5, throughput
Sensor 14, three-way sensor can be acquired to electric current, voltage, three kinds of electrical quantitys of throughput in real time, in the present embodiment,
Sample frequency is 200 500 points/second.
Source of welding current positive pole 17 is electrically connected with welding gun 9, and forms welding circuit with welding operation platform 6, the source of welding current 16.
Welding gun 9 is arranged on the end effector of robot 8, is subjected on welding operation platform 6, and robot 8 is arranged on
The accessibility of robot 8 is ensured on robot bearing 7.
General devicenet1 is connected with intelligent controller 11, and general devicenet1 carries out the setting of electrical quantity, and will
The next electric current of collection, voltage, throughput parameter typing intelligent controller 11, and can show in controlling interface 10, by intelligence
Controller 11 preserves and analyzes.The built-in control software of intelligent controller 11, analyzes and assesses the electrical quantity collected, and judges collection
To data whether mate with standard value, in the present embodiment, collection electric current, the waveform values of voltage and throughput, and with predetermined
Value carries out the matching analysis, assessment, judges matching degree, determines subsequent operation according to pre-set control programs and mismatch degree, determines weldering
Connect and whether continue.If Waveform Matching or mismatch degree are in the range of ± the 10% of standard value, welding continues；If mismatching, and
Mismatch degree exceeds yellow early warning value (± the 10% of setting value), carries out yellow early warning by warning device 12, illustrates now have
There may be weld defect, but defect be not enough to affect welding quality, weld defect in allowed band, record data and current
Situation, welding continues；As degree of mismatch exceeds red early warning value (higher than setting value+20% or less than setting value -18%),
Red early warning is carried out by warning device 12, illustrates now to there must be major defect, be now invoked in intelligent controller 11
Relevant information in the defect database of foundation, and real-time electric current, voltage, throughput Parameters variation curve are entered and intelligence
Identification, is analyzed in intelligent controller 11, obtains prediction and the assessment of current defect, records current event.According to coupling
Situation, selects default program in intelligence control system, executes corresponding subsequent operation.The collection of electrical quantity and with standard value
Matching step real-time continuous are carried out, and run through whole welding process, red alarm, welding suspends, after Resolving probiems, welding
Continue, the collection of repetitive cycling electrical quantity and with standard value matching step.
As shown in figure 1, in the present embodiment, welding operation system includes welding operation platform 6, robot base 7, machine
People 8 and welding rifle 9；Welding control system includes robot demonstrator 3, robot control cabinet 4, current sensor 2, voltage sensor
Device 5, mass-air-flow sensor 14 and protection gas cylinder 13；Intelligence control system includes general devicenet1, intelligent controller 11, control
Interface 10 processed and warning device 12, in actual applications, can increase or decrease section components as needed, or by multiple parts
It is integrally formed a part, such as welding operation platform 6, robot base 7, robot 8 are integrated into a fixed structure, will lead to
It is integrated on an intelligent type computer with devicenet 1, intelligent controller 11 and controlling interface 10, various combination sides
Formula, here does not constrain.In the utility model, warning device 12 can carry out double-colored warning, real-time electrical quantity and standard value
Match condition is divided into three kinds, in actual applications, can be different and set different according to the requirement standard of welding quality
Join situation distribution and different warning measures.In the present embodiment, collection electric current, voltage, three kinds of throughput are real-time simultaneously
Electrical quantity waveform values carry out the comparative analysis with standard value, in actual applications, can with Real-time Collection therein one or more
Electrical parameter values are analyzed with standard value, collection or other any electrical quantitys that weld defect can be made a decision with foundation and
Set corresponding standard value, the electrical quantity collecting is also not necessarily limited to waveform, with any applicable, analysis can be compared data
Form, is not limited.
The utility model additionally provides one kind simultaneously and carries out real-time monitoring using real-time weld defect on-Line Monitor Device
Method, comprise the following steps：
S1, arranges the standard value of one or more electrical quantity in intelligence control system, sets up defect database.
In long-term welding operation, compile all kinds of weld defects, form defect database, and constantly update, mend
Fill new data.Can select to need the different electrical parameters standard value of collection, will mark according to usual means in actual applications
Quasi- value and defect database input stand-by in intelligence control system in advance, in the utility model, are entered by general devicenet 1
The standard value setting of row electrical quantity.
S2, in welding process, by the next corresponding electrical quantity real-time Transmission of collection to intelligence control system, and is protected
Deposit.
In the present embodiment, the electrical quantity needing collection includes but is not limited to voltage, electric current, throughput, in practical application
In, the electrical parameter values of needs can be gathered as needed, can gather therein a kind of or any two kinds or all, or determine and need
To be gathered other can be used for judging the electrical quantity of weld defect.
S3, the electrical quantity that intelligence control system is come to collection carries out contrasting, analyze, assess and judging with standard value, according to
Result of determination, selects corresponding control program, controls welding operation.
Pre-set control programs in intelligence control system, different result of determination, the different control programs of correspondence, to welding control
System feedback control signal processed, controls welding operation process by welding control system.Therefore：
S31, when the real-time electrical quantity collecting is matched with standard value, welding continues；When the electricity ginseng in real time collecting
Number is mismatched with standard value, is reported to the police, and determines whether welding continues according to pre-set programs and mismatch degree.
Because welding process typically all can have certain deviation, will not coupling completely very, therefore, when collecting
Electrical quantity and standard value when contrasting although there is mismatch degree, but mismatch degree in the range of ± the 10% of standard value when, depending on
Meet regulation for welding operation to require, there is not weld defect, therefore, intelligence control system sends control signal, is controlled by welding
System processed controls welding to continue.
When mismatch degree exceeds ± 10% scope of standard value it is considered that welding existing defects, but in practical application
In, according to practical experience, according to the order of severity of weld defect, determine whether welding continues, therefore, when the electricity ginseng in real time collecting
Number with standard value mismatch, mismatchs degree higher than standard value 10% to 20% or be less than -10% to -18% in the range of when,
Reported to the police by warning device, intelligence control system record data, and feedback control signal continues welding operation；When the reality collecting
When electrical quantity and standard value mismatch, when mismatchs degree exceeds the 20% of standard value or is less than -18%, call defect database,
Real-time electrical quantity change curve is carried out with intelligence real other, be analyzed in intelligence control system, obtain current weld defect
Prediction and assessment, record current event, reported to the police by warning device, and stop weld.
It is pointed out that the monitoring device that the utility model provides, it is applicable not only to the welding process of Al-alloy parts, and
And equally it is widely portable to other kinds of welding process.
In sum, a kind of real-time weld defect on-Line Monitor Device that the utility model provides, can be to welding ginseng
Number carries out online monitor in real time.And monitoring data is preserved.Pass through the electrical quantity standard value of setting and by super simultaneously
The data going out standard value mismatch degree and defect database carries out contrast and can pass judgment on weldquality.The utility model can quickly have
The parameter to automatic welding of effect is monitored, and passes judgment on and improve the quality of automatic welding.
As described above, combining given plan content, similar technical scheme can be derived.In every case it is without departing from this
The content of utility model technical scheme, any is simply repaiied according to what technical spirit of the present utility model made to above example
Change, equivalent variations and modification, all still fall within the range of technical solutions of the utility model.
Claims (6)
1. a kind of real-time weld defect on-Line Monitor Device it is characterised in that：Including by the interconnective weldering of the source of welding current
Connect operating system, welding control system and intelligence control system, wherein,
Welding operation system, under the control of welding control system, is subjected to；
Welding control system, one or more electrical quantity in collection welding operation systematic procedure is simultaneously transferred to Based Intelligent Control system
According to the signal of intelligence control system feedback, system, controls whether welding operation system is subjected to；
Intelligence control system, the standard value of one or more electrical quantity of setting, set up defect database, welding control system is adopted
Collect and transmit the electrical quantity coming to carry out contrasting, analyze, assess and judging with standard value, according to result of determination, select control program,
And control signal is fed back to welding control system, thus controlling welding operation, and record electrical quantity and result of determination.
2. as claimed in claim 1 a kind of real-time weld defect on-Line Monitor Device it is characterised in that：Described Based Intelligent Control
System includes general devicenet and intelligent controller, and described general devicenet carries out the setting of electrical quantity, with described weldering
The power supply port connecing power supply is connected, and intelligent controller described in the electrical quantity typing of collection is preserved and analyzes.
3. as claimed in claim 2 a kind of real-time weld defect on-Line Monitor Device it is characterised in that：Described Based Intelligent Control
The electrical quantity that system is analyzed by built-in control software and assessment receives, judge electrical quantity and described standard value whether mate with
And matching degree, corresponding pre-set control programs, output control signal are selected according to matching degree, and signal is fed back to welding control
Program.
4. as claimed in claim 3 a kind of real-time weld defect on-Line Monitor Device it is characterised in that：When the electricity collecting
Parameter and described standard value match or Qu Peidu in the range of ± the 10% of standard value when, welding continues.
5. as claimed in claim 3 a kind of real-time weld defect on-Line Monitor Device it is characterised in that：When the reality collecting
When electrical quantity and standard value mismatch, mismatchs degree beyond standard value 20% or -18% when, call defect database, to reality
When electrical quantity change curve carry out that intelligence is real not to be analyzed in intelligence control system, obtain the pre- of current weld defect
Survey and assess, record current event, reported to the police by warning device, and stop welding.
6. a kind of real-time weld defect on-Line Monitor Device as described in any one of claim 1 to 5 it is characterised in that：Institute
State electrical quantity and include voltage parameter and/or current parameters and/or throughput parameter.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201620437547.2U CN205967855U (en) | 2016-05-12 | 2016-05-12 | Real -time weld defects on -line monitoring device |
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| CN201620437547.2U CN205967855U (en) | 2016-05-12 | 2016-05-12 | Real -time weld defects on -line monitoring device |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105855757A (en) * | 2016-05-12 | 2016-08-17 | 中车青岛四方机车车辆股份有限公司 | Real-time welding defect on-line monitoring method and device |
| CN110340486A (en) * | 2019-06-28 | 2019-10-18 | 西安交通大学 | A kind of electric arc increasing material manufacturing status monitoring feedback system and status monitoring feedback method |
-
2016
- 2016-05-12 CN CN201620437547.2U patent/CN205967855U/en active Active
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105855757A (en) * | 2016-05-12 | 2016-08-17 | 中车青岛四方机车车辆股份有限公司 | Real-time welding defect on-line monitoring method and device |
| CN110340486A (en) * | 2019-06-28 | 2019-10-18 | 西安交通大学 | A kind of electric arc increasing material manufacturing status monitoring feedback system and status monitoring feedback method |
| CN110340486B (en) * | 2019-06-28 | 2020-07-28 | 西安交通大学 | Arc additive manufacturing state monitoring feedback system and state monitoring feedback method |
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