CN209811398U - Welding closed loop monitoring system - Google Patents
Welding closed loop monitoring system Download PDFInfo
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- CN209811398U CN209811398U CN201920233264.XU CN201920233264U CN209811398U CN 209811398 U CN209811398 U CN 209811398U CN 201920233264 U CN201920233264 U CN 201920233264U CN 209811398 U CN209811398 U CN 209811398U
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- welding
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- monitoring system
- soldering
- soldering iron
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Abstract
The utility model discloses a welding closed loop monitoring system. The welding closed-loop monitoring system comprises a welding mechanism (1) and an information acquisition and monitoring mechanism (2); the welding mechanism (1) comprises a first terminal (11), a second terminal (12), a welding material (13) and a soldering iron head (14); the voltage acquisition and monitoring mechanism (2) is used for acquiring and monitoring information between the first terminal (11) and the second terminal (12), between the first terminal (11) and the soldering material (13), between the first terminal (11) and the soldering iron head (14) and between the soldering material (13) and the soldering iron head (14). This welding closed loop monitoring system can effectively monitor the welding process, and, based on the utility model discloses a welding method of welding closed loop monitoring system can effectively monitor the welding process, improves the solder joint quality, effectively sparingly welds the material quantity, reduces the welding cost.
Description
Technical Field
The utility model relates to the field of welding technology, concretely relates to welding closed loop monitoring system.
Background
Through welding, the two separated materials can be seamlessly spliced, and the use plasticity of the materials is improved. The welding technology is very widely applied in industry, especially in the field of mechanical processing, the welding technology becomes an indispensable technical means, and provides technical support for the production of various mechanical devices.
In the existing welding technology, the quality of welding in the welding process is generally judged according to the experience of welding workers, an objective monitoring system is not provided, the subjectivity is strong, and over-welding or missing welding is easily caused, so that the produced product is easily uneven in quality and uneven; moreover, depending on manual judgment, considerable experience is required, and the operation by a novice is not facilitated, so that flexible scheduling of production and reduction of production cost are not facilitated. In addition, in the existing welding process, due to the fact that corresponding monitoring means are not available, in the welding process based on experience, the welding materials of welding seams with the same size are used more and less, control over welding quality is not facilitated, and meanwhile welding cost is not saved.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to prior art not enough, provide a welding closed loop monitoring system. This welding closed loop monitoring system can effectively monitor the welding process, and, based on the utility model discloses a welding method of welding closed loop monitoring system can effectively monitor the welding process, improves the solder joint quality, effectively practices thrift welding material volume, reduces the welding cost.
The purpose of the utility model is realized through the following technical scheme.
A welding closed loop monitoring system comprises a welding mechanism and an information acquisition and monitoring mechanism; the welding mechanism comprises a first terminal, a second terminal, a welding material and a soldering bit;
the information acquisition and monitoring mechanism is used for acquiring and monitoring information between the first terminal and the second terminal, between the first terminal and the soldering material, between the first terminal and the soldering bit and between the soldering material and the soldering bit.
Preferably, the information acquisition and monitoring mechanism comprises a PLC (programmable logic controller) and a singlechip; the PLC is connected with the single chip microcomputer through a line.
More preferably, the first terminal, the second terminal, the welding material and the soldering bit are respectively connected with the information acquisition port of the single chip microcomputer through wires.
Still further preferably, the information acquisition port of the single chip microcomputer is provided with an analog-to-digital conversion module.
Still further preferably, the soldering material and the soldering iron head are respectively and independently connected with a grounding circuit.
More preferably, the information acquisition and monitoring mechanism further comprises a touch display screen; the touch display screen is connected with the PLC through a circuit.
Preferably, the information comprises an electrical signal and a contact time; the electrical signal comprises a voltage signal or a current signal.
The welding method based on the welding closed-loop monitoring system comprises the following steps:
(1) pre-calculating the amount of welding materials required by a welding spot between a first terminal to be welded and a second terminal to be welded;
(2) simulating welding of the first terminal and the second terminal based on the welding material amount in the step (1), and storing electric signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the soldering bit and between the welding material and the soldering bit in an information acquisition and monitoring mechanism as comparison data in the welding process;
(3) and actually welding the first terminal and the second terminal, acquiring electric signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the soldering bit and between the welding material and the soldering bit through the information acquisition and monitoring mechanism, comparing and analyzing the electric signals and the contact time with contrast data stored in the information acquisition and monitoring mechanism, and then monitoring the amount of the welding material actually consumed by the welding spot between the first terminal and the second terminal, thereby monitoring the quality of the welding spot.
Preferably, in the information collecting and monitoring means, the electrical signal and the contact time are displayed in the form of a waveform graph in which the electrical signal varies with the contact time.
Compared with the prior art, the utility model has the advantages of as follows and beneficial effect:
(1) the welding closed-loop monitoring system of the utility model can effectively monitor and collect the information between the terminal I and the terminal II, between the terminal I and the welding material, between the terminal I and the soldering bit and between the welding material and the soldering bit; the single chip microcomputer can be used for efficiently and accurately acquiring electric signal information and time information, and the PLC can be used for displaying and monitoring the acquired information in real time in a waveform mode and the like; meanwhile, the PLC can be connected with the welding machine, receives welding output signals of the welding machine, and performs feedback automatic control on the welding process by combining information acquired by the single chip microcomputer, so as to realize high-quality welding control; and, based on the utility model discloses a welding closed loop monitoring system's welding method can effectively monitor welding process, improves the solder joint quality, effectively practices thrift the welding material volume, reduces welding cost.
Drawings
Fig. 1 is a schematic structural diagram of a welding closed-loop monitoring system according to the present invention in embodiment 1;
FIG. 2 is a schematic view showing a welding process for performing welding in embodiment 2;
FIG. 3a is a graph showing the voltage between the tip and the tin bar during the soldering process as a function of time, as measured by the closed loop soldering monitoring system of example 1, in example 2;
FIG. 3b is a graph of voltage versus time between terminal one and terminal two during a welding process using the closed loop welding monitoring system of example 1 in example 2;
FIG. 3c is a graph of voltage versus time between terminal one and the solder bar during a soldering process using the closed loop monitoring system for soldering of example 1 in example 2;
FIG. 3d is a graph showing the voltage between the soldering tip and the first terminal during the soldering process as a function of time according to embodiment 2, which is monitored by the closed-loop monitoring system for soldering according to embodiment 1;
the attached drawings are marked as follows: 1-a welding mechanism, 11-a terminal I, 12-a terminal II, 13-a welding material, 14-a soldering iron head, 2-an information acquisition and monitoring mechanism, 21-a PLC (programmable logic controller), 22-a singlechip, 23-a touch display screen, 24-a switching power supply and 3-a welding machine.
Detailed Description
The technical solution of the present invention will be described in further detail with reference to the following specific embodiments and accompanying drawings, but the scope of protection and the implementation of the present invention are not limited thereto.
Example 1
A welding closed-loop monitoring system according to the present embodiment is shown in fig. 1, and includes a welding mechanism 1 and an information collecting and monitoring mechanism 2. The soldering mechanism 1 includes a first terminal 11, a second terminal 12, a soldering material 13, and a soldering iron tip 14.
The information collecting and monitoring mechanism 2 is used for collecting and monitoring information between the first terminal 11 and the second terminal 12, between the first terminal 11 and the soldering material 13, between the first terminal 11 and the soldering iron tip 14 and between the soldering material 13 and the soldering iron tip 14. The monitored information electrical signal and contact time are collected, and, in particular, the electrical signal comprises a voltage signal or a current signal.
Specifically, the information collecting and monitoring mechanism 2 includes a PLC controller 21 and a single chip 22. The PLC controller 21 is connected with the single chip microcomputer 22 through a line, and the single chip microcomputer 22 transmits acquired data to the PLC controller 21 for processing. Meanwhile, the PLC controller 21 may also transmit an editing control signal to the single chip 22 to adjust or switch the comparison analysis parameters.
And the first terminal 11, the second terminal 12, the welding material 13 and the soldering iron tip 14 are respectively connected with an information acquisition port of the singlechip 22 through wires. The information acquisition port of the single chip 22 is provided with an analog-to-digital conversion module, and the analog-to-digital conversion module can convert the received information such as the electric signal and the like after comparing and analyzing the received information with the analog quantity.
The welding material 13 and the soldering iron 14 are also respectively and independently connected with a grounding circuit, and a resistor R is connected in series on the grounding circuit of the welding material 131. In this exampleThe circuits of the first terminal 11, the second terminal 12 and the welding material 13 connected with the singlechip 22 are respectively connected with external port circuits in parallel, and the external port circuits are respectively connected with resistors R in series2、R3And R4。
Further, the information collecting and monitoring mechanism 2 further includes a touch display screen 23. The touch display screen 23 is connected with the PLC controller 21 through a circuit, and the PLC controller 21 can analyze and transmit the collected information to the touch display screen 23 for display. Meanwhile, the touch display screen 23 can also transmit the control signal outputted by touch to the PLC controller 21 for editing, analyzing and adjusting.
Further, in the present embodiment, referring to fig. 1, the single chip microcomputer 22 in the information collecting and monitoring mechanism 2 is externally connected to a 220V power supply through the switching power supply 24; meanwhile, the PLC controller 21 is also directly connected to a 220V power supply through a wire.
Further, in this embodiment, as shown in fig. 1, the PLC controller 21 is connected to the welding machine 3, receives a welding output signal of the welding machine 3, and performs feedback automatic control on a welding process by combining information acquired by the single chip microcomputer 22, thereby implementing high-quality welding control.
Example 2
In this embodiment, the first terminal 11 and the second terminal 12 are welded, and the welding process is as shown in fig. 2, first, at t0When the soldering iron is used, the first terminal 11, the second terminal 12, the welding material 13 and the soldering iron head 14 are in a separated state and are not in contact; at t, when welding is performed1When the soldering iron head 14 is contacted with the first terminal 11; while continuing to weld, at t2When the soldering material 13 is contacted with the soldering iron head 14 and simultaneously contacted with the first terminal 11, heating and soldering are started; after the first terminal 11 and the second terminal 12 are fusion-welded by the welding material 13, the first terminal 11 and the second terminal 12 are connected by the spot welding material, and t3When the soldering material 13 is separated from the soldering iron head 14, the soldering iron head 14 still keeps in contact with the first terminal 11; finally, at t4When the soldering iron head 14 is separated from the first terminal 11, the soldering material 13 and the soldering iron head 14 are all in a separated state, and the first terminal 11 and the second terminal 12 are connected through the soldering material. Thus, the welding is completed.
In addition, the welding process adopts the welding closed-loop monitoring system of the embodiment 1 to perform welding monitoring, and comprises the following steps:
(1) and calculating the amount of welding materials needed by welding points between the first terminal and the second terminal to be welded in advance.
(2) And (2) simulating the welding of the first terminal and the second terminal based on the welding material amount in the step (1), and displaying voltage signals and contact time between the first terminal (T1) and the second terminal (T2), between the first terminal (T1) and the welding material (S), between the first terminal (T1) and the soldering iron head (H) and between the welding material (S) and the soldering iron head (H) in the welding process, wherein in the information acquisition and monitoring mechanism, the acquired voltage signals and contact time are displayed in the form of a waveform diagram of the voltage signals changing along with the contact time, and specifically, the waveform diagram of the acquired voltage changing along with the time is shown in a diagram in a figure 3a ~ figure 3 b.
Here, as can be seen from FIG. 3a, at t0、t1、t3And t4At time t, since there is no contact between the solder material (S) and the soldering iron tip (H), at time t0、t1、t3And t4When the welding head is in use, the resistance between the welding material (S) and the welding head (H) is large, so that the voltage between the welding material (S) and the welding head (H) is high; and at t2At time t, the solder material (S) is in contact with the soldering iron tip (H)2In this case, the resistance between the solder material (S) and the soldering iron tip (H) is small, which causes a decrease in voltage between the solder material (S) and the soldering iron tip (H).
As can be seen from FIG. 3b, at t0And t1At time, there is no contact between terminal one (T1) and terminal two (T2), so at T0And t1At this time, the resistance between the first terminal (T1) and the second terminal (T2) is large, resulting in a higher voltage between the first terminal (T1) and the second terminal (T2); and at t2Due to contact between terminal one (T1) and terminal two (T2), and at T3Are welded together, thus at t2And thereafter, the resistance between the first terminal (T1) and the second terminal (T2) is small, resulting in a decrease in the voltage between the first terminal (T1) and the second terminal (T2).
As can be seen from FIG. 3c, at t0、t1、t3And t4At time, there is no contact between terminal one (T1) and solder (S), so at T0、t1、t3And t4When the voltage is high, the resistance between the terminal I (T1) and the welding material (S) is high, so that the voltage between the terminal I (T1) and the welding material (S) is high; and at t2At time T, since the first terminal (T1) is in contact with the solder (S), at T2At this time, the resistance between the terminal one (T1) and the solder material (S) is small, resulting in a decrease in voltage between the terminal one (T1) and the solder material (S).
As can be seen from FIG. 3d, at t0And t4There is no contact between terminal one (T1) and tip (H), so at T0And t4At this time, the resistance between terminal one (T1) and tip (H) is high, resulting in a higher voltage between terminal one (T1) and tip (H); and at t1、t2And t3At time T, because of contact between terminal one (T1) and tip (H), at T1、t2And t3At this time, the resistance between terminal one (T1) and tip (H) is low, resulting in a decrease in the voltage between terminal one (T1) and tip (H).
Meanwhile, the collected information is used as comparison data to be stored in an information collecting and monitoring mechanism.
(3) And actually welding the first terminal and the second terminal, acquiring voltage signals and contact time between the first terminal and the second terminal, between the first terminal and the welding material, between the first terminal and the soldering bit and between the welding material and the soldering bit through the information acquisition and monitoring mechanism, comparing and analyzing the voltage signals and the contact time with contrast data stored in the information acquisition and monitoring mechanism, and then monitoring the amount of the welding material actually consumed by the welding spot between the first terminal and the second terminal, thereby monitoring the quality of the welding spot.
So, through calculating the welding material volume that the passing weld needs in advance to set up contrast signal of telecommunication wave form and contact time, voltage signal wave form and contact time among the rethread welding closed loop monitoring system real-time supervision welding process, and with contrast voltage signal wave form and contact time contrastive analysis, go the actual welding material volume at the solder joint of control, thereby control the solder joint quality, effectively save the welding material quantity, reduce welding cost, effectively improve the welding quality simultaneously.
The above embodiments are merely preferred embodiments of the present invention, and only lie in further detailed description of the technical solutions of the present invention, but the protection scope and the implementation manner of the present invention are not limited thereto, and any changes, combinations, deletions, replacements, or modifications that do not depart from the spirit and principles of the present invention will be included in the protection scope of the present invention.
Claims (7)
1. A welding closed-loop monitoring system is characterized by comprising a welding mechanism (1) and an information acquisition and monitoring mechanism (2); the welding mechanism (1) comprises a first terminal (11), a second terminal (12), a welding material (13) and a soldering iron head (14);
the information acquisition and monitoring mechanism (2) is used for acquiring and monitoring information between the first terminal (11) and the second terminal (12), between the first terminal (11) and the soldering material (13), between the first terminal (11) and the soldering iron head (14) and between the soldering material (13) and the soldering iron head (14).
2. The welding closed-loop monitoring system according to claim 1, characterized in that the information acquisition and monitoring mechanism (2) comprises a PLC controller (21) and a single chip microcomputer (22); the PLC controller (21) is connected with the single chip microcomputer (22) through a line.
3. The welding closed-loop monitoring system as set forth in claim 2, wherein the first terminal (11), the second terminal (12), the welding material (13) and the soldering iron head (14) are respectively connected with an information acquisition port of the single chip microcomputer (22) through wires.
4. The welding closed-loop monitoring system of claim 3, characterized in that an information acquisition port of the single chip microcomputer (22) is provided with an analog-to-digital conversion module.
5. A closed loop welding monitoring system as claimed in claim 3, characterized in that said welding material (13) and said soldering iron tip (14) are each further independently connected to a ground line.
6. The welding closed-loop monitoring system according to any one of claims 2 ~ 5, wherein the information collecting and monitoring mechanism (2) further comprises a touch display screen (23), and the touch display screen (23) is connected with the PLC (21) through a line.
7. The welding closed-loop monitoring system of claim 1, wherein the information comprises electrical signals and contact time; the electrical signal comprises a voltage signal or a current signal.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201920233264.XU CN209811398U (en) | 2019-02-22 | 2019-02-22 | Welding closed loop monitoring system |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201920233264.XU CN209811398U (en) | 2019-02-22 | 2019-02-22 | Welding closed loop monitoring system |
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| CN209811398U true CN209811398U (en) | 2019-12-20 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109807423A (en) * | 2019-02-22 | 2019-05-28 | 仝达科技（惠州）有限公司 | A kind of welding closed loop monitoring system and welding method |
| CN109807423B (en) * | 2019-02-22 | 2024-04-23 | 仝达科技（惠州）有限公司 | Welding closed-loop monitoring system and welding method |
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2019
- 2019-02-22 CN CN201920233264.XU patent/CN209811398U/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109807423A (en) * | 2019-02-22 | 2019-05-28 | 仝达科技（惠州）有限公司 | A kind of welding closed loop monitoring system and welding method |
| CN109807423B (en) * | 2019-02-22 | 2024-04-23 | 仝达科技（惠州）有限公司 | Welding closed-loop monitoring system and welding method |
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