DE102013226571A1 - Method for the iterative generation of a reference curve - Google Patents

Abstract

The invention relates to a method for the iterative generation of a reference curve for a controlled welding process at startup of a hardware component, wherein after a removal of an original hardware component in a welding production initially after installation of another hardware component in the welding production plant first at least a short circuit Measurement with the other hardware component and a static hardware resistance adjustment is performed, wherein in a next step by means of an iterating device in n-iterative steps with each m-welded processes for a predetermined number of welding programs clearly assigned one of the other hardware component, in particular Temporary, resistance, and force reference curve of the other hardware component is automated, regulated and monitored originally based on the original resistance, and force reference curve of ur hardware component is generated by an iterative process, and where m, n are integers and each greater than zero.

Description

The present invention relates to a method for the iterative generation of a reference curve for a controlled welding process when starting up a hardware component according to the preamble of claim 1 and to a corresponding method according to the preamble of claim 9.

The method described here for the iterative generation of a reference curve for a controlled welding process when a hardware component is put into operation comprises a first step, after a removal of an original hardware component in a welding production plant, at least after installation of another hardware component in the welding production plant a short circuit measurement with the other hardware component as well as a static hardware resistance adjustment is performed.

However, methods for generating a reference curve after a hardware replacement of a hardware component are already known from the prior art. In particular, however, the need to regenerate a reference curve for a newly assembled hardware component, for example, is due to the fact that after hardware replacement in welding equipment, e.g. a change of pliers or the change of a part of the welding tongs, it can lead to changes of process-typical measuring curves for the measured quantities resistance and force. The change can be seen in a shift of the curve in the offset, but also by a changed dynamic behavior of the curve.

In addition to the intervention in the hardware of the welding system, a production-related necessary point displacement or a change of the component (weld metal) can have the same effect on a reference curve. Since the reference curve is the basis for process control and quality monitoring of a welding process, these functions are influenced by a change in the reference curve.

The resulting effects are larger variations in the control loop of the controller and in the monitoring result. In the worst case, it could lead to a misjudgment of the quality of welding or to a small dot diameter or increased spatter.

Known from the prior art method for recreating a new hardware component adapted to the reference curve deal exclusively with the relearning of the reference curve, with the above-described negative behavior and the impacting changed circumstances can be prevented, possible. However, this procedure is time consuming and costs production capacity. The customer therefore requires an automatic adjustment of the reference curve to the changed conditions without a complicated completely new learning and recalibration of the reference curve.

Proceeding from this, it is therefore an object of the present invention to provide a method for the iterative generation of a reference curve for a controlled welding process when commissioning a hardware component, which enables particularly cost-effective and time-saving, in particular fully automatic, iterative creation of the new hardware component associated reference curve ,

This object is solved by the subject matter of claim 1.

In order to provide a method for the iterative generation of a reference curve for a controlled welding process when a hardware component is put into operation, which enables the generation of a reference curve assigned to the new hardware components in a cost-effective and time-saving manner, the present invention makes use, inter alia, of the idea in that in a next step by means of an iteration device in n-iterative steps with respectively m-welded sequences for a predeterminable number of welding programs, one of the other hardware component uniquely assigned, in particular temporary resistance and force reference curve of the other hardware component automates, controls and monitored, based on the resistance and force reference curve of the original hardware component by means of an iterative method, where m, n are integers and> 0, respectively.

In this respect, with the offered method, an automatic adaptation of the reference curve to the changed conditions, for example a changed welding tongs, a changed point position or component changes. The effort for the plant operator is therefore reduced in a particularly simple manner, for example, only an activation of the iteration process after the replacement of the hardware component.

In particular, a generation of the new, temporary reference curves in a user interface, for example, in the manner of the pattern BOS 6000 done. It is conceivable that after each of the n-iterative steps, the temporary reference curve is written to the controller and there as a new resistance and force reference curve is used for control and monitoring.

In this respect, the advantages of the invention are, on the one hand, the saving of production resources and, on the other hand, the avoidance of welding and monitoring errors according to a production-technically necessary change of the welding hardware and, in particular, therefore also of the hardware components. In particular, moreover, the number of iterative steps n and the number of processes determined per step (actual curves) can be set by the user via the user interface and, for example, preset.

It is also conceivable that iterative teaching is activated, configured and, if necessary, aborted or terminated prematurely via the user interface. The activities "Activate", "Cancel" and "Exit" can be executed globally for all programs of, for example, an electrode of a welding gun or selectively for individual programs.

It is also conceivable that the status of the iterative learning for each of the programs involved in the learning mode is displayed on the user interface, for example via a computer screen. The general status, function active / inactive, the percentage progress of the function for the corresponding program and a comparison of "old" reference curve to the current, iteratively generated reference curve are displayed.

In accordance with at least one embodiment, the method for the iterative generation of a reference curve for a controlled welding process when a hardware component is put into operation comprises a first step, after a removal of an original hardware component in a welding production plant, first after installation of another hardware component in the welding technology First, at least a short circuit measurement with the other hardware component and a static hardware resistance compensation is performed. In a next step, by means of an iterative device in n-iterative steps with m-welded processes for a predeterminable number of welding programs one of the other hardware component clearly assigned, especially temporary resistance and force reference curve of the other hardware component is automated, controlled and monitored originally starting from of the original resistance and force reference curve of the original hardware component by an iterative process, where m, n are integers and> 0, respectively.

In accordance with at least one embodiment, for the numbers m, n, m> 1 and a product of m * n> 20, where m is the number of actual curves to be determined and n is the number of iteration steps and where the product m · n stands for a number of the curves used for the iteration method for training. In this embodiment, it can therefore be ensured, according to experience, that an electrode and program selection can take place when these two conditions are met, without the generated reference curve being too inaccurate.

For the selection of the actual curves to be acquired, the same settings as are known for a UIR setup can be made available. The selection can be linked to different conditions. Conditions here may represent a spatter frequency or spatter size, a current correction factor (adjustment) to a wear of the hardware component. It is conceivable that only welding processes are used for the treatment of the teach-in function, which correspond to the parameterized specifications. As a further condition, it is conceivable that the current adjustment by a controller is used for the use of a curve. The limit values used for this purpose can be predetermined, for example. It is conceivable that these limits are not parameterized.

Basically, for an input of the numbers m, n, which represent functional parameters, these can be preset and parameterized by the user. In particular, it is conceivable that other functional parameters apart from the functional parameters m, n can also be set and parameterized by the respective user. It is also conceivable that basic settings for these parameters are also predefined as an aid to the operator.

In accordance with at least one embodiment, the hardware component comprises at least one welding tongs or at least one component of a welding tongs. It has been found that the method described here for the iterative generation of a reference curve can be applied particularly individually to welding tongs or the welding tongs themselves. So far, namely a replacement of a welding tongs with a complete redefinition of the reference curve was connected. However, welding guns belong to particularly individually used hardware components, which often have to be replaced in various welding processes. In this respect, there has hitherto been the continuous problem of an elaborate new creation of the reference curve, which is particularly easily remedied by the method described above. The iterative Namely, a method for generating the new reference curve, which is unambiguously, preferably one-to-one, associated with the welding tongs described here, saves a considerable amount of pre-setting time and thus presetting costs.

In accordance with at least one embodiment, the iteration method is then terminated, in particular automatically, when a maximum ratio of curves of a welding program welded for the iteration method to the number of curves used for the training method for training exceeds a predefinable limit value.

With such a ratio or with such a parameter is therefore advantageously prevented that the learning process takes too long. For example, if the conditions for teaching were chosen so that very few curves can be used, this may be the case. This parameter defines the maximum number of welds of a program with respect to the number of required curves for the teach-in function. By way of example, it should be noted that 4 (n) * 4 (m), ie 16 curves, can be required for the training. If the ratio is now 10, this ratio is exceeded for a number of 160 bends. In this case, the curve recording is stopped on this program number and the status for this program is displayed with a red bar, for example, by the control in, for example, a status area.

In accordance with at least one embodiment, the iteration method can be aborted by an operator or automatically in accordance with a predefinable termination condition, wherein after the termination of the iteration method, the original resistance and force reference curve is stored as a permanent resistance and force reference curve. Should e.g. the teach-in mode is aborted before a regular end of the iteration procedure because e.g. If the temporary, instantaneous reference curve does not lead to a satisfactory result or the process control is too large, premature termination may take place. It is conceivable that such abort can be done with a right-click on a program number of the control element, for which program the cancellation (cancel) can be selected in an example popup window.

Cancel in this context means that the old, original reference curve is loaded back into the controller. All temporary data concerning the program will be deleted. The status line for this program is removed from the status area of the teach-in window.

In accordance with at least one embodiment, the termination condition is met when the instantaneous temporary reference curve lies at least partially outside a predefinable target tolerance zone for the reference curve. Such a target tolerance curve may be defined and limited by target tolerance limits which define the reference zone in the form of a tolerance band in a measurement curve for the reference curve. In this respect, the present target tolerance zone allows a band area within which the reference curve may move without the reference curve caused by excessive deviations, for example, in a regular welding process incorrect welding processes, especially welding processes that do not meet the quality and quality criteria of the user.

In accordance with at least one embodiment, the iteration method is then terminated or can be terminated as soon as the current temporary reference curve lies within a target tolerance zone, after which the current generated temporary generated reference curve is stored as a new permanent resistance and force reference curve. In particular, this is a termination if the program is aborted before the regular course of all n iteration steps. For example, if the teach-in mode is to be ended before the regular end, e.g. the current temporary reference curve already meets the necessary requirements, so premature termination can take place. For example, with a right-click on a program number, for example, this program can be selected to exit in a pop-up window.

Ending therefore means in this context that the current temporary reference curve remains in the controller and will continue to be used for this program. All temporary data concerning the program will be deleted. The status line for this program can be removed from the status area of the teach-in window.

According to at least one embodiment, in the event that due to material errors and / or positioning errors of the new hardware component after the expiration of the n-iterative steps, no resistance and force reference curve has been generated and / or generated, the original resistance and force reference curve as The new resistance and force reference curve is stored. This may be the case if the temporary reference curves constantly generated by the new iteration steps are at least partially outside the target tolerance zone, so that after the end of the entire iteration process and thus after the expiration of the n-iterative steps there is still no sufficiently optimized reference curve. insofar the possibility is opened to be able to refer to the originally deposited, preferably permanently deposited resistance and force reference curve in order to be able to correspond, for example, at least substantially to the above quality criteria.

Furthermore, a device for the iterative generation of a reference curve for a controlled welding process when starting up a hardware component is specified. For example, the device described herein may be used in a method as described in at least one of the above embodiments, i. The features listed for the method described here are also disclosed for the device described here and vice versa.

In accordance with at least one embodiment, after a removal of an original hardware component in a welding production plant, at least one short circuit measurement with the other hardware component and a static hardware resistance compensation can be carried out after installing another hardware component in the welding technology. In this case, by means of an iterative device in n-iterative steps with m-welded processes for a predeterminable number of welding programs one of the other hardware components clearly assigned, especially temporary resistance and force reference curve of the other hardware component automated, regulated and monitored originally starting from the original resistance and force reference curve of the original hardware component can be generated by an iterative process, and where m, n are integers and each> 0.

Here, the device described here has the same advantages and refinements as the method described above.

In the following, the method described here and the device described here will be explained in more detail with reference to an embodiment and the associated figures.

In the 1 is a schematic embodiment of a device described here described, with the embodiment of the method described herein can be performed.

In the 2 By way of example, a screenshot of an input of functional parameters is shown.

In the 3 schematically a tabular overview of basic settings and parameters and the input range of the respective parameters is shown.

In the 4 a screenshot of an example status display of the functional progress during the iteration process is shown.

In the exemplary embodiment and the figures, identical or equivalent components are each provided with the same reference numerals. The elements shown here are not to be considered as true to scale, but individual elements may be exaggerated to better understand.

In the 1 is a schematic plan view of a device 100 for the iterative generation of a reference curve for a controlled welding process when a hardware component is put into operation 2 shown. After a removal of an original hardware component 1 in a welding production plant 2 will first after installing another hardware component 1 in the welding production plant 3 First, at least one short circuit measurement with the other hardware component 2 and performed a static hardware resistance adjustment.

By means of an iteration device 4 (Computer) becomes one of the other hardware components in n-iterative steps with m-welded operations for a given number of welding programs 2 clearly assigned, in particular temporary resistance and force reference curve of the other hardware component 2 automates, controls and monitors originally based on the original resistance and force reference curves of the original hardware component 1 generated by an iterative process, where m, n are integers and each> 0 and is a product of m * n> 20, which guarantees that the iteration program will neither take too long nor that an iteration would be too inaccurate for the reference curve.

In the 2 is a schematic and tabular overview of basic settings and areas of the function parameters shown.

The necessary basic parameters and input ranges are defined for the parameterization of the input values. Only values from these input areas can be selected in the interface. The first time the function is used, the basic settings are applied from the surface. The following should be explained in addition to and explanatory to the above table:

Number of steps:

There are a maximum of 10 steps to select in the present embodiment, a minimal one. The default is 4.

Curves per step:

At least two curves must be recorded. The maximum number of curves is set at 50, the default value is 5.

The curve ratio indicates after how many total welded curves the function is terminated, if by that time the number of iteration steps has not yet been completed. The number is calculated from m · n · parameterized ratio. Minimum: 4, maximum: 25,000.

The default is 10, which sets the number of curves to 200 with the other basic settings.

In the 4 schematically a screenshot of a status display of the functional progress is shown.

As can be seen, the current function status is displayed for each program with active "iterative teach-in" function. The current number of iteration steps compared to the defined steps (n), the number of detected curves compared to the required number of curves per step (m) and an overall status of detected curves to actual welded curves of a program are displayed. The ratio of detected curves to the total number of welded curves is displayed as a progress bar. This contains a different color depending on the ratio.

For programs with active "iterative teach-in" function, any other option to load a reference curve into the controller is disabled.

In particular, the programs described herein may be incorporated into or form part of a welding control firmware.

The invention is not limited by the description and the embodiment. Rather, the invention encompasses any novel feature as well as any combination of features, including in particular any combination of features in the claims, even if this feature or combination itself is not explicitly shown in the claims or in the embodiment.

LIST OF REFERENCE NUMBERS

1

 original hardware component

2

 new hardware component

3

 Welding production plant

4

 Iterationsvorrichtung

500

 method

100

 contraption

Claims (10)

Procedure ( 500 ) for iteratively generating a reference curve for a controlled welding process when a hardware component is put into operation ( 2 ), after replacing a first hardware component ( 1 ) in a welding production plant ( 3 ) by installing a second hardware component ( 2 ) in the welding production plant ( 3 ) by means of the second hardware component ( 2 ) a short circuit measurement and a static hardware resistance adjustment is carried out, wherein in a next step by means of an iteration device ( 4 ) and an iterative process in n-iterative steps with respectively m-welded processes for a predeterminable number of welding programs one of the second hardware component ( 2 ) uniquely assignable, in particular temporary, resistance and / or force reference curve is generated. Procedure ( 500 ) according to claim 1, characterized in that: m> 1 and a product of m · n> 20 , where m is the number of actual curves to be averaged, and n is the number of iteration steps, and where the product m x n is a number of the curves used for the training iteration method. Procedure ( 500 ) according to claim 1 or 2, characterized in that the hardware component ( 1 . 2 ) comprises at least one welding tongs or at least one component of a welding tongs. Procedure ( 500 ) according to at least one of the preceding claims, characterized in that the iteration method is interrupted, in particular automatically, when a maximum ratio of curves of a welding program welded for the iteration method to the number of curves used for the training method for training exceeds a predeterminable limit value. Procedure ( 500 ) according to at least one of the preceding claims, characterized in that the iteration method according to a predeterminable termination condition can be aborted by an operator or automatically specifiable, wherein after termination of the iteration method, the original resistance, - and Force reference curve as a permanent resistance, - and force reference curve is deposited. Procedure ( 500 ) according to at least one of the preceding claims, characterized in that the termination condition is met when the current, temporary reference curve is at least partially outside a predetermined target tolerance zone for the reference curve. Procedure ( 500 ) according to at least one of the preceding claims, characterized in that the iteration method is terminated or can be terminated if the current, temporary reference curve lies within a target tolerance zone, wherein after termination, the current, until then generated, temporary reference curve as a new permanent Resistance and / or force reference curve is deposited. Procedure ( 500 ) according to at least one of the preceding claims, characterized in that in the event that due to material defects and / or positioning errors of the other hardware component ( 2 ) after the expiration of the n-iterative steps no resistance and / or force reference curve has been generated and / or can be generated, the original resistance and force reference curve is stored as the new resistance and force reference curve. Contraption ( 100 ) for iteratively generating a reference curve for a controlled welding process when a hardware component is put into operation ( 2 ), after removing a first hardware component ( 1 ) in a welding production plant ( 3 ) first after installation of a second hardware component ( 2 ) in the welding production plant ( 3 ) first at least one short-circuit measurement with the second hardware component ( 3 ) as well as a static hardware resistance adjustment is feasible, whereby by means of an iteration device ( 4 ) in n-iterative steps, each with m-welded sequences, for a predeterminable number of welding programs, one of the second hardware component ( 2 ), in particular temporary, resistance and / or force reference curve of the second hardware component ( 2 ) is automated, regulated and monitored. Apparatus according to claim 9, wherein the resistance and force reference curve is based on the original resistance and / or force reference curve of the first hardware component ( 1 ) is producible by means of an iteration method, and wherein m, n are integers and each greater than zero.

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