JP2005238267A - Welding monitor - Google Patents

Welding monitor Download PDF

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JP2005238267A
JP2005238267A JP2004049658A JP2004049658A JP2005238267A JP 2005238267 A JP2005238267 A JP 2005238267A JP 2004049658 A JP2004049658 A JP 2004049658A JP 2004049658 A JP2004049658 A JP 2004049658A JP 2005238267 A JP2005238267 A JP 2005238267A
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welding
unit
calculation
monitor
value
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Atsuhiro Kawamoto
篤寛 川本
Yasushi Hamamoto
康司 濱本
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Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To solve a conventional problem in which controlling set values of welding conditions (welding current, voltage and speed) is insufficient to secure welding quality and in which, in the occurrence of variance of a projection length or slippage of a wire, abnormal welding results may flow out. <P>SOLUTION: The welding monitor is equipped with: a welding voltage detector that detects a welding voltage; a welding current detector that detects a welding current; an arithmetic unit that, using the detection signals of the welding voltage and current as input, calculates the average or instantaneous value of each signal; a monitoring section that stores or displays the calculation results of the arithmetic unit, that sets a welding speed or a calculation threshold value or the like of the calculation results, and that transmits the prescribed values to the arithmetic unit; and an I/O section that transmits/receives each output of the arithmetic unit and the monitoring section. Based on the detected values of the welding current and voltage and the welding speed, calculation is conducted for each value, heat input or a resistance value in the arc, with discrimination performed on the prescribed threshold values, and with the results displayed or stored in the welding monitor. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、アークを発生させて金属を接合させるアーク溶接の溶接状態をモニタする溶接モニタ装置に関する。   The present invention relates to a welding monitor device for monitoring a welding state of arc welding in which an arc is generated to join metals.

近年、ロボットを用いて自動的にアーク溶接を行うアーク溶接装置などが省人化の面から多用されてきている一方、このような溶接において人による溶接に比べて溶接不良を検出できない場合が多くなってきているので、溶接品質を管理・モニタする傾向が高まってきている。   In recent years, arc welding equipment that automatically performs arc welding using a robot has been used frequently from the viewpoint of labor saving, but in such welding, there are many cases where a welding defect cannot be detected compared to welding by a person. As a result, there is an increasing tendency to manage and monitor welding quality.

このような溶接不良を判定するものとしては、溶接電流・溶接電圧・溶接速度等の溶接条件が適正範囲かどうかを管理するもの（例えば特許文献１参照）や、ワイヤ送給状態を管理するためにモータ電流を管理するもの（例えば特許文献２）がある。
特開平０４−２３７５６５号公報 特開平６−４７５４４号公報 As for determining such a welding failure, for managing whether or not the welding conditions such as welding current, welding voltage and welding speed are within an appropriate range (for example, refer to Patent Document 1), and for managing the wire feeding state. There is one that manages motor current (for example, Patent Document 2).
Japanese Patent Laid-Open No. 04-237565 Japanese Patent Laid-Open No. 6-47544

この溶接品質を管理する場合には溶接状態管理と溶接不良管理がある。   When managing the welding quality, there are a welding state management and a welding defect management.

この溶接状態管理には例えば溶接部に供給される入熱の管理があり、この入熱は溶接電流及び溶接電圧より演算できるが、溶接施工時の出力状態を時々刻々演算し演算結果を記憶できるものがこれまで無く、溶接状態を管理するものとして要望されている。   This welding state management includes, for example, management of heat input supplied to the welded portion, and this heat input can be calculated from the welding current and welding voltage, but the output state at the time of welding can be calculated momentarily and the calculation result can be stored. There is nothing so far, and there is a demand for managing the welding state.

また、溶接不良管理には、溶け落ちやビード飛びの発生を管理するものがあり、溶け落ちはワークに対してアーク入熱が大きい時に発生し、ビード飛びはワイヤ送給経路の過負荷によりワイヤが送給されなくなる場合に発生するが、ロポットを用いた自動溶接等では多数の溶接個所を１回で溶接することが多いため、見落とす可能性があり、さらに溶接不良を検出するのに時間を費やすという課題があり、溶接不良の予知策として溶接状態をモニタすることが要望されている。   In addition, welding failure management includes the management of the occurrence of burn-out and bead skipping, which occurs when the arc heat input to the workpiece is large, and bead skipping is caused by overloading of the wire feed path. However, since automatic welding using a ropot often welds many welding points at one time, it may be overlooked and more time is required to detect defective welding. There is a problem of spending, and it is desired to monitor the welding state as a predictive measure of welding failure.

さらに、溶接装置から溶接ワークまで距離が離れている場合や大型構造物を溶接する場合は、溶接装置の二次側を延長して使用する場合が多く、延長のためのケーブルが長くなるに伴い電圧降下が大きくなるので良好なアークを出力するために、溶接装置の出力にケープルで消費される電力を加算する調整を実施しなければならず、この調整に時間がかかるという課題があった。   Furthermore, when the distance from the welding device to the welding workpiece is large, or when welding large structures, the secondary side of the welding device is often extended and used as the cable for extension becomes longer. Since the voltage drop becomes large, in order to output a good arc, it is necessary to adjust the power consumed by the cable to the output of the welding apparatus, and there is a problem that this adjustment takes time.

本発明は、上記課題を解決する溶接モニタ装置を提供することを目的とする。   An object of this invention is to provide the welding monitor apparatus which solves the said subject.

上記目的を達成するために本発明の溶接モニタ方法及び溶接モニタ装置は、スイッチング素子によって溶接出力を制御するアーク溶接装置に設けた溶接電圧検出部と溶接電流検出部と、前記スイッチング素子の動作を制御する演算部を備え、前記演算部とモニタ部の間でデータ通信を行うＩ／Ｏ部を設け、前記溶接電圧検出部と溶接電流検出部の検出値を前記演算部に入力し、前記Ｉ／Ｏ部を介して入熱に関する演算結果を前記演算部からモニタ部に出力するものである。   In order to achieve the above object, a welding monitoring method and a welding monitoring apparatus of the present invention include a welding voltage detection unit, a welding current detection unit, and an operation of the switching element provided in an arc welding apparatus that controls a welding output by a switching element. An I / O unit for performing data communication between the calculation unit and the monitor unit, and input detection values of the welding voltage detection unit and the welding current detection unit to the calculation unit; A calculation result related to heat input is output from the calculation unit to the monitor unit via the / O unit.

また、溶接ワイヤを送給するワイヤ送給装置に溶接ワイヤを送給するモータの回転数を検出するモータ回転数検出部を設けるとともに溶接ワイヤの送給経路に送給量を検出する送給量検出部を設け、前記モータ回転数検出部と送給量検出部からの検出値を前記演算部に入力し、前記Ｉ／Ｏ部を介して前記モータ回転数と送給量及びこれらの差分をモニタ部に出力するものである。   In addition, a wire feeding device for feeding the welding wire is provided with a motor rotation number detecting unit for detecting the number of rotations of the motor for feeding the welding wire, and a feeding amount for detecting the feeding amount in the welding wire feeding path. A detection unit is provided, and detection values from the motor rotation number detection unit and the feed amount detection unit are input to the calculation unit, and the motor rotation number, the feed amount, and the difference between them are input via the I / O unit. This is output to the monitor unit.

また、前記演算結果が所定の上限リミッタ値あるいは下限リミッタ値の範囲外の場合に警告信号を前記Ｉ／Ｏ部を介して出力するものである。   Further, when the calculation result is outside the range of the predetermined upper limit value or the lower limit value, a warning signal is output via the I / O unit.

このように、溶接中の溶接電圧・溶接電流・溶接速度を検出し演算することで被加工物に供給される入熱を演算でき、また、モータ回転数・ワイヤ送給量を検出し演算することでワイヤすべりを検出でき、さらに、全ての溶接結果をモニタできるので溶接の順番によりモニタ結果と溶接結果を照合でき、溶接軌跡とモニタ結果を照合でき、溶接が正常でない個所を溶接の施工後から特定できる。   In this way, the heat input supplied to the workpiece can be calculated by detecting and calculating the welding voltage, welding current, and welding speed during welding, and the motor rotation speed and wire feed amount are detected and calculated. Since wire slip can be detected, and all welding results can be monitored, the monitoring results and welding results can be collated according to the welding order, the welding trajectory can be collated with the monitoring results, and locations where welding is not normal can be detected after welding. Can be identified from

以上のように、本発明の溶接モニタ装置によれば、被加工物に供給される入熱やこれに基づく溶接不良を管理することができる。   As described above, according to the welding monitor device of the present invention, it is possible to manage heat input supplied to a workpiece and welding defects based on the heat input.

（実施の形態１）
図１のように構成される溶接モニタ装置について説明する。 (Embodiment 1)
A welding monitor apparatus configured as shown in FIG. 1 will be described.

１は入力側に商用電源を接続した１次整流部で、商用電源から供給される交流電力を整流する。２は１次整流部１の出力側に接続した平滑コンデンサで、１次整流部１の整流出力電力を平滑する。３は平滑コンデンサ２に接続したスイッチング素子で、平滑された電力を所望のタイミングでスイッチングする。４はスイッチング素子３の出力側を１次側と接続したトランスで、スイッチング素子３でスイッチングされた電力を変換する。５はトランス４の２次側出力に接続した２次整流部で、トランス４で変換された電力を整流する。６は２次整流部５と溶接出力端の間に接続したリアクタ、７はスイッチング素子３のスイッチング駆動を行う駆動部、８は所望の溶接出力を得るために駆動部７を介してスイッチング素子３を制御する演算部、９は演算部８と接続したＩ／Ｏ部で、演算部９の演算結果を外部に出力するとともに外部から演算部８へ信号を入力する。１０は溶接出力端間に設けた溶接電圧検出部で、検出した溶接電圧を演算部８に入力する。１１は溶接出力端とトランス４の間に設けた溶接電流検出部で、検出した溶接電流を演算部８に入力する。１８は１次整流部１と平滑コンデンサ２とスイッチング素子３とトランス４と２次整流部５とリアクタ６と駆動部７と演算部８とＩ／Ｏ部９と溶接電圧検出部１０と溶接電流検出部１１を備えたアーク溶接装置である。１２は溶接ワイヤを送給するワイヤ送給装置、１３はワイヤ送給装置１２内部に設けたワイヤ送給用モータ（図示せず）の回転数を検出するモータ回転数検出部で、検出した溶接用モータの回転数を演算部８に入力する。１４はワイヤ送給用モータの回転によって送給される溶接ワイヤの実際の送給量を検出するワイヤ送給量検出部で、エンコーダ等をワイヤに接触させて検出する接触検出手段を用いても良いしレーザ光等を照射する非接触手段を用いても良く、配置する場所についても検出した送給量を演算部８に入力するように構成すればワイヤ送給経路のどこでも良い。例えばトーチ内部でも良い。１５はワイヤ送給用モータに流れる電流を検出するモータ電流検出部で、検出したモータ電流を演算部８に入力する。１６は被加工物である母材で、アーク溶接装置１８の溶接出力端の一方と溶接ケーブルで接続する。１７は溶接用のトーチで、アーク溶接装置１８の溶接出力端の他方と溶接ケーブルで接続する。１９はモニタ部で、Ｉ／Ｏ部９を介して演算部８とデータのやり取りを行うようにする。   Reference numeral 1 denotes a primary rectification unit having a commercial power supply connected to the input side, and rectifies AC power supplied from the commercial power supply. Reference numeral 2 denotes a smoothing capacitor connected to the output side of the primary rectification unit 1 and smoothes the rectified output power of the primary rectification unit 1. A switching element 3 connected to the smoothing capacitor 2 switches the smoothed power at a desired timing. 4 is a transformer in which the output side of the switching element 3 is connected to the primary side, and converts the power switched by the switching element 3. Reference numeral 5 denotes a secondary rectifier connected to the secondary side output of the transformer 4 to rectify the electric power converted by the transformer 4. 6 is a reactor connected between the secondary rectification unit 5 and the welding output end, 7 is a driving unit that performs switching driving of the switching element 3, and 8 is the switching element 3 via the driving unit 7 in order to obtain a desired welding output. An arithmetic unit 9 controls the I / O unit connected to the arithmetic unit 8, and outputs a calculation result of the arithmetic unit 9 to the outside and inputs a signal to the arithmetic unit 8 from the outside. Reference numeral 10 denotes a welding voltage detection unit provided between the welding output terminals, and inputs the detected welding voltage to the calculation unit 8. Reference numeral 11 denotes a welding current detection unit provided between the welding output end and the transformer 4 and inputs the detected welding current to the calculation unit 8. Reference numeral 18 denotes a primary rectifier 1, a smoothing capacitor 2, a switching element 3, a transformer 4, a secondary rectifier 5, a reactor 6, a drive unit 7, a calculation unit 8, an I / O unit 9, a welding voltage detection unit 10, and a welding current. An arc welding apparatus including a detection unit 11. Reference numeral 12 denotes a wire feeding device for feeding a welding wire, and reference numeral 13 denotes a motor rotation number detecting unit for detecting the rotation number of a wire feeding motor (not shown) provided in the wire feeding device 12. The rotation speed of the motor is input to the calculation unit 8. Reference numeral 14 denotes a wire feed amount detection unit for detecting the actual feed amount of the welding wire fed by the rotation of the wire feed motor, and contact detection means for detecting the encoder by contacting the wire with the wire can be used. Alternatively, non-contact means for irradiating a laser beam or the like may be used, and any part of the wire feed path may be used as long as the feed amount detected for the place to be arranged is input to the calculation unit 8. For example, it may be inside the torch. Reference numeral 15 denotes a motor current detection unit that detects a current flowing through the wire feeding motor, and inputs the detected motor current to the calculation unit 8. Reference numeral 16 denotes a base material, which is a workpiece, and is connected to one of the welding output ends of the arc welding apparatus 18 by a welding cable. A welding torch 17 is connected to the other welding output end of the arc welding apparatus 18 with a welding cable. A monitor unit 19 exchanges data with the arithmetic unit 8 via the I / O unit 9.

さて、アーク溶接電源１８は供給された商用電源を所望とする溶接出力に変換し、トーチ１７を経由し、トーチ先端より送給された溶接ワイヤ先端と母材１６との間にアークを点孤させアーク溶接を行う。   The arc welding power source 18 converts the supplied commercial power source into a desired welding output, and the arc is ignited between the tip of the welding wire fed from the tip of the torch and the base material 16 via the torch 17. Arc welding.

このときの溶接電圧を溶接電庄検出部ｌ０で検出し、溶接電流を溶接電流検出部１１で検出し、それぞれの検出値を演算部８に入力する。   The welding voltage at this time is detected by the welding voltage detection unit 10, the welding current is detected by the welding current detection unit 11, and each detection value is input to the calculation unit 8.

また、溶接速度及び各検出値に対するしきい値はモニタ部ｌ９で入力及び設定し、これらの設定値をＩ／Ｏ部９を介して演算部８に送信する。   Further, the welding speed and the threshold value for each detected value are input and set by the monitor unit 19, and these set values are transmitted to the calculation unit 8 via the I / O unit 9.

なお、演算部８のデータとモニタ部１９のデータはＩ／Ｏ部９を介して双方向に送受信可能としている。   The data of the calculation unit 8 and the data of the monitor unit 19 can be transmitted and received bidirectionally via the I / O unit 9.

そして演算部８では前記溶接電圧検出部１０からの検出信号（溶接電圧の検出値）と前記溶接電流検出部１１からの検出信号（溶接電流の検出値）から各々の平均値あるいは瞬時値を乗算した値を時間毎に演算し、その演算結果をデータはＩ／Ｏ部９を介してモニタ部１９へ出力する。また溶接速度値から単位長さ当たりの値を演算する。これによりアーク溶接装置１８の二次側に対する供給量を管理でき、突き出し長さ変動等による変化を管理できる。入熱過多により発生する溶け落ちは、溶け落ちの発生前から溶接電圧検出値が上昇するので前記管理を行うことで検出あるいは予知できる。   Then, the arithmetic unit 8 multiplies each average value or instantaneous value from the detection signal (detection value of the welding voltage) from the welding voltage detection unit 10 and the detection signal (detection value of the welding current) from the welding current detection unit 11. The calculated value is calculated every time, and the calculation result is output to the monitor unit 19 via the I / O unit 9. Further, a value per unit length is calculated from the welding speed value. Thereby, the supply amount with respect to the secondary side of the arc welding apparatus 18 can be managed, and the change due to the protrusion length variation or the like can be managed. The burn-out generated due to excessive heat input can be detected or predicted by performing the above management because the welding voltage detection value rises before the occurrence of burn-out.

また、前記溶接電圧の検出値と前記溶接電流の検出値から各々の平均値あるいは瞬時値から溶接中の抵抗値が演算できる。この抵抗値はアーク長と対応するため、アーク長が一定であるか管理できる。   Further, the resistance value during welding can be calculated from the average value or instantaneous value of each of the detected value of the welding voltage and the detected value of the welding current. Since this resistance value corresponds to the arc length, it can be managed whether the arc length is constant.

前記の演算結果は正常溶接か否かを判別する所定のしきい値と比較し、しきい値を越えた場合、警告表示を行うことで溶接後に溶接結果と照合できる。   The calculation result is compared with a predetermined threshold value for determining whether or not the welding is normal, and when the threshold value is exceeded, a warning display is displayed to check the welding result after welding.

このため、正常でない溶接が行われた場合はその溶接品が流出するのを防止できる。   For this reason, when an abnormal welding is performed, it is possible to prevent the welded product from flowing out.

また、ワイヤ送給量検出部１４からの出力とモータ回転数検出部１３出力との差分によりすべりが発生しているかどうかが判別でき、差分としきい値との判別を実施すれば検出値に重畳するノイズ成分を考慮できる。   Further, it is possible to determine whether or not a slip has occurred based on the difference between the output from the wire feed amount detection unit 14 and the output from the motor rotation number detection unit 13, and if the difference and the threshold value are determined, the detection value is superimposed. Noise components to be taken into account.

さらに、モータ電流を併せて判別すればさらに判別の精度が向上する。これによりワイヤのすべりを検出でき、前記のアーク溶接装置１８の二次側に対する供給量管理においても、ワイヤのすべりとの関連が管理できる。   Furthermore, if the motor current is determined together, the accuracy of the determination is further improved. Thereby, the slip of the wire can be detected, and the relationship with the slip of the wire can also be managed in the supply amount management to the secondary side of the arc welding apparatus 18.

なお、モニタ部ｌ９は専用の装置として準備することもできるが、望ましくは溶接に用いる口ボットのコントローラで併用するのが良い。この場合、ロボットの軌跡動作も含めて管理できるので、正常でない溶接管理データと溶接個所が照合でやすく特定するための時間短縮が可能となる。   Although the monitor unit 19 can be prepared as a dedicated device, it is preferably used in combination with a mouth bot controller used for welding. In this case, since the robot trajectory can be managed as well, it is possible to reduce the time required for easily identifying the abnormal welding management data and the welding location by collation.

また、正常な溶接か判別するしきい値は、正常溶接かどうかの判別だけでなく、しきい値の設定によって不良発生予知として効果を有する。
（実施の形態２）
図２は図１で説明したモニタ部１９内に、二次側ケーブルのインピーダンスを設定し、Ｉ／Ｏ部９を介して演算部８へ設定値を送る二次側設定部２０を追加したものである。 Further, the threshold value for determining whether the welding is normal is effective not only for determining whether the welding is normal, but also for predicting the occurrence of defects by setting the threshold value.
(Embodiment 2)
2 is obtained by adding a secondary side setting unit 20 that sets the impedance of the secondary side cable and sends a set value to the calculation unit 8 via the I / O unit 9 in the monitor unit 19 described in FIG. It is.

本実施の形態において実施の形態１と同様の構成については同一の番号を付して詳細な説明を省略する。   In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

この二次側設定部２０は、アーク溶接装置１８の二次側の状態、特に二次側ケーブルのインピーダンスを設定入力するもので、例えば使用しているケーブル長が２０ｍで断面積が６０ｍｍ２であればケーブル長２０ｍ断面積６０ｍｍ２と設定する。 The secondary side setting unit 20 is used to set and input the secondary side state of the arc welding apparatus 18, particularly the impedance of the secondary side cable. For example, the cable length used is 20 m and the cross-sectional area is 60 mm 2 . If there is, the cable length is set to 20 m and the cross-sectional area is set to 60 mm 2 .

この設定値が演算部８に送信されると、演算部８では前記設定値より溶接ケーブルのインピーダンスが演算される。   When this set value is transmitted to the calculation unit 8, the calculation unit 8 calculates the impedance of the welding cable from the set value.

実施の形態１で演算されたアーク溶接装置１８の二次側に対する供給量から前記二次側インピーダンスの演算結果に溶接電流検出値を乗算した結果を減算すると溶接部に供給される入熱量が演算できる。これにより溶接部への入熱量を精度良く管理できる。   When the result obtained by multiplying the calculation result of the secondary side impedance by the welding current detection value is subtracted from the supply amount to the secondary side of the arc welding apparatus 18 calculated in the first embodiment, the amount of heat input supplied to the weld is calculated. it can. Thereby, the heat input to the welded portion can be managed with high accuracy.

また、二次側ケーブルのインピーダンスによる消費電力が予め演算できるので、溶接条件設定する際に前記消費電力を加算でき、適正な溶接条件調整に費やす時間を短縮できる。
（実施の形態３）
図３は図１の演算部８内の構成に二次側検出部２１を追加したものである。 In addition, since the power consumption due to the impedance of the secondary cable can be calculated in advance, the power consumption can be added when setting the welding conditions, and the time spent for adjusting appropriate welding conditions can be shortened.
(Embodiment 3)
3 is obtained by adding a secondary side detection unit 21 to the configuration in the calculation unit 8 of FIG.

本実施の形態において実施の形態１と同様の構成については同一の番号を付して詳細な説明を省略する。   In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

本実施の形態は、実施の形態２と目的は同様で二次側ケーブルのインピーダンスを演算し、溶接部への入熱量を演算すると共に適正な溶接条件調整に費やす時間を短縮するものである。   The purpose of this embodiment is the same as that of Embodiment 2, and calculates the impedance of the secondary cable, calculates the amount of heat input to the welded portion, and reduces the time spent for adjusting appropriate welding conditions.

本実施の形態において実施の形態２と異なる点は、アーク溶接装置１８の二次側に微小電流を流し、その場合の電圧降下量でインピーダンスを演算することである。   The present embodiment is different from the second embodiment in that a minute current is supplied to the secondary side of the arc welding apparatus 18 and the impedance is calculated based on the voltage drop amount in that case.

その点について説明する。溶接時とは別に溶接ワイヤ先端と母材を接触させ、溶接ワイヤを溶融させない微小な一定電流を通電させる。その場合の電流値は溶接電流検出部１１で検出でき、電圧降下は溶接電圧検出部１２で検出できる。前記検出値は二次側検出部２１に入力され、除算により二次側インピーダンスを演算する。この演算により求めた二次側インピーダンスを演算部８へ出力し、実施の形態１で演算されたアーク溶接装置１８の二次側に対する供給量から前記二次側インピーダンスの演算結果に溶接電流検出値を乗算した結果を減算すると溶接部に供給される入熱量が演算できる。これにより溶接部への入熱量を精度良く管理できる。   This will be described. Separately from welding, the tip of the welding wire and the base material are brought into contact with each other, and a small constant current that does not melt the welding wire is applied. The current value in that case can be detected by the welding current detector 11, and the voltage drop can be detected by the welding voltage detector 12. The detected value is input to the secondary side detection unit 21, and the secondary side impedance is calculated by division. The secondary side impedance obtained by this calculation is output to the calculation unit 8, and the welding current detection value is calculated from the supply amount to the secondary side of the arc welding apparatus 18 calculated in the first embodiment to the calculation result of the secondary side impedance. If the result of multiplying is subtracted, the amount of heat input supplied to the weld can be calculated. Thereby, the heat input to the welded portion can be managed with high accuracy.

また、二次側ケーブルのインピーダンスによる消費電力が予め演算できるので、溶接条件設定する際に前記消費電力を加算でき、適正な溶接条件調整に費やす時間を短縮できる。   In addition, since the power consumption due to the impedance of the secondary cable can be calculated in advance, the power consumption can be added when setting the welding conditions, and the time spent for adjusting appropriate welding conditions can be shortened.

また、二次側インピーダンスが大きすぎる場合、溶接状態を悪化する可能性があるためしきい値により警告することもできる。   Further, when the secondary side impedance is too large, the welding state may be deteriorated, so that a warning can be given by a threshold value.

本発明の溶接モニタ装置によれば、正常でない溶接個所及び部分を特定することが可能となり、正常でない溶接結果が流出するのを防止でき、溶接業界全般に適用可能で、生産性向上に大きく貢献できる。   According to the welding monitor device of the present invention, it is possible to identify an abnormal welding location and part, prevent an abnormal welding result from flowing out, and can be applied to the entire welding industry, greatly contributing to productivity improvement. it can.

本発明のアーク溶接装置の実施の形態１における全体構成図Overall configuration diagram of Embodiment 1 of arc welding apparatus of the present invention 本発明のアーク溶接装置の実施の形態２における全体構成図Overall configuration diagram of Embodiment 2 of arc welding apparatus of the present invention 本発明のアーク溶接装置の実施の形態３における全体構成図Whole block diagram in Embodiment 3 of the arc welding apparatus of this invention

符号の説明Explanation of symbols

８ 演算部
９ Ｉ／Ｏ部
ｌ０ 溶接電圧検出部
１１ 溶接電流検出部
１２ ワイヤ送給装置
１３ モータ回転数検出部
１４ ワイヤ送給量検出部
１５ モ一夕電流検出部
１６ 母材
１７ トーチ
１８ アーク溶接電源
１９ モニタ部
２０ 二次側設定部
２１ 二次側検出部 DESCRIPTION OF SYMBOLS 8 Calculation part 9 I / O part 10 Welding voltage detection part 11 Welding current detection part 12 Wire feeding apparatus 13 Motor rotation speed detection part 14 Wire feed amount detection part 15 Mototsubo current detection part 16 Base material 17 Torch 18 Arc Welding power source 19 Monitor unit 20 Secondary side setting unit 21 Secondary side detection unit

Claims (8)

スイッチング素子によって溶接出力を制御するアーク溶接装置に設けた溶接電圧検出部と溶接電流検出部と、前記スイッチング素子の動作を制御する演算部を備え、前記演算部とモニタ部の間でデータ通信を行うＩ／Ｏ部を設け、前記溶接電圧検出部と溶接電流検出部の検出値を前記演算部に入力し、前記Ｉ／Ｏ部を介して入熱に関する演算結果を前記演算部からモニタ部に出力する溶接モニタ装置。 A welding voltage detection unit and a welding current detection unit provided in an arc welding apparatus that controls welding output by a switching element, and a calculation unit that controls the operation of the switching element are provided, and data communication is performed between the calculation unit and the monitor unit. An I / O unit to perform is provided, and detection values of the welding voltage detection unit and the welding current detection unit are input to the calculation unit, and a calculation result related to heat input via the I / O unit is transferred from the calculation unit to the monitor unit. Welding monitor device to output. 前記Ｉ／Ｏ部を介して溶接速度を前記演算部に入力し、前記溶接電圧検出部と溶接電流検出部の検出値と溶接速度から溶接長さ当たりの入熱を演算し、前記Ｉ／Ｏ部を介して演算部の演算結果をモニタ部に出力する請求項１記載の溶接モニタ装置。 A welding speed is input to the calculation unit via the I / O unit, and a heat input per weld length is calculated from detection values and welding speeds of the welding voltage detection unit and welding current detection unit, and the I / O The welding monitor device according to claim 1, wherein the calculation result of the calculation unit is output to the monitor unit via the unit. アーク溶接装置の二次側ケーブルのインピーダンスを前記演算部に入力して溶接電流の平均値あるいは瞬時値を前記インピーダンスに乗じた値を入熱に関する演算結果から減ずる請求項１または２記載の溶接モニタ装置。 The welding monitor according to claim 1 or 2, wherein an impedance of a secondary cable of an arc welding apparatus is input to the calculation unit, and a value obtained by multiplying an average value or instantaneous value of a welding current by the impedance is subtracted from a calculation result related to heat input. apparatus. アークを発生する電極と被加工物を接触させた状態でアーク溶接を開始しない程度の微小電流を通電させることにより発生するアーク溶接装置の出力電圧を前記溶接電圧検出部で検出し、前記出力電圧と微小電流からアーク溶接装置の二次側ケーブルのインピーダンスを前記演算部で演算する請求項３記載の溶接モニタ装置。 The welding voltage detection unit detects the output voltage of the arc welding apparatus that is generated by passing a minute current that does not start arc welding in a state where the work piece is in contact with the electrode that generates the arc, and the output voltage The welding monitor device according to claim 3, wherein an impedance of a secondary side cable of the arc welding device is calculated by the calculation unit from the minute current. 溶接ワイヤを送給するワイヤ送給装置に溶接ワイヤを送給するモータの回転数を検出するモータ回転数検出部を設けるとともに溶接ワイヤの送給経路に送給量を検出する送給量検出部を設け、前記モータ回転数検出部と送給量検出部からの検出値を前記演算部に入力し、前記Ｉ／Ｏ部を介して前記モータ回転数と送給量及びこれらの差分をモニタ部に出力する請求項１から４のいずれかに記載の溶接モニタ装置。 A wire feed device for feeding a welding wire is provided with a motor rotation speed detection unit for detecting the rotation speed of a motor for feeding the welding wire, and a feed amount detection unit for detecting the feed amount in the feed path of the welding wire The detection value from the motor rotation number detection unit and the feeding amount detection unit is input to the calculation unit, and the motor rotation number, the feeding amount and the difference between them are monitored via the I / O unit. The welding monitor device according to claim 1, wherein the welding monitor device outputs to 前記溶接電圧検出部と溶接電流検出部の検出値として瞬時値を用い、溶接電圧と溶接電流の瞬時値からアーク中の抵抗値を演算し、前記Ｉ／Ｏ部を介して演算部の演算結果をモニタ部に出力する請求項１から５のいずれかに記載の溶接モニタ装置。 The instantaneous value is used as the detection value of the welding voltage detection unit and the welding current detection unit, the resistance value in the arc is calculated from the instantaneous value of the welding voltage and welding current, and the calculation result of the calculation unit is obtained via the I / O unit. The welding monitor device according to any one of claims 1 to 5, wherein the output is output to a monitor unit. 前記演算結果が所定の上限リミッタ値あるいは下限リミッタ値の範囲外の場合に警告信号を前記Ｉ／Ｏ部を介して出力する請求項１から６のいずれかに記載の溶接モニタ装置。 The welding monitor device according to any one of claims 1 to 6, wherein a warning signal is output via the I / O unit when the calculation result is outside a range of a predetermined upper limiter value or lower limiter value. 警告信号出力時の時間または溶接箇所とともに演算部の演算結果をモニタ部で記憶する請求項７記載の溶接モニタ装置。 The welding monitor device according to claim 7, wherein the monitor unit stores the calculation result of the calculation unit together with the time when the warning signal is output or the welding location.
JP2004049658A 2004-02-25 2004-02-25 Welding monitor Pending JP2005238267A (en)

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