JPH0133274Y2 - - Google Patents

Description

[Detailed explanation of the idea]

[Industrial Application Field] The present invention relates to a welding condition monitoring device.
When welding special structures that require high-quality welding, we monitor whether the welding quality of the joint and each bead in the joint is as specified, and we also monitor the welding history, welding data, and welding index. This invention relates to a welding condition monitoring device that records values. [Prior Art] Special steel containers that are subjected to high pressure from the outside or inside, such as submarine pressure hulls, nuclear reactor pressure vessels,
Special tubular structures such as pen stocks for power plants and cold storage containers use tempered high-strength steel as their structural material. In this case, it is required to ensure that the joints for connecting each member are of appropriate quality. In order to guarantee this appropriate quality, we have developed a method to ensure that there are no physical defects through post-weld non-destructive testing, and to indirectly check the welding conditions to ensure that the welded part has the required performance. There is a method of managing and guaranteeing this. The former type of guarantee through non-destructive testing is already generally practiced, but this is done after the welding work is completed. Among the welding construction conditions, it is preferable to manage the amount of heat input, which is closely related to the performance of the joint, during the welding operation, but in the latter method, conventionally, the actual data is organized after the welding operation is completed and the suitability is determined. There is. One of these latter methods, as shown in FIG.
The suitability of each weld of one pass 4 consisting of an appropriate number of beads 3 and one joint 1 consisting of an appropriate number of stacked passes 4 is managed, and the welding work is performed by an operator or an automatic welding machine. It is done sequentially. For example, if one bead 3 has been formed, but it is determined that the weld is not of appropriate quality, that bead may be removed and the temperature of the structural material being increased may be waited until the temperature reaches a predetermined value, or , After working on other joints, form the bead again at the same location. [Problem to be solved by the invention] The suitability judgment made in the above case involves, for example, measuring the voltage and current during one bead welding, the time required for one bead, the length of one bead, etc., and using those values. Based on this, the amount of heat input for each bead and the average amount of heat input for each joint are calculated separately, but this imposes a large work burden on operators and inspectors and requires time. Considering the actual situation of this work, it cannot be done during welding, so as mentioned above, after a series of welding work is completed, the data is organized and saved for quality assurance, so that future work conditions can be adjusted. It is used as a material for considering whether there are any changes and their extent. By the way, Japanese Unexamined Patent Publication No. 53-128552 describes an arc welding method in which welding data is measured, the suitability of the data is determined, and the data is recorded. This is to automatically measure welding heat input and compare it with a preset value in order to facilitate adjustment of heat input during manual or semi-automatic arc welding. In order to calculate the welding heat input, arc sensors are placed at regular intervals, and their transit time is determined. In such welding methods, in order to control and guarantee the quality of welded joints, welding data has not been measured, calculated, compared with reference values, and stored. Therefore, it is not possible to centrally manage various data such as weld joint numbers, worker names, and welding postures. Additionally, there is a problem in that a single control device cannot manage multiple workers at the same time. Furthermore, when calculating heat input, the operator measures the welding length, inputs it into the terminal, calculates the welding speed by dividing this by the arc duration, and calculates the heat input. I can't do it either. In this way, it is not possible to immediately reflect the above data and the results of its arrangement on the welding part currently being worked on, so it is possible to automatically measure and record the welding conditions during work, and also to judge suitability. It would be desirable to have a device that can do this instantly. The present invention was developed in view of the above-mentioned problems, and its purpose is to weld joints made of special structural materials.
It is possible to measure and calculate various welding data during welding and immediately reflect it in the welding work in order to maintain welding quality, and to be able to instruct and manage welding conditions in detail to welding operators, and there are problems with welding quality. It is possible to stop and maintain the welding machine function and keep the man-hours for welding rework to a minimum.
Welding that realizes the ability to organize and output welding management data, record this data and save it as quality assurance data, and use it as a guideline for future welding work to improve the efficiency of welding work. An object of the present invention is to provide a condition monitoring device. [Means for Solving the Problems] The welding condition monitoring device of the present invention is applied to a welding monitoring device capable of measuring various data during welding work and determining the suitability of the welding. . As shown in FIG. 2, its features include a data check section 15 that determines suitability of various welding data during welding work measured by the measuring means 10 based on predetermined limit values; a calculation unit 17 that calculates welding index values, organizes various welding data and welding index values for each bead in each joint as welding management data, and outputs the same; and determines suitability of welding index values based on predetermined specified values. It has a determination unit 18, a lock command unit 24 that stops and holds the function of the welding machine 9 when the determination unit 18 makes a negative determination, and a lock release command unit 25 that releases the welding machine 9 from being held stopped. Data processing means 11 and data processing means 1
1, an input section 21 for inputting the above predetermined limit values and predetermined regulation values to instruct the welding operator about the welding conditions; an input/output/storage means 12 having a storage section 20 for storing and outputting the determined welding index value; a display means 13 for notifying the welding operator and the work leader of the results and various data in the determination section 18; and determination. If the welding index value determined by the part 18 deviates from a predetermined specified value, an alarm means 14 issues an alarm to the welding operator and the work leader. [Operation] After confirming the joint and the welding worker, the work leader inputs the welding history, predetermined values for welding, and further predetermined limit values through the input section 21 of the input/output/storage means 12. . The welding operator uses the display means 1
After confirming several types of input values shown in 3, welding work is started. The measuring means 10 measures various welding data and inputs the data to the data checking section 15 of the data processing means 11. Welding data are compared with limit values, and if all measured values are not within the respective limit values, no arc is generated from the welding rod and no welding is performed. If all measured values are within their respective limits,
It is assumed that predetermined welding is being performed, and these values are input to the calculating section 17, where the welding index value of one bead for which welding has been completed is calculated. The determination unit 18 determines whether this calculated value is within the specified value, and if it is outside the specified value, the alarm means 14
An alarm is issued to the welder and work leader. Then, the welding machine 9 is locked by a signal from the lock command section 24. The welding operator deletes the bead, and when the work leader issues a release command using the lock release command unit 25, welding can be restarted. If it is determined that the welding index value is smaller than the specified value, the welding index value is input and stored in the storage unit 20 together with the various welding data, and the value is displayed on the display means 13. Referring to this value, the welding operator changes the welding conditions if necessary. Such operations and measurements are repeated to store various welding data and welding index values for each bead. These values are printed by the printing unit 22 at any time according to the operator's instructions, such as every time the formation of one bead is completed. When the formation of the final bead in one joint is completed, the calculation unit 17 calculates the welding index value per bead in one joint, and organizes and outputs the welding data and welding index value for each bead in each joint. , can be printed out by the printing section 22. Therefore, the welding operator can weld the several joints he or she is responsible for sequentially or in an irregular order without having to wait, thereby suppressing wasted time and performing the work efficiently. The stored accumulated data is printed out,
The work leader can obtain various welding data for each bead and welding index values for each joint as a record card, which can be organized and stored. Once the entire welding work for the day is completed, the welding history and various welding data for each bead can be organized and used as a reference for the next day's work. [Effects of the invention] According to the invention, various welding data and heat input can be determined for each bead, and it is possible to not only simply measure and process welding conditions, but also to guarantee a metallurgically sound welded joint. Heat input management is performed for each weld beat and each weld joint, and it is possible to monitor in real time whether or not welding is being performed properly. In addition, each data can be used to guide welding operations for the next day or other joints. Moreover, since these various data including the welding history can be recorded and left behind, it is possible to save them as quality assurance materials for the entire welding work. In addition, if one key station controls multiple remote boxes and sensor boxes so that one welder handles multiple joints, the temperature of the joints where the temperature rises due to welding will increase until the specified temperature is reached. Other joints can be welded, allowing operators to work continuously. In addition to measuring various data at the welding area and importing it into the processing unit, we not only provide detailed instructions for welding conditions to minimize the number of welding repair steps, but also output a welding machine lock signal. This enables two-way information exchange, such as the following, and improves the efficiency of welding work. If there is a problem with the welding results, the welding machine can be electrically locked to prevent further work. [Examples] Hereinafter, the present invention will be described in detail based on examples thereof. FIG. 2 is a sequence block diagram of a welding condition monitoring device 8 showing an embodiment of the present invention. This is its main structure. To be more specific, the welding machine 9 mentioned above is a covered arc welding machine, other automatic welding machine, semi-automatic welding machine, etc. used by a welding operator, and is an object on which most of the welding data described below is measured. be. The above measuring means 10 collects various welding data measured by the welding machine 9, such as the atmospheric temperature and humidity at the welding site, the base material temperature of the joint, the welding voltage and current, the arc time for each bead, and the length of one bead. It is used to measure things such as strength. Therefore, although there are various known devices that can measure these data, the arc time and the length of one bead are measured individually by the welding operator and inputted into the measurement data input device 23.
Alternatively, it may be measured as the moving speed of the automatic welding machine (length of one bead/arc time of one bead). These welding data are output from the measuring means 10 to the data processing means 11. The data processing means 11 includes a data check section 15
and a predetermined limit value inputted in advance to this data check section 15, for example, the allowable minimum voltage value.
Limit value setting section 1 that outputs Vmin, maximum allowable current value Imax, minimum allowable arc time for one bead Tmin, minimum allowable length Lmin for one bead, and maximum allowable speed Vmax of the welding machine 9 as necessary.
6, the data check unit 15 receives the data after determining the suitability of the welding data, calculates welding index values such as the amount of heat input, and also calculates various welding data for each bead in each joint as welding management data. and a calculation unit 17 that organizes and outputs welding index values, a determination unit 18 that determines the suitability of the welding index values calculated by this calculation unit 17, and a predetermined specified value that is input in advance to this determination unit 18. , and a specified value setting unit 19 that outputs, for example, the allowable large heat input amount Hmax for one bead. The data processing means 11 is provided with a lock command section 24, which will be described later, and a lock release command section 25, which releases the operational lock of the welding machine 9 held in a stopped state by the lock command section 24. The input/output/storage means 12 is the data processing means 11
A storage section 20 receives and stores various welding data and welding index values from the data check section 15 and calculation section 17, and further outputs them. an input unit 21 for inputting limit values and predetermined regulation values to instruct welding conditions to a welding operator; and a storage unit 2
It has a printing section 22 that prints stored data within 0 as necessary. The display means 13 is a display of a remote box 32 (to be described later) that allows a worker during welding to visually check the data stored in the storage section 20, or a display unit that allows a worker at a separately provided key station to visually check the data. Display screen (CRT) installed in a location where it is possible
It is. If the welding index value of the bead that has just been completed exceeds a specified value, the alarm means 14 warns the user of the work by e.g. sound, text, light, etc. based on the signal output from the determination section 18 of the data processing means 11. This is to issue an alarm to the person in charge and the work leader. Note that when such an alarm is issued, the determination unit 18
A signal is input to the lock command section 24 of the central controller that electrically controls each of the above-mentioned constituent means, and the corresponding remote box is inputted to prevent the welding operation of the worker who is welding the joint from proceeding to the next step. Via 32, the corresponding welding machine 9 is locked. Incidentally, the above-mentioned welding condition monitoring device 8 can be used to monitor the welding conditions of, for example, eight people by one work leader at the key station 31 of the command room, which is located in a position where the workers in charge can be seen visually, as shown in FIG. It has become possible to direct the work of workers. In such a case, a personal computer that combines a central controller operated by a work leader for monitoring and directing, the above-mentioned data processing means 11, input/output/storage means 12, display means 13, and alarm means 14 is used. Eight remote boxes 32 (two shown in the figure) each have a display means 13, an alarm means 14, etc. in one key station 31 for a data processing microcomputer, etc., and are located at the hands of each of the eight workers. Eight sensor boxes 33 (two shown) are installed to measure various welding data. In addition, welding workers should use Remote Box 3.
The welding operator performs the work while checking the various welding data displayed in 2, and there is a case where it is necessary for the welding operator to actually measure one bead length using the measuring means 10 of the sensor box 33 and input that data. A measurement data input device 23 is installed in the sensor box 33. According to an embodiment having such a configuration, it can be operated as follows. The following description will be made based on the sequence block diagram shown in FIG. 2 and the operating procedure flowchart shown in FIG. First, the work leader at key station 31 activates the central controller, and then identifies the joints to be constructed that day.

【table】

[Table] After confirming the welding operator in charge and the corresponding remote box 32, input/output/storage means 12
For example, the welding history (bibliographical items) as shown in Table 1 is input through the input unit 21 of. That is,
Input necessary data such as remote box 32 number, work date, work time, manufacturing number, worker number, work location, welding method, welding material brand, welding rod diameter and its rod number (step 1 of the flowchart). , hereinafter referred to as S1). Next, the work leader inputs, for example, the specified values shown in Table 2 into the specified value setting section 19 of the data processing means 11. Note that one work leader can supervise eight melters.

[Table] Assuming that one welder is able to direct the workers and weld four joints A, B, C, and D, the joint selection for each joint is number, card number,
Joint number, maximum specified value of heat input per bead
Input hmax, the target specified value Hobj of the average heat input per bead of each joint, the welding posture, and whether or not to add the heat input of the first pass (S2). Note that whether or not the heat input amount is added in the first pass means, for example, if the groove shape of the joint is X-shaped as shown in FIG. Since the first pass 6a is gouged before welding, when calculating the average heat input per bead in the joint,
Since the amount of heat input in the first pass 6a must be ignored, a command to that effect is issued. Furthermore, the work leader inputs the maximum permissible current value Imax, the minimum permissible voltage value Vmin, the permissible minimum time Tmin, the permissible minimum length Lmin, and the maximum permissible speed as necessary into the limit value setting section 16 of the data processing means 11.
Enter Vmax (S3). These are used to determine whether or not an arc is generated from the welding rod by comparing each with various welding data individually measured by the measuring means 10 as described later. Therefore, if a welder mistakenly works without an arc, one of these values will be an abnormal value outside the limit value, and this will be immediately obvious, and the automatic welder will You can also check the operating status of the When the various values are input in this way, the welder in charge of the welding work can
After checking the various input values displayed on the display panel (S4), if the temperature and humidity at the welding site and the temperature of the base material at the joint are acceptable for welding, welding can begin. (S5). When welding starts, it is confirmed that the welding has started because the arc continues for a certain period of time, and then each detection device of the measuring means 10 of the sensor box 33 measures various welding data (S6), and the Data processing means 1
The data is input to the data check section 15 of No. 1 (S7).
The welding data is entered automatically for the voltage, current, and arc time of the welding machine 9, and by the welding operator measuring and inputting the bead length each time one bead is welded. It will be done.
Note that when an automatic welding machine is employed, the moving speed is automatically measured instead of the arc time and one bead length described above. These welding data are first compared with respective limit values individually stored in the limit value setting section 16 (S8). In other words, whether the voltage measured during one bead welding is greater than the minimum allowable voltage value Vmin, whether the measured current is smaller than the maximum allowable current value Imax, and whether the welding length is greater than the minimum allowable length Lmin. It is determined whether or not. If all of these measured values are not within their respective limits, no arc will be generated from the welding rod and no welding will occur. If all the measured values are within their respective limit values, it is assumed that an arc is generated from the welding rod and a predetermined welding is being performed. By the way, if the current exceeds the maximum allowable current value Imax,
It is indirectly determined from the measured value that the welding rod and the structural material are in contact and no arc is generated and welding is not performed. Once the current and voltage that generate an arc are measured, the arc time, bead length, or welding speed is calculated in the calculation section 1.
7, and there, the heat input h [joule/cm] which is the welding index value of the one bead that has just been welded
is calculated based on the following equation (S9). h = (measured voltage V) x (measured current I) x 60 x (arc time sec) / (one bead length cm)...(1) This calculated heat input amount h is determined by the determination unit 18 in the specified value setting unit 19 Maximum specified value of heat input within hmax
It is determined whether it is smaller (S10). if,
If the heat input h exceeds hmax, the bead is inferior to the required values in terms of yield stress, toughness, etc., so the alarm means 14 immediately sends a sound or the like to the welding worker and the work leader to inform them of the heat input. An overload warning is issued (S11). At this time, various welding data and heat input amount are erased and are not input into the storage section 20. Furthermore, the function of the remote box 32 of the welding operator is locked by a signal from the lock command unit 24 (S12), so that the welding operator does not accidentally start welding the next bead. Therefore, the welding operator deletes the bead (S13) and operates the remote box 32 to indicate that the bead has been completed, and the work leader at the key station issues a release command via the lock release command unit 25 and restarts welding. (S5).
When it is determined that the above-mentioned heat input amount is smaller than the maximum specified value hmax, the heat input amount is inputted and stored in the storage unit 20 together with various welding data (S14), and the value is displayed on the display means 13. At this time, based on the sum of the heat input of the previous bead in that joint, the average heat input per bead hmean hmemn=Σhi/i...(2) However, i is also calculated as the number of beads for which welding has been completed ( S15), it also displays how much this average heat input differs from the target heat input hobj (S16), so the welding operator can change the welding conditions by, for example, changing the current setting value on the remote box. , the subsequent heat input amount of the bead is adjusted (S17). Such operations and measurements are repeated to store various welding data and welding index values for each bead. These values are printed by the printing unit 22 at any time according to the operator's instructions, such as every time the formation of one bead is completed. When the formation of the final bead in one joint is completed (S18), the calculation unit 17 calculates a predetermined value such as the average heat input per bead in one joint and the standard deviation of the heat input in one joint from the heat input of each bead. The welding index value of is calculated (S19). These stored values are stored in the printing unit 22 in the format shown in Table 3 for each joint.
It can be launched by

[Table] In addition, in the above-mentioned welding work, when it is necessary to adjust the structural material temperature of a joint, regardless of the number of passes or beads of the joint, it is necessary to adjust the temperature of the structural material of other joints being worked on at the same time. You can also start bead welding on the remaining passes, and in that case, by inputting this into the remote box 32, the welding condition monitoring device 8 will be able to monitor various welding data and welding indicators without confusing the joints. Values can be processed. Therefore, the welding operator can weld, for example, the four joints he is responsible for sequentially or in an irregular order without having to wait, thereby suppressing wasted time and performing the work efficiently. Of course, the stored accumulated data is printed out, and the work leader can obtain various welding data for each bead and welding index values for each joint as a record card, which can be organized and stored. Therefore, once the entire welding work for the day is completed, the heat input per bead, average heat input, welding history, and other welding data can be organized and used as a reference for the next day's work. Since various welding data for each bead in the entire one welding work can be automatically obtained as a record card, a histogram of heat input amount can be automatically created from the welding data in the calculation section 17, and the welding quality can be checked. You can also do it.
As a result, the quality of the entire welding work can be controlled and quality guaranteed. Note that after the entire welding work is completed, non-destructive tests and the like are conducted as necessary to determine whether each joint welded successfully. As can be seen from the above explanation, since the welding condition monitoring device is equipped with a measuring means, a data processing means, an input/output/storage means, a display means, and an alarm means having the functions described above, welding conditions for each bead are By determining data and heat input, it is possible to monitor in real time whether welding is being performed properly. In addition, each data can be used to guide welding operations for the next day or other joints. Moreover, since these various data including the welding history can be recorded and left behind, it is possible to save them as quality assurance materials for the entire welding work. In addition, if one key station controls multiple remote boxes and sensor boxes so that one welder handles multiple joints, the temperature of the joints where the temperature rises due to welding will increase until the specified temperature is reached. It is possible to weld other joints, the operator can work continuously, and there is no longer only a one-way flow of information where various data are measured at the weld and taken into the processing section. It is possible to improve the efficiency of welding work by enabling bidirectional flow of information, such as sending welding condition instructions from the processing section to the welding section and outputting a welding machine lock signal from the lock command section. That is, in addition to simply measuring and processing the welding conditions, it is possible to perform heat input management on a weld beat basis and on a welded joint basis in order to ensure a metallurgically sound welded joint. In addition, even though the device is primarily intended for manual welding, it can also deal with cases where a temporary arc is emitted prior to welding, or where an arc start fails. In addition, it is possible to manage welding workers, show working conditions to workers, summarize and record work results, and if there is a problem with welding results, welding machines can be electrically switched off. It is possible to prevent the next operation from being performed unless the device is locked and some kind of action is taken. Therefore, when welding a joint made of special structural materials, various welding data during welding can be measured and calculated and immediately reflected in the welding work in order to maintain welding quality. Welding conditions can be instructed and managed in detail to welding workers, and if there is a problem with welding quality, the function of the welding machine can be stopped and maintained, thereby minimizing the number of man-hours for welding rework. Welding management data can be organized and output, and this data can be recorded and saved as quality assurance materials, which can be used as guidelines for future welding work and improve the efficiency of welding work.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of a welded part in a joint, Fig. 2 is a sequence block diagram of a welding condition monitoring device which is an embodiment of the present invention, Fig. 3 is an overall schematic configuration diagram of the welding condition monitoring device, and Fig. 4 is a FIG. 5, which is a flowchart of the operating procedure of the present invention, is a perspective view of a welded portion of a joint having an X-shaped groove. DESCRIPTION OF SYMBOLS 1... Joint, 3... Bead, 8... Welding condition monitoring device, 9... Welding machine, 10... Measuring means, 11
...Data processing means, 12...Input/output/storage means, 13...Display means (display body, CRT), 14...
...Alarm means, 15...Data check section, 17...
...Calculating section, 18... Judgment section, 21... Input section, 2
2...Printing section, 24...Lock command section, 25...
Lock release command unit.

Claims (1)

[Scope of Claim for Utility Model Registration] (1) In a welding monitoring device that is capable of measuring various data during welding work and determining the suitability of the welding, data during welding work that is measured by a measuring means. a data check section that determines suitability of various welding data based on predetermined limit values; and a data check section that calculates welding index values based on the welding data, and also includes welding data and welding index values for each bead in each joint as welding management data. a calculation unit that organizes and outputs the welding index value; a determination unit that determines whether the welding index value is appropriate based on a predetermined specified value; and a lock command unit that stops and maintains the function of the welding machine when the determination unit determines that the welding index value is inappropriate. and a data processing means having a lock release command unit for releasing the stop state of the welding machine, and inputting the predetermined limit value and the predetermined regulation value to the data processing means to inform the welding operator of welding conditions. an input/output/storage means having an input section for giving instructions, and a storage section for storing and outputting various welding data determined to be appropriate by the data checking section and welding index values determined to be appropriate by the determining section; a display means for notifying a welding operator and a work leader of the results and various data in the judgment unit; A welding condition monitoring device comprising: an alarm means for issuing an alarm; and a welding condition monitoring device. (2) The welding condition monitoring device according to claim (1), wherein the input/output/storage means is provided with a printing section for printing the accumulated data.