KR101542471B1 - Welding monitoring devise - Google Patents

Abstract

The present invention relates to a welding monitoring device comprising: a welding history managing part (160) to manage the history of welding factors for each welding position; an acceptance criterion generating part (170) to generate an acceptance criterion for each welding position from the history of the welding factors; a quality determining part (180) to determine a quality for each welding position depending on the acceptance criterion; and a process/production managing part (190) to conduct process management. A welding process can be managed overall with a single device by monitoring the operation of a welding system and connecting data, which have been accumulated by monitoring, to the product information of a material being welded, a welding situation for each part, a welding quality and the managed items of the welding system. Moreover, the quality of welding conducted by the welding system can be improved as the inspected items necessary for monitoring can be set by statistically analyzing data accumulated by monitoring.

Description

{WELDING MONITORING DEVISE}

The present invention monitors the operation of the welding system and monitors the accumulated data in accordance with the product information of the welded material, the welding condition of each part, the welding quality, and the welding system management item, In addition, the present invention relates to a welding monitoring apparatus capable of statistically analyzing data accumulated and monitored to set inspection items necessary for monitoring, thereby improving the welding quality of the welding system.

The welding system controls the behavior of the robot, moves the electrode of the welding gun to the welding position of the welding material, controls the welding gun, and energizes the welding current for a predetermined time while pressing the welding position with the electrode.

However, even if the welding system is initially set correctly, the precision of the welding point is deteriorated due to factors such as the motion error of the robot, the design error of the welding material, the position error on the assembly line of the welding material, and the alignment error of the electrode.

In addition, the welding operation of the welding gun depends on the welding conditions such as the welding current, the welding voltage, the welding resistance, the welding time, the pressing force, the electrode temperature, etc. Even if the welding conditions are set correctly at the initial stage, The reliability of the welding quality may not always meet the acceptance criteria due to factors such as the specification error of the welded material and the difference in material by welding position.

In order to solve the problem of the accuracy of the welding position and the problem of the reliability of the welding quality of the welding position, Japanese Patent Laid-Open Nos. 10-2013-0138574, 10-1219473 and 10-1275097, The welding conditions for the welded joints were received from the welding system and weld defects were detected. According to the above conventional techniques, the welding current and the welding voltage are compared with the reference waveform data, and the fitting / non-matching of the welding quality is determined through comparison of appearance positions of main points related to the welding quality.

However, when the welding quality is discriminated by comparing the sizes of the extracted data as in the above-described conventional techniques, due to factors such as electrode abrasion, specification error of the welded material, and material difference depending on the welding position, The data values of the welding parameters may be different, and the time point at which the main points appear may also fluctuate severely, resulting in errors in quality inspection.

KR 10-2013-0138574A 2013.12.19. KR 10-1219473 B1 201.01.02. KR 10-1275097 B1 2013.06.10.

Accordingly, it is an object of the present invention to provide a welding monitoring apparatus capable of improving the accuracy and reliability of a welding quality inspection even in a situation where the state of the welding material or the state of the welding system is variable.

According to another aspect of the present invention, there is provided a welding monitoring apparatus comprising: a user interface unit for inputting user information and outputting information; An alarm unit 130 for issuing a user-recognizable alarm; A storage unit 140 for storing data; A signal input / output unit 150 installed in a welding gun for receiving welding waveform data from a sensor 22 for detecting a welding parameter and receiving a welding position from a robot controller for controlling the robot equipped with the welding gun; A welding history management unit 160 for receiving the welding parameter waveform data for each welding position divided by the welding position received from the robot controller from the sensor 22 and storing the received welding parameter waveform data in the storage unit 140; A passing criterion generating unit 170 for generating and storing a reference waveform type that is a welding condition acceptance criterion for a waveform type after the melting point in the welding factor waveform data; A quality judging unit 180 for comparing the melting point of the welding waveform data received from the sensor 22 with the melting point of the reference waveform type, comparing the waveform type after the melting point with the reference waveform type, and alarming the alarm unit 130 at the rejection judgment time ); The quality determination unit 180 generates a reference waveform type from the welding factor waveform data selected by the user interface unit 120 to the acceptance criterion generation unit 170. Thereafter, A control unit 110 for controlling to determine whether or not the vehicle is traveling on a road; And a control unit.

The melting point is characterized by being able to be replaced by an? Peak which is represented by the lowest resistance value due to an increase in the contact surface area between the welded material and a rise in the temperature of the contact surface due to the current flow.

The acceptance criterion generating unit 170 generates a reference waveform type based on the welding position, and the quality determining unit 180 compares the reference waveform with the reference waveform type corresponding to the welding position received from the robot controller. do.

The welding history management unit 160 receives the waveform data from the sensor 22 using the welding voltage and the welding current as welding factors, acquires the welding factor waveform data for the welding resistance based on the received waveform data, The welding current, and the welding resistance, and the controller 110 controls the welding waveform data of the welding parameter selected by the user interface unit 120 as the reference waveform type Is generated by the acceptance criterion generator (170), and the quality determining unit (180) is operated to determine acceptance based on the reference waveform type for the selected welding factor.

The acceptance criterion generating unit 170 generates the acceptance criterion generating unit 170 based on the average reference waveform type obtained by averaging the waveforms after the melting point in the state where the melting point of the plurality of welding factor waveforms is matched with each other, Of the average reference waveform type, the representative reference waveform type, and the range designation reference waveform type within the range of the user specification waveform type data within the range The quality determining unit 180 determines that the reference waveform is generated by the acceptance criterion generating unit 170 as being selected by the interface unit 120. The quality determining unit 180 determines whether the reference waveform generated by the quality determining unit 180 is an average reference waveform or a representative reference waveform, If it is out of the error range, it is judged as failure and if the generated reference waveform type is the range specifying reference waveform type If the out of range, characterized in that the rejected.

The welding history management unit 160 receives the electrode temperature waveform data from the sensor 22 and stores the electrode temperature waveform data corresponding to the welding position. The quality determination unit 180 decodes the electrode temperature waveform data received from the sensor 22 When the rising trend of the electrode temperature is less than a predetermined trend line, it is determined that the welding is performed in a state in which there is no welded ashtray or welded out of the welding position and welded to the air hole.

The welding history managing unit 160 receives the pressing force waveform data and the electrode temperature waveform data from the sensor 22, extracts the welding time from the waveform data, And the acceptance criterion generating unit 170 is configured to acquire and store pressurized force waveform data, electrode temperature waveform data, and reference data for the welding time for each welding position, and the control unit 110 controls the pressing force waveform And the quality determining unit 180 is operated to determine that the welding data is not acceptable when the welding temperature, the electrode temperature waveform data, and the welding time selected by the user interface unit 120 during the welding time exceed the predetermined error range with the reference data. do.

The quality determining unit 180 sets the predetermined error range to two levels according to the magnitude of the error and sets the range of the range specifying reference waveform type to two levels according to the error magnitude from the average. A preliminary alarm is given to the alarm unit 120 when the error is out of a relatively small range and the error is within a relatively large range, and the alarm is displayed when the error is out of a relatively large range.

The storage unit 140 stores information on items to be checked for the welding operation by the robot and the welding gun and information about check sheets related to the execution of the check items. The signal input / And the welding monitoring apparatus is connected to the welding controller for controlling the operation of the robot controller and the welding controller, and when the check sheet creating mode is selected through the user interface unit 120, the commands corresponding to the respective check items included in the check sheet are sequentially The check result is generated by inserting the weld factor waveform data received from the sensor 22 into the check sheet at the time of performing the check item and transmitting the generated check result report to the controller And a process / production management unit (190) that enables the user to inquire the user on the user inquiry screen do.

The signal input / output unit 150 is connected to the tip dresser 30 so as to be capable of data transmission. The storage unit 140 stores product information and images on the welded material, welding position information on the welded material, And the dressing period and the dressing period are stored. The quality judging unit 180 displays a mark on the welding re-image to distinguish the pass and fail of the welding quality with respect to the welding position to be received from the robot controller, The process / production management unit 190 outputs the product information of the welded material to be welded to the user interface unit 120 in real time. The process / production management unit 190 alerts the alarm unit when the electrode tip replacement cycle comes, And transmits a command for dressing to the robot controller and the tip dresser when the dressing cycle comes, and the welding history for the workpiece The quality control information including the welding current, welding voltage, welding resistance, welding time, welding temperature, pressing force, the pass / fail judgment result regarding characterized in that it can be viewed with the user interface 120.

The present invention having the above-described structure is characterized in that, even if the data of welding parameters fluctuate with respect to the same rubbing point, the waveform after the melting point, which reflects the welding quality, The quality of the welding can be judged by the type, so that the accuracy and reliability of the quality inspection can be improved.

In addition, since the reference waveform type used for determination of the welding quality can be easily obtained from the DB-converted data in the previous quenching process, the present invention can be easily optimized in accordance with the change of the welding environment.

Further, since the present invention generates and uses the reference waveform type by welding position, it can further improve the accuracy and reliability of quality inspection, can be used for overall management of the welding system, It is also possible to detect the occurrence of air gap welding and to manage the welding system.

1 is a waveform graph of a welding resistance.
FIG. 2 is an installation view of a welding monitoring apparatus according to an embodiment of the present invention; FIG.
3 is a configuration diagram of a welding monitoring apparatus according to an embodiment of the present invention;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In the following description of the present invention, detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear.

First, terms are defined with reference to the waveform graph of the welding resistance shown in Fig.

Referring to FIG. 1, the contact resistance between the welded materials to be welded in a welding process in which the welded material is pressurized with an electrode is divided into I, II, III, IV and V sections.

In section I, as the welding starts, the contaminants on the contact surface between the welds collapse and the resistance decreases sharply.

In section II, as the irregularities of the contact surface disappear, the area of the contact surface through which the current flows increases, and the resistance decreases. At the same time, the resistivity increases due to the temperature rise of the contact surface. As a result, the resistance decrease factor and the resistance increase factor coexist, resulting in an? Peak.

In section III, the copper resistance continues to increase with temperature rise, and partly causes melting at the contact surface.

In the IV section, melting starts in earnest at the contact surface, the resistance increases due to the temperature rise, and the increase in the nugget increases the cross-sectional area of the current flow, thereby causing a resistance reduction factor. As a result, a? Peak occurs in this section.

In the V section, the melting nugget continues to grow and the thickness is reduced by plastic deformation of the welded material, thereby remarkably reducing the resistance.

The following terms are defined based on the graph of the contact resistance between the welded materials as described above.

α peak is defined as the factor of increase of contact surface area between welded materials and the minimum resistance value which is caused by temperature rise of contact surface due to current flow.

The β peak is defined as the highest resistance value that occurs in the process of increasing the nugget.

Since the melting point starts to substantially melt between the alpha peak and the beta peak, the melting point can be set to a point determined by a predetermined rule (for example, an intermediate point) according to the detection position of the alpha peak and the beta peak.

Further, according to the embodiment of the present invention, it is assumed that the melting point can be used in place of the? Peak. That is, since the temperature of the contact surface rises according to the flow of electric current and is then melted and welded, an alpha peak reflecting the melting point substantially in the graph is used instead of the melting point. In the embodiment of the present invention, The melting point to be detected can be replaced with an alpha peak.

On the other hand, since the position corresponding to the melting point, alpha peak and beta peak can be detected on the graph of the welding voltage, the welding current or the heat input amount, it can be detected from the welding parameters belonging to the welding condition at the time of welding.

Hereinafter, a welding monitoring apparatus according to an embodiment of the present invention will be described.

2 is an installation view of a welding monitoring apparatus 100 according to an embodiment of the present invention.

2, the welding monitoring apparatus 100 includes a robot controller 11 for controlling the operation of the robot 10 equipped with the welding gun 20 to move and weld the welding gun 20 to the welding position, A welding controller 21 for supplying a welding current to the welding gun 20 and circulating the cooling water to lower the electrode temperature, a sensor 22 installed on the welding gun 20 for detecting a welding factor, And is connected to the integrated management server 200 via the network 300. The integrated management server 200 is also connected to the integrated management server 200 via the network 300. [

The welding monitoring apparatus 100 installed in this manner monitors the state of the welding by the operation of the robot 10 and the welding operation of the welding gun 20, and manages the welding process and the welding quality, In addition, the robot 10, the robot controller 11, the welding gun 20, the welding controller 21, the sensor 22, and the tip dresser (not shown) 30) to be monitored and managed as a whole.

Here, the robot 10, the robot controller 11, the welding gun 20, the welding controller 21, the sensor 22 and the tip dresser 30 are well known in the technical field of the present invention, The sensor 22 for detecting the welding parameters will be briefly described. In the following description of the present invention, only the parts required when it is judged necessary for the understanding of the present invention will be described .

In the embodiment of the present invention, the sensor 22 is installed in the welding gun 20 to detect the welding voltage, the welding current, the pressing force and the electrode temperature, respectively.

Illustratively, a sensor for detecting the welding voltage is connected to two electrodes of the welding gun 20 to detect a voltage between the electrodes, and a sensor for detecting the welding current is connected to two electrodes (For example, Rogowski coil) is installed in any one of the electrodes (usually called the lower electrode) to detect the current flowing between the electrodes, and a sensor for detecting the pressing force is generally used for the welding gun pressurization A pressure sensor is installed to measure the supplied air pressure, and a sensor for detecting the electrode temperature detects the electrode temperature by providing a thermocouple (or RTD temperature sensor) on the electrode.

The present invention receives data of the welding parameters from the sensor 22 installed on the welding gun 20 in this way.

3 is a configuration diagram of a welding monitoring apparatus according to an embodiment of the present invention.

The welding monitoring apparatus according to an embodiment of the present invention includes a user interface unit 120 provided for user operation input and screen output of various information; An alarm unit 130 provided for the user to issue a recognizable alarm; A storage unit 140 provided to store various data or information necessary for performing the function of the welding monitoring apparatus; A signal input / output unit 150 which is electrically or signal-connected to exchange or transmit data or information with the robot controller 11, the welding controller 21, the sensor 22 and the tip dresser 30; A welding history management unit 160 for managing data or information to be transmitted when welding is performed; A passing criterion generating unit 170 for generating a passing criterion for welding; A quality judging unit (180) for judging the welding quality according to acceptance criteria; A process / production management unit 190 for managing a welding process comprising a welding system and managing products manufactured by welding; A communication module (191) connected to the network for communicating with the integrated management server (200); And a control unit (110) for controlling the overall operation of the welding monitoring apparatus.

Since the user interface unit 120 is installed on a production process line where welding is performed, it is preferable to configure the user interface unit 120 as a touch screen capable of input and output for user's convenience.

The alarm unit 130 is satisfied, for example, if it has an acoustic or visually alarming configuration. Here, the alarm may be generated at the same time when the alarm notification screen is output to the user interface unit 120.

The storage unit 140 stores various information generated by the operations of the welding history management unit 160, the acceptance criterion generation unit 170, the quality control unit 180, and the process / production management unit 190, And the like.

Particularly, according to the embodiment of the present invention, the welding operation of the robot 10 and the welding gun 20 controlled by the robot controller 11 and the welding controller 21 is checked in the storage unit 140 And the check sheet regarding the command for execution of the check item are stored for execution of a check mode to be described later, and the welding position of the product information / image and the welded material to the welded material is monitored Mode, and the replacement period and the dressing period of the electrode tip are stored for the management of the electrode tip.

The signal input / output unit 150 may be connected to a sensor 22 installed on the welding gun 20 and detecting a welding factor, and may receive waveform data on the welding parameters. Since the welding parameters obtainable by the sensor 22 in the embodiment of the present invention include the welding voltage, the welding current, the pressing force, and the electrode temperature, sensors for detecting data on the welding parameters are installed in the welding gun 20 .

The signal input / output unit 150 is connected to the robot controller 11 for controlling the robot 10 on which the welding gun 21 is mounted, and receives the welding position and interrupts the operation of the robot 10 It is possible to transmit a signal including a lock signal and a command for operation control. Of course, receiving the welding position means receiving the welding start and end points for each welding position including the welding start and end points.

The signal input and output unit 150 is also connected to a welding controller 21 for controlling the welding operation of the welding gun 20 so that a signal for controlling the welding operation of the welding gun 20 is supplied to the welding controller 21 It can also be delivered.

The signal input / output unit 150 may be connected to the tip dresser 30, and may transmit a command to the tip dresser 30 to polish the electrode tip. Here, the electrode tip is constructed such that an end of the electrode of the welding gun 20, which is in contact with the welded material, is replaceable.

The welding history management unit 160 receives the welding pressure waveform data for each welding position from the sensor 22 and stores the welding pressure waveform data in the storage unit 140. The welding history management unit 160 stores welding waveform data corresponding to the welding position received from the robot controller 11, .

Since the waveform data of the welding voltage, the welding current, the pressing force, and the electrode temperature are received from the sensor 22 in the welding parameters, the waveform data of the welding resistance and the heat input included in the welding parameters are acquired from the welding voltage and the welding current And stores it. The welding time, one of the welding parameters, is obtained from the waveform data of the welding current and stored corresponding to the welding position.

The acceptance criterion generating unit 170 generates a acceptance criterion for the welding condition for the waveform type after the melting point in the weld factor waveform data and stores the acceptance criterion in the storage unit 140, 180).

Here, the acceptance criterion is not set to the size of the date value of the welding parameters but consists of the type of the welding factor waveform that appears after the point of time at which the weld surface of the welded material melts, which is referred to as a reference waveform type in the present invention.

These reference waveform types are generated and stored for each welding position so as to be classified according to the welding position. That is, it is generated and stored for each of the different RBs set in the robot controller.

The reference waveform type can generate the reference waveform type for the welding resistance by using the welding resistance illustrated in FIG. 1 as the welding factor. However, it is preferable that the welding parameter selected by the user among the welding resistance, the welding voltage, The acceptance criterion generating unit 170 is configured to generate the acceptance criterion generating unit 170. [

In addition, the reference waveform type includes a reference waveform type that averages waveforms after melting point in a state where a plurality of welding factor waveforms are matched with each other, a representative reference waveform type that is closest to the average, The user selects the range designation reference waveform type designated by the range consisting of the welding factor waveform data.

In addition, the acceptance criterion generating unit 170 acquires the pressing force waveform data, the electrode temperature waveform data, and the reference data for the welding time for each welding position separately from the welding resistance, the welding voltage, the welding current, (140).

Here, the reference data for the pressing force, the electrode temperature, and the welding time are different from the above-mentioned reference waveform type and include the pre-melting point data and reflect the magnitude of the value. The average reference data of the welding factor, And range designation reference data that is specified in a range consisting of welding factor waveform data whose error with the average is within a predetermined range.

The quality determination unit 180 determines the acceptance and rejection of the welding condition for the welding parameters selected by the user during the welding parameters.

In the case where the selected welding parameter is the welding resistance, the welding voltage, the welding current or the heat input amount, the welding pressure waveform data transmitted from the welding controller 21 is used to adjust the melting point to the melting point of the reference waveform type, To determine whether it is a pass or fail. The comparison determination with the reference waveform type is a comparison determination with the reference waveform type corresponding to the welding position transmitted from the robot controller 11. [

The determination is made according to the format of the reference waveform type as follows.

If the reference waveform type generated and stored by the acceptance criterion generating unit 170 is an average reference waveform type or a representative reference waveform type, then if the waveform after the melting point is out of a predetermined error range in the state where the melting point is adjusted, If it is within the predetermined error range, it is determined to be acceptable.

If the reference waveform type generated and stored by the acceptance criterion generating unit 170 is the range specifying reference waveform type, the waveform after the melting point is the waveform of the range specifying reference waveform type in a state where the melting point position is matched with the average waveform of the range specifying reference waveform type. If it is out of the range, it is judged as rejection, and if it is within the range, it is judged as acceptable.

At this time, the predetermined error range is set to two stages according to the magnitude of the error, and the range of the range designation reference waveform type is also set to two stages according to the error magnitude from the average, A preliminary alarm is given to the alarm unit 120 when the error is within a relatively small range and the error is within a relatively large range, and the alarm can be made when the error is out of a relatively large range.

If the selected welding parameter includes any one of the pressing force, the electrode temperature, and the welding time, the waveform data relating to the welding parameter is compared with the reference data of the corresponding welding parameter, and when the selected welding parameter is out of a predetermined error range, (130). If it is within the predetermined error range, the decision is accepted.

The quality determination unit 180 decodes the electrode temperature waveform data received from the sensor 22 and alerts the alarm unit 130 when the rising trend is less than a predetermined trend line in the rising period of the electrode temperature. Here, the predetermined trend line is selected to be higher than the electrode temperature curve of the welding gun when the welding operation is performed in a state where there is no welding material, or when the welding point is out of the welding spot and welded to the air. Accordingly, when the welding is performed in the air, the temperature does not rise, or even when the temperature rises, the rising speed is low.

In addition, the quality determining unit 180 may display a screen displaying a mark indicating a welding position transmitted from the robot controller 11 on the welding re-image, and a screen showing product information on the welding material to be welded at present, And outputs it to the user interface unit 120 in real time. Here, the marking makes it possible to distinguish between acceptance and rejection based on the determination result of the welding quality. For example, if they pass, they are marked with a blue marker, and if they are rejected, they are marked with a red marker.

The process / production management unit 190 manages the electrode tips of the welding guns and the welding quality judgment result management.

The electrode tip management of the welding gun includes an alarm to the alarm unit 130 to allow the welding system administrator to replace the electrode tip when the replacement period of the electrode tip arrives during the processing of the welding process with the welding system. Here, when the welding system is configured so that the electrode tip can be replaced by the robot 10, a command to replace the electrode tip is transmitted to the robot controller 11. [

In addition, the electrode tip management of the welding gun includes an operation of transmitting a command for dressing to the robot controller 11 and the tip dresser 30 when the dressing period of the electrode tip arrives. That is, the robot controller 11 causes the welding gun to move to the tip dresser 30 according to the instruction, and then the electrode tip of the welding gun is polished by the tip dresser 30.

The welding quality determination result management unit combines and stores the pass / fail determination results determined by the quality determination unit 180 in the welding hysteresis for each welding position of the workpiece stored by the welding history management unit 160, The quality management information on the welding is converted into a DB, and the quality control information can be inquired by the user interface 120. [

Meanwhile, since the welding monitoring apparatus 100 according to the present invention is installed for each unit welding system, the communication module 191 can connect the plurality of welding monitoring apparatuses 100 at the production site through the internal network, , And connects to the Internet via the internal network. The communication module 191 communicates with the integrated management server 200 connected via the internal network or the Internet, and receives the quality management information from the integrated management server 200 to remotely manage the quality management information.

The control unit 110 provides the setup mode, the monitoring mode, the check mode, and the inquiry mode on the screen through the user interface unit 120 to control the operation of the welding monitoring apparatus according to a mode selected by the welding system manager.

In the setting mode, a welding parameter to be used for quality determination is selected, a reference waveform type or a format of reference data is selected, and a screen for selecting welding waveform waveform data used for generating a reference waveform type or reference data is displayed on a user interface (120) to select the setting items necessary for the operation of the welding monitoring apparatus, and generates the acceptance criterion by operating the acceptance criterion generating unit (170) according to the selected setting items.

The welding parameters used for quality determination are selected from at least one of welding resistance, welding voltage, welding current and heat input, and it is also possible to select two or more. Further, at least one of the pressing force, the electrode temperature, and the welding time, which are welding factors, can be further selected.

The format of the reference waveform type is a type of reference waveform type for comparing the welding resistance, the welding voltage, the welding current or the heat input to the waveform data with the welding factor for the determination of the welding quality. The average reference waveform type, Type and Scope Reference Waveforms are selected from any of the types.

The format of the reference data is a format of reference data for comparing the welding time, the pressing force, or the electrode temperature with the waveform data obtained by using the welding parameters for the determination of the welding quality. The reference data is any one of the average reference data, representative reference data, One is selected.

The weld waveform waveform data used to generate the reference waveform type or reference data is selected by the user from among data obtained by inputting data previously obtained in the welding process or operating in the monitoring mode. In the selection method, a list of the welding factor waveform data may be outputted on the screen for each welding position, and a method of taking the data checked by the user in the list may be adopted.

The acceptance criterion generating unit 170 generates a acceptance criterion according to the selection of the user interface unit 120. Of course, acceptance criteria are generated for each weld location.

The reference waveform type, which is one of the acceptance criteria, statistically analyzes the waveform data corresponding to the welding factor selected in the setting mode among the waveform data selected in the setting mode, and calculates the average reference waveform type, the representative reference waveform type, . ≪ / RTI > Here, since the welding parameters are selected from the welding resistance, the welding voltage, the welding current, and the heat input amount, a reference waveform type is generated for each welding factor when there are a plurality of selected welding parameters.

The reference data, which is one of the acceptance criteria, is generated when any of the welding factors of welding time, pressing force and electrode temperature is selected. At this time, too, it is generated in accordance with the waveform data selected in the setting mode, the welding factor, and the reference data format.

The acceptance criterion generated for each welding position is stored in the storage unit 140 as described above.

In the monitoring mode, the welding history management unit 160, the quality determination unit 180, and the process / production management unit 190 are operated.

Specifically, the welding history management unit 160 receives the welding voltage, the welding current, the electrode temperature, and the pressing force waveform data from the sensor 22 through the signal input / output unit 150 in real time, Generates the waveform data for the heat input amount, generates the welding time, and stores the received data and the acquired data in the storage unit 140 in correspondence with the welding position received from the robot controller 11.

At the same time, the quality determining unit 180 receives data corresponding to the welding parameters selected in the setting mode among the data received or generated in real time by the welding history management unit 160, and determines the welding quality for each welding position. When determining the welding quality, the quality is determined for each welding factor when a plurality of welding factors selected in the setting mode are determined. When the quality of any one welding factor is determined to be unacceptable, Alarm.

Also, even if the electrode temperature is not selected as the welding factor for the quality determination in the setting mode, the quality determination unit 180 receives the electrode temperature waveform data from the welding history management unit 160 and extracts the rising temperature of the electrode temperature If the temperature rising trend line in the extracted section is below the predetermined trend line in graphical representation, it is judged that the temperature rising tendency line is welded to the air and alarm is given to the alarm unit 130.

The quality determining unit 180 outputs a screen showing the product information of the welded material and the product information about the welded material to the user interface unit 120 in real time and transmits the image to the robot controller 11 And outputs a mark at a position on the welded object corresponding to the received welding position. At this time, the mark indicates the determination result of the welding quality. When a failure is determined with respect to the welding quality, a screen is displayed on the screen output to the user interface unit 120 to notify which weld defect has occurred with respect to which welding factor, It is preferable to know whether or not it has occurred.

At the same time, the process / production management unit 190 stores the quality determination result of the quality determination unit 180 corresponding to the welding history stored by the welding history management unit 160, The information is converted into a DB, and an alarm is sent to the alarm unit or an electrode tip is changed to the robot controller 11 when the replacement period of the electrode tip or the electrode tip arrives, and a command for dressing when the dressing cycle comes To the robot controller (11) and the tip dresser (30).

In the check mode, an operation mode in which a check result report is generated by the operation of the process / production management unit 190 and the quality management unit 180 is generated.

In the check sheet stored in advance in the storage unit 140, an item to be checked for the welding operation is written and a command for execution of the check item is stored correspondingly. In the check mode, the check sheet is transferred to the user interface unit 120 ), The welding system manager sends a command corresponding to the selected check item to the robot controller 11 or the welding controller 21 every time the welding system manager selects the check item sequentially, so that the check item is performed according to the command, The quality control unit 180 determines the quality of the weld factor waveform transmitted from the sensor 22 and substitutes the weld factor waveform data and the quality determination result into the check sheet to generate a check result report. At this time, the check result report is created only when all check items are selected and stored in the storage unit.

The check result report is prepared periodically for the management of the actual welding process. In the present invention, the welding monitoring apparatus 100 is used to make a report without omission, and even if the welding system is not operated according to the check item, Can be easily performed by selection by a touch so that a check result can be obtained.

On the other hand, if the quality determination result of the quality control unit 180 is found to be rejected during the generation of the check result report, the welding system manager alerts the welding system manager to adjust the setting value of the welding system.

In the query mode, the process / production management unit 190 outputs a screen for querying the quality management information and the check result report DB, to the user interface unit 120 so that the welding system administrator can inquire.

As described above, the welding monitoring apparatus according to the present invention is configured to select welding conditions suitable for the welding material and the welding position in the welding conditions by the setting mode, and to select the determination method of various welding qualities as the appropriate determination method Thus, it is possible to optimize the setting for improving the reliability and accuracy of the welding quality judgment, and in addition to the monitoring mode, the welding mode can be also managed by setting the check mode and the inquiry mode as operation modes.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, . ≪ / RTI > Accordingly, such modifications are deemed to be within the scope of the present invention, and the scope of the present invention should be determined by the following claims.

10: welding robot 11: robot controller
20: welding gun 21: welding controller
30: The tip dresser
100: Welding monitoring device
110: control unit 120: user interface unit
130: alarm unit 140:
150: signal input / output unit 160: welding history management unit
170: Pass criterion generating unit 180: Quality judging unit
190: Process / production management section 191: Communication module
200: Integrated management server

Claims (10)

A user interface unit 120 for user operation input and information output;
An alarm unit 130 for issuing a user-recognizable alarm;
A storage unit 140 for storing data;
A signal input / output unit 150 installed in a welding gun for receiving welding waveform data from a sensor 22 for detecting a welding parameter and receiving a welding position from a robot controller for controlling the robot equipped with the welding gun;
A welding history management unit 160 for receiving the welding parameter waveform data for each welding position divided by the welding position received from the robot controller from the sensor 22 and storing the received welding parameter waveform data in the storage unit 140;
A passing criterion generating unit 170 for generating and storing a reference waveform type that is a welding condition acceptance criterion for a waveform type after the melting point in the welding factor waveform data;
A quality judging unit 180 for comparing the melting point of the welding waveform data received from the sensor 22 with the melting point of the reference waveform type, comparing the waveform type after the melting point with the reference waveform type, and alarming the alarm unit 130 at the rejection judgment time );
The quality determination unit 180 generates a reference waveform type from the welding factor waveform data selected by the user interface unit 120 to the acceptance criterion generation unit 170. Thereafter, A control unit 110 for controlling to determine whether or not the vehicle is traveling on a road;
Wherein the welding monitoring device comprises: The method according to claim 1,
Wherein the melting point can be replaced by an alpha peak which is represented by the lowest resistance value due to an increase in the contact surface area between the welded material and a rise in the temperature of the contact surface due to the current flow. 3. The method of claim 2,
The acceptance criterion generating unit 170 generates a reference waveform type by dividing the welding position by welding position,
Wherein the quality determination unit (180) compares the reference waveform type corresponding to the welding position transmitted from the robot controller. The method of claim 3,
The welding history management unit 160 receives the waveform data from the sensor 22 using the welding voltage and the welding current as welding factors, acquires the welding factor waveform data for the welding resistance based on the received waveform data, , The welding current, and the welding resistance as welding factors,
The control unit 110 causes the acceptance criterion generating unit 170 to generate a reference waveform type for the waveform data of the welding parameters selected by the user interface unit 120 from the welding factor waveform data, And operates the quality judging unit (180) to judge acceptance or not based on the reference waveform type. 5. The method of claim 4,
The acceptance criterion generating unit 170 generates the acceptance criterion generating unit 170 based on the average reference waveform type obtained by averaging the waveforms after the melting point in the state where the melting point of the plurality of welding factor waveforms is matched with each other, A range designation reference waveform type designating unit that designates a range designation reference waveform type within a range made up of welding factor waveform data within a range,
The control unit 110 causes the acceptance criterion generator 170 to generate the average reference waveform type, the representative reference waveform type, and the range designation reference waveform type selected by the user interface unit 120,
If the generated reference waveform type is the average reference waveform type or the representative reference waveform type, the quality determination unit 180 determines that the generated reference waveform type is a range designation reference waveform type And if it is out of the range, a rejection is determined. The method according to any one of claims 1 to 5,
The welding history management unit 160 receives the electrode temperature waveform data from the sensor 22 and stores the electrode temperature waveform data corresponding to the welding position,
The quality judging unit 180 decodes the electrode temperature waveform data received from the sensor 22, and when the rising trend of the electrode temperature is less than a preset trend line, And the alarm is alarmed. The method according to any one of claims 1 to 5,
The welding parameters include the pressing force, the electrode temperature, and the welding time,
The welding history management unit 160 receives the pressing force waveform data and the electrode temperature waveform data from the sensor 22, extracts the welding time from the waveform data, stores the welding time corresponding to the welding position,
The acceptance criterion generating unit 170 is configured to acquire and store pressurized force waveform data, electrode temperature waveform data, and reference data for a welding time for each welding position,
The controller 110 controls the quality determiner (not shown) so as to determine a rejection of the welding force parameter, the electrode temperature waveform data, and the welding parameters selected by the user interface unit 120 during the welding time, 180). ≪ / RTI > The method according to any one of claims 1 to 5,
The quality determining unit 180 sets the predetermined error range to two stages according to the magnitude of the error and also sets the range of the range specifying reference waveform type to two stages according to the error magnitude from the average,
A preliminary alarm is given to the alarm unit 120 when the error is out of a relatively small range and the error is within a relatively large range, and when the error is out of a relatively large range, Welding monitoring device. The method according to any one of claims 1 to 5,
The storage unit 140 stores items to be checked for the welding operation by the robots and the welding gun, and information about check sheets related to the execution of the check items,
The signal input / output unit 150 is connected to a welding controller for controlling the welding operation of the welding gun,
The welding monitoring device
When the check sheet creation mode is selected through the user interface unit 120, commands corresponding to the respective check items included in the check sheet are sequentially transmitted to the robot controller and the welding controller to perform check items, Generating a check result report by assigning the weld factor waveform data received from the sensor 22 to the check sheet at the time of performing the process, and storing the generated check result report in the storage unit to display the user check screen, And a production management unit (190). 10. The method of claim 9,
The signal input / output unit 150 is connected to the tip dresser 30 to enable data transmission,
The storage unit 140 stores product information and images of the welded material, welding position information on the welded material, electrode tip replacement cycle, and dressing cycle,
The quality judging unit 180 judges whether or not the product information on the welded material to be welded at present is displayed on the screen on which the marking for distinguishing the welding quality from the weld quality received from the robot controller on the welding re- Real-time screen output to the user interface unit 120,
The process / production management unit 190
A command for alarming or replacing the electrode tip is transmitted to the robot controller when a replacement cycle of the electrode tip arrives and a command for dressing is transmitted to the robot controller and the tip dresser when the dressing cycle comes, The quality control information including the welding current, the welding voltage, the welding resistance, the welding time, the welding temperature, the pressing force, and the pass / fail determination result regarding the welding history with respect to the welding object can be inquired by the user interface 120 Welding monitoring device.

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