KR101558154B1 - Management System and method for Digital welding machine - Google Patents

Abstract

According to the present invention, the structural arrangement and the planning of the steel sheet in the design process are determined according to the welding design, and the welding posture and conditions determined according to the block method of operation in the production process determine the productivity of the entire shipbreaking process. Efficient management of welding information affects the competitiveness of the entire shipyard, but since data is often lost in the absence of a management system to manage it properly and costs and time are spent again to obtain information like the past, And more particularly, to a digital welding machine control and welding pattern management system that collects, manages,

Description

Technical Field [0001] The present invention relates to a digital welding machine,

The present invention relates to a digital welding machine control and welding pattern management system and method, and in particular, a structural arrangement and a plan of a steel sheet in a design process are determined according to a welding design, and in a production process, Since the conditions affect the productivity of the entire shipbuilding process, efficient management of the welding information in the shipbuilding will affect the competitiveness of the entire shipyard. However, data can be stored in a management system to be managed properly, And more particularly, to a digital welding machine control and welding pattern management system and method for collecting, managing, and using data generated during welding.

In general, arc welding has been widely used as a major welding method in industrial fields since it has superior characteristics in terms of efficiency improvement, quality safety, and cost reduction as compared with electric welding. In performing such arc welding, It is necessary to set up the arc welding machine according to the working conditions, including the basic matters, review of the welding process, and whether there is improvement or not.

The welding current and the arc voltage are important factors for determining the arc welding. The arc welding is a method of adjusting the current and voltage separately (individual adjustment). When the current is adjusted, the voltage is automatically set. (One-way adjustment), so that it is possible to select and operate the current and voltage as needed.

Welding current is an important factor in determining the rate of penetration and deposition, and the arc voltage is an important factor in controlling the bead shape and transition mode. However, since there is a mutual relationship between the two, proper results can not be obtained even if only one of them is proper, and if the conditions are not met, it is a cause of poor penetration, excessive melting, and spatter.

The welding speed is also an important factor together with the current and the voltage. As the welding speed increases, the penetration becomes shallow and the bead width decreases and becomes a block type bead having a narrow width. When the welding speed becomes very slow, Penetration is reduced and causes overlap.

Since a conventional welding machine has only a structure for generating an arc, it performs an output according to only a current value and a voltage value set by an operator, and is affected by various factors, Information on the size of the welding parameters such as current, arc voltage, welding time, and equipment utilization can not be known.

Accordingly, it is necessary to confirm and review the necessary information for efficiently performing arc welding, such as setting the current and voltage appropriately in order to form the welding leg length in the designated shape, the performance and the utilization rate of the welding machine, And it is difficult to accurately perform welding work by improving and setting in consideration of the state and characteristics of the welded portion.

In order to solve such a problem, the present invention determines a structural arrangement and a plan of a steel sheet in a design process according to a welding design, and in a production process, a welding posture and conditions determined according to a block- The efficient management of the welding information in the shipyard affects the competitiveness of the entire shipyard. However, the data can not be managed properly due to the absence of the management system and the cost and time are consumed again to obtain the information as in the past. So that it is possible to collect and manage data generated at the time of welding, and to utilize it when necessary.

A welder body having identification information according to an embodiment of the present invention and transmitting and receiving signals with a plurality of feeders and a plurality of feeders in accordance with identification information to provide operation state information, , connected to the welding machine main body, and is interconnected through the CO ₂ gas supply device and the welding machine main unit and a wireless communication network for supplying CO ₂ gas to the welding machine, and storing the digital welder control information provided from the welding machine unit to the radio signal, And a welding management server that provides the stored welding pattern information to the welder body.

As an example related to the present invention, the feeder includes a voltage value or current value input unit for inputting a voltage value or a current value numerically, a crater selection switch for selecting whether craters are used or not, And may include a control unit for adjusting the primary voltage or the primary current, the secondary voltage, or the secondary current using the voltage value or the current value.

As an example related to the present invention, the welder main body includes digital / analog converters for converting digital voltage signals and current signals into analog voltage values and current values and outputting them to a feeder, and digital-to-analog converters Off control signal, a gas check on / off control signal, a crater on open control signal, a solenoid valve control signal, and a torching on / off control signal in response to the on / off control signal of the control unit in response to the welding process information A gas check portion, a crater portion, and a solenoid valve.

As an example related to the present invention, the driving unit may be a photocoupler.

As an example related to the present invention, the welding machine main body may further include a wireless communication unit for transmitting and receiving welding process information through a wireless communication method with the welding management server.

As an example related to the present invention, the welder main body can transmit at least one or more of voltage value, current value, CO ₂ gas usage amount, and wire usage amount information to the welding management server.

According to one aspect of the present invention, there is provided a feeder comprising: a voltage input unit capable of setting a voltage value; a current input unit capable of setting a current value; and a control unit operable stably in response to a torching on / off control signal of the welding unit main body, And a controller for controlling the voltage value and the current value to be displayed through the display unit according to an input voltage value and a current value input through the current input unit.

When the crater is turned off, the welding current is supplied while the torch switch is turned on. When the crater is turned on, the welding current is supplied from the first turning on point to the turning off point of the torch switch. have.

As an example related to the present invention, the welding management server generates welding conditions through simulation of the welding temperature distribution, and transmits the generated welding conditions to the welding machine main body. The tonguing means can be controlled.

As an example related to the present invention, the welding management server, based on the unsteady heat conduction finite element method, determines the real time (temperature rise and cooling) temperature distribution considering the moving effect of the heat source for the clear analysis of the welding heat source distribution (Non-heat, density, and thermal conductivity) of the material changes due to the temperature change with time in the case of welding, and considering the temperature dependency of the material, the unsteady heat conduction problem is formulated by the finite element method, In the case of heat transfer, the nonlinear thermal boundary condition is applied, the optimum heat input model is selected according to the arc welding, the main variables are analyzed as the input data of the analysis condition, Determine the heat transfer and heat radiation for the model analysis model and determine the maximum temperature to determine the time increment The analysis results obtained by the above welding temperature distribution simulation are provided to the welder main body. The main variables are the number of weld metal elements, the heat input of the elements, the welding time of the elements, the temperature rise and the cooling time, And a heat transfer, etc., may occur.

In the digital welding control and welding pattern management method according to the embodiment of the present invention, when each welding worker performs welding work through a welding machine feeder, the digital welding machine control and welding pattern management server, Data corresponding to ID, welder start time, wire start time, voltage, current, solenoid valve time, crater use status, etc. are transmitted to the weld management server through the wireless module of the welder main body as welding data, Storing the received welding data in the DB, and the welding management server is configured to monitor the energy usage through the welding operation of each welder through the energy management algorithm, the energy usage statistical information, and the CO ₂ emission amount to the administrator terminal device To the user terminal device.

As an example related to the present invention, the welding management server, based on the unsteady heat conduction finite element method, determines the real time (temperature rise and cooling) temperature distribution considering the moving effect of the heat source for the clear analysis of the welding heat source distribution (Non-heat, density, and thermal conductivity) of the material changes due to the temperature change with time in the case of welding, and considering the temperature dependency of the material, the unsteady heat conduction problem is formulated by the finite element method, In the case of heat transfer, the nonlinear thermal boundary condition is applied, the optimum heat input model is selected according to the arc welding, the main variables are analyzed as the input data of the analysis condition, Determine the heat transfer and heat radiation for the model analysis model and determine the maximum temperature to determine the time increment The analysis results obtained by the above welding temperature distribution simulation are provided to the welder main body. The main variables are the number of weld metal elements, the heat input of the elements, the welding time of the elements, the temperature rise and the cooling time, And a heat transfer, etc., may occur.

The present invention has the effect of reducing the cost by 19% or more compared to the existing welding equipment in consideration of the welding productivity alone, excluding environmental factors.

In addition, the present invention has the effect that the effect will continue even after the 6th year when the effect of welding productivity is calculated only for 5 years excluding environmental factors, the investment payback period is 2 years, cumulative investment effect is 13 billion, and ROI is 210%.

FIG. 1 is a block diagram for explaining a digital welder control and welding pattern management system according to the present invention.
2 is a flowchart illustrating a digital welder control method and a welding pattern management method according to the present invention.

It is noted that the technical terms used in the present invention are used only to describe specific embodiments and are not intended to limit the present invention. In addition, the technical terms used in the present invention should be construed in a sense generally understood by a person having ordinary skill in the art to which the present invention belongs, unless otherwise defined in the present invention, Should not be construed to mean, or be interpreted in an excessively reduced sense. In addition, when a technical term used in the present invention is an erroneous technical term that does not accurately express the concept of the present invention, it should be understood that technical terms can be understood by those skilled in the art. In addition, the general terms used in the present invention should be interpreted according to a predefined or prior context, and should not be construed as being excessively reduced.

Furthermore, the singular expressions used in the present invention include plural expressions unless the context clearly dictates otherwise. In the present invention, terms such as "comprising" or "comprising" and the like should not be construed as encompassing various elements or various steps of the invention, Or may further include additional components or steps.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, wherein like reference numerals refer to like or similar elements throughout the several views, and redundant description thereof will be omitted.

In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail. It is to be noted that the accompanying drawings are only for the purpose of facilitating understanding of the present invention, and should not be construed as limiting the scope of the present invention with reference to the accompanying drawings.

Hereinafter, a digital welder control and welding pattern management system according to the present invention will be described in detail with reference to the accompanying drawings.

1 is a view for explaining a configuration of a digital welding machine control and a welding pattern management system according to the present invention.

1, a feeder 100, a welder main body 200, a CO ₂ gas supply device 300, a welding management server 400, and a wireless communication network 500 are shown.

The plurality of feeders 100 have identification information and provide operation status information by matching with identification information.

The welder main body 200 transmits and receives signals to and from a plurality of feeders 100 in a wireless communication manner and controls the operation state of the feeder 100.

The CO ₂ gas supply device 300 is connected to the welder main body 200 and supplies CO ₂ gas to the welder.

The welding management server 400 is connected to the welder main body 200 via a wireless communication network and stores digital welding machine control information provided as a radio signal from the welder main body 200 and transmits the stored welding pattern information to the welder main body 200 ).

The feeder 100 includes a voltage value or current value input unit for inputting a voltage value or a current value numerically, a crater selection switch for selecting whether or not to use the crater, a voltage value or current value input through a voltage value or current value input unit, And a control unit for adjusting the primary voltage or the primary current, the secondary voltage, or the secondary current using the value.

The welding machine main body 200 includes digital / analog converters for converting digital voltage signals and current signals into analog voltage values and current values and outputting them to a feeder, and welding process information Off control signal, a gas check on / off control signal, a crater on open control signal, a solenoid valve control signal, and a torching on / off control signal in response to the on / off control signal of the control unit, A crater unit, and a driving unit for selectively driving the solenoid valve. Here, the driving unit is an optocoupler.

The welding machine main body 200 may further include a wireless communication unit for transmitting and receiving welding process information through a wireless communication system with the welding management server.

The welder main body 200 can transmit at least one or more of the voltage value, the current value, the CO ₂ gas usage amount, and the wire usage amount information to the welding management server 400.

The feeder 100 operates in a stable manner in response to a torching on / off control signal of the welder main body, and a voltage value input through the voltage input unit And a controller for controlling the voltage value and the current value to be displayed through the display unit, in response to the current value input through the current input unit.

When the crater is turned on, the welding current is supplied while the torch switch is turned on. When the crater is turned on, the welding current is supplied from the first turning on point to the turning off point of the torch switch. Can be controlled.

The welding control server 400 generates welding conditions through simulation of the welding temperature distribution, transmits the generated welding conditions to the welding machine main body, and controls the feeder and the toque means so that welding is performed according to the received welding conditions. can do.

Based on the unsteady heat conduction finite element method, the welding control server (4000) analyzes the temperature distribution in real time (temperature rise and cooling) considering the moving effect of the heat source for a clear analysis of the welding heat source distribution, Since the physical parameters (specific heat, density, and thermal conductivity) of the material change due to the temperature change with time, the temperature dependence of the material is considered, and the unsteady thermal conduction problem is formulated by the finite element method, and the Fourier law is applied In the case of heat transfer considering the heat transfer, nonlinear thermal boundary conditions are applied, the optimal heat input model is selected according to the arc welding, the main variables are interpreted as the input data of the analysis condition, Determining whether the heat transfer and the heat radiation exists, determining the maximum temperature, The analysis results obtained from the distribution simulation are provided to the welder main body. The main variables are number of weld metal elements, heat input of element, welding time of element, temperature rise and cooling time, Or the like may occur.

That is, the welding management server 400 belonging to the digital welding machine control and welding pattern management system efficiently manages the energy consumption due to the operation of each welding machine at the shipbuilding site where the welding operation is performed at various places simultaneously, The energy management SW for each welding worker performs the welding work through the welder feeder, the welding machine ID, feeder ID, welder start time, wire start time, voltage, current, solenoid valve time, crater use The welding data is transmitted to the server through the wireless module of the welding machine main body, and the server stores the received welding data in the DB. The server provides the welding data through the energy management algorithm, monitoring the energy usage through the welding work of each welding machine, and providing the energy usage statistical information and CO ₂ emission (harmful gas) to the administrator or user through the web browser and the mobile web browser .

A) Power consumption algorithm

Power consumption should be calculated by multiplying the used power by the welding time and the efficiency of the welding machine. The efficiency of the welding machine is about 50% for the DC welding machine and about 80% for the AC welding machine.

The loss of electric power due to the no-load operation of the welding machine is 25 ~ 45% in the DC welding machine, but the AC welding machine need not be considered.

Power is displayed as cumulative value of power per hour

Power (W / h) = Primary Voltage (V) x 1 Current (A) x Second Time (sec) / 3600 + Secondary Voltage (V) x 2 Current (A)

B.) Welding machine operation time algorithm

The starting time of the welding machine is stored based on the time when the welding machine is turned on, and the operation time of the welding machine is calculated by calculating the difference from the welding start time to the current time value.

Welding machine operation time = current time Welding machine start time

C) CO ₂ gas usage algorithm

The reference value of the CO ₂ gas use amount is set to 25 / min, and the reference value of the CO ₂ gas amount may be changed.

CO ₂ gas consumption () = 25 x (SOL time / 60)

D) Wire usage algorithm

(Amount of primary welding wire used) + (amount of secondary welding wire used)

The wire usage reference value is changed according to the welding current.

WFS = aL + bl2

WFS: wire feed speed, L: wire protrusion length, I: welding current, a / b: proportional constant L (wire protrusion length)

Calculate wire usage using wire feed rate (speed = distance / time)

E) Algorithm of CO ₂ emissions per process

toe (ton of equivalent) is the oil conversion tonnage specified by the International Energy Agency (IEA). The toe is defined as 107Kcal, which is a unit that can be conveniently used with a calorific value close to the net calorific value of 1 ton of crude oil.

Toe = fuel calorific value (Kcal) / (107Kcal)

Toe conversion is calculated by using the total calorific value of "energy calorie conversion standard".

(Example) Toe calculation of power consumption 1KWh

= 2300 Kcal / (107 Kcal)

= 0.00023 toe

The toe of the fuel is multiplied by the carbon emission factor.

TC = toe of corresponding fuel * Carbon emission factor (TC / toe)

To convert to TCO ₂ , multiply the TC value in the above formula by (carbon dioxide molecular weight) / carbon atom amount).

TCO ₂ = TC * 44/12

CO2 emission factor of electric power 0.4705tCO ₂ eq / MWh

(Example) TCO ₂ calculation of power consumption 1KWh

TC = 0.00023 * 0.47 = 0.001081

TCO ₂ = 0.001081 * (44/12) = 3.7 (TCO ₂ )

On the other hand, in the welding management server 400, the IDs of the respective welders on which the online connection is made are recorded as LOG, and the currently connected welder IP and PORT are recorded as LOG.

In addition, the welding control server 400 transmits a status confirmation signal of each welder main body 200, and a control command for writing the control item of the welding machine for controlling is transmitted, and the status confirmation LOG of each welder main body is output.

The welding management server 200 can set the welding power source ON / OFF, the crator power source / non-welding power source, and the voltage / current setting by designating the welding machine ID, the feeder ID, the IP address, , Alarms and waveforms.

The manager or the worker can inquire the welding schedule for one day according to the work instruction through the welding management server 400 and support the welding schedule for the day according to the work instruction through the welding management server 400.

Also, the welding management server 400 supports the real-time energy usage status (welding time, welding time, voltage, current, consumed power, consumed wire, consumed CO ₂ ) of the digital welder main body 200.

In addition, the welding management server 400 can select the digital welding machine main body 200 to check the energy usage statistics, output the real-time safety management situation of the application site on the factory layout, and output the CO ₂ pollution degree by time .

Then, the welding management server 400 selects the digital welder main body 200, selects the date to be searched to search the CO ₂ emission statistics, selects the digital welder main body 200, selects a date to search for It can search the main power status.

In particular, the welding pattern management software applied to the welding management server 400 may cause the welding block to be re-applied due to a high defect rate of the welding block when welding is carried out by a foreign worker at a small-sized shipbuilding site where the proportion of foreign workers is very high In this case, the welding time, the welding material and the energy consumption are increased, that is, the productivity is lowered. To solve these problems, the standard welding data for each welding block is analyzed to provide a standard welding pattern for the welding block. The welding control server 400 provides a weld pattern corresponding to the weld block and the worker can assist welding by setting the weld pattern provided on the welder feeder.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or essential characteristics thereof. Therefore, the embodiments disclosed in the present invention are intended to illustrate rather than limit the scope of the present invention, and the scope of the technical idea of the present invention is not limited by these embodiments. The scope of protection of the present invention should be construed according to the following claims, and all technical ideas within the scope of equivalents should be construed as falling within the scope of the present invention.

Claims (12)

A plurality of feeders having identification information and matching the identification information to provide operation status information;
A welder body for transmitting and receiving signals to and from the plurality of feeders in a wireless communication manner and controlling an operation state of the feeder;
A CO ₂ gas supply device connected to the welder main body for supplying CO ₂ gas to the welder; And
And a welding management server connected to the welding machine body via a wireless communication network and storing digital welding machine control information provided as a radio signal from the welding machine body and providing stored welding pattern information to the welding machine body,
The welding management server generates a welding condition through simulation of a welding temperature distribution, transmits the generated welding condition to the welder body,
Wherein the welder body controls the feeder and the toothed means so that welding is performed according to the received welding conditions,
Based on the unsteady heat conduction finite element method, the welding management server interprets the temperature distribution in real time (temperature rise and cooling) in consideration of the moving effect of the heat source for a clear analysis of the welding heat source distribution,
In the case of welding, the physical parameters (specific heat, density, and thermal conductivity) of the material change due to temperature changes with time. Considering the temperature dependence of the material, the unsteady heat conduction problem is formulated by the finite element method,
Applying the Fourier law with the thermal boundary condition, applying the nonlinear thermal boundary condition when the heat transfer is considered,
The heat input model based on the arc welding is selected, the main variables are analyzed as the input data of the analysis condition,
The analysis result obtained through the welding temperature distribution simulation for determining the time increment by judging the heat transfer and the heat radiation to the analytical model shape and determining the maximum temperature is input to the welding machine main body,
The main parameters are at least one or at least one of the factors causing the number of weld metal elements, the heat input of the elements, the welding time of the elements, the temperature rise and cooling time selection, A digital welding control and welding pattern management system. The method according to claim 1,
The feeder includes a voltage value or a current value input unit for inputting a voltage value or a current value numerically, a crater selection switch for selecting whether or not to use the crater, a voltage value or current value input through the voltage value or current value input unit And a control unit for adjusting the primary voltage or the primary current, the secondary voltage, or the secondary current using the control unit. The method according to claim 1,
The welder main body includes digital / analog converters for converting the digital voltage signal and the current signal into an analog voltage value and a current value, respectively, and outputting the digital voltage signal and the current value to a feeder, and a controller for controlling the welding process information provided by the operator, Off control signal, a gas check on / off control signal, a crater on open control signal, a solenoid valve control signal, and a torching on / off control signal in response to the on / off control signal of the control unit, And a drive unit for selectively driving the solenoid valve, the crater unit, and the solenoid valve. The method of claim 3,
Wherein the driving unit is a photocoupler. The method according to claim 1,
Wherein the welder main body further includes a wireless communication unit for transmitting and receiving welding process information through the wireless communication system with the welding management server.
The method according to claim 1,
Wherein the welding machine main body transmits at least one or more of a voltage value, a current value, a CO ₂ gas usage amount, and a wire usage amount information to the welding management server. The method of claim 3,
Wherein the feeder stably operates in response to a torching on / off control signal of the welding machine main body, and a voltage value and a current And a controller operative in response to the current value input through the input unit and controlling the voltage value and the current value to be displayed through the display unit. The method according to claim 1,
When the crater is turned off, the welding current is supplied while the torch switch is turned on. When the crater is turned on, the feeder current is supplied from the first on-state to the off-state of the torch switch and the crater current is supplied during the second on- A digital welding control and welding pattern management system.
delete delete A digital welding control method and a welding pattern management method,
When each welding worker performs the welding work through the welder feeder, the welding control server checks each welding worker ID, feeder ID, welder start time, wire start time, voltage, current, solenoid valve time, To be transmitted to the welding management server through the wireless module of the welder main body as welding data;
The welding management server storing the received welding data in a DB; And
Wherein the welding management server includes a step of providing the welding data to the manager terminal or the user terminal through the energy management algorithm by monitoring the energy usage through the welding operation of each welder, the energy usage statistical information and the CO ₂ emission amount,
Based on the unsteady heat conduction finite element method, the welding management server interprets the temperature distribution in real time (temperature rise and cooling) in consideration of the moving effect of the heat source for a clear analysis of the welding heat source distribution,
In the case of welding, the physical parameters (specific heat, density, and thermal conductivity) of the material change due to temperature changes with time. Considering the temperature dependence of the material, the unsteady heat conduction problem is formulated by the finite element method,
Applying the Fourier law with the thermal boundary condition, applying the nonlinear thermal boundary condition when the heat transfer is considered,
The heat input model based on the arc welding is selected, the main variables are analyzed as the input data of the analysis condition,
The analysis result obtained through the welding temperature distribution simulation for determining the time increment by judging the heat transfer and the heat radiation to the analytical model shape and determining the maximum temperature is input to the welding machine main body,
The main parameters are at least one or at least one of the factors causing the number of weld metal elements, the heat input of the elements, the welding time of the elements, the temperature rise and cooling time selection, Wherein said control means is operable to control said welding process.
delete

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