KR101970775B1 - Welding monitoring device and monitoring method - Google Patents

Abstract

The present invention relates to a welding monitoring device and a monitoring method. When using an arc created between a welding torch and base metal to perform welding work of the base metal after connecting a pair of electrode cables extended from a welding machine body to the welding torch and the base metal, voltage data inputted into a CPU from measurement cables connected to the electrode cables through a surge module for blocking high frequencies and a voltage sensing module, and current data inputted into the CPU through a sensor cable of a current sensor connected to an electrode cable are used to monitor change situations of voltage and current generated during the welding work in real time. Allowable upper limits and lower limits of a voltage value and a current value can set in accordance with a type of base metal or a welding method by using a setting knob and a monitor. When a voltage value and a current value measured during welding work exist within a preset range, a green light of a tower lamp is turned on. When the corresponding voltage value and current value exceed the preset range, a red light of the tower lamp is turned on and an alarm is transmitted. All processes are digitized to transmit data to a main computer and store the data in real time to provide a basic function of investigating a time and a cause of a welding defect without performing expensive non-destructive inspection. A worker is frequently made to pay attention while performing welding work at a work site to maximally reduce a rate of welding defects and greatly improve productivity.

Description

[0001] Welding monitoring device and monitoring method [0002]

In the present invention, when a pair of electrode cables extending from a welding machine main body are connected to a welding torch and a base material, respectively, and welding is performed using an arc generated between the welding torch and the base material, Voltage data from the measuring cable connected to the high-frequency surge module and the voltage sensing module and the current data input to the CPU through the sensor cable of the current sensor connected to one electrode cable, And more particularly, to a welding monitoring apparatus and a monitoring method capable of real-time monitoring of a fluctuation situation of a voltage and a current occurring.

In general, TIG (Tungsten Inert Gas) welding uses a heat generated during arc discharge generated between a welding torch having a non-consumable tungsten electrode and a base material to melt the molten additive into the joint surface of the base material, (+) Electrode cable extending from the welder main body is charged with the tungsten electrode of the welding torch, while another (-) electrode cable extending from the welder main body is charged on the base material, and then tungsten A welding operation is performed while an inert gas such as argon (Ar) is supplied to the periphery of the electrode.

The TIG welding is advantageous for thin plate welding because of easy adjustment of the heat input amount. Since the tungsten electrode rod is non-consumable, only the base material can be melted and joined without adding the filler. Since inert gas is used, : Solvent) is unnecessary, it can be widely applied to most metal welding including non-ferrous metal welding work, has excellent mechanical properties and corrosion resistance of welded part, minimizes deformation of welded part, and has various advantages to provide.

In the TIG welding, there are two kinds of arc generating method which is the source of the welding heat: contact arc generation method and high frequency arc generation method. In the former case, the tungsten electrode is instantly brought into contact with the base material, A method of generating an arc in the process is advantageous in that an arc can be generated even at a low voltage. On the other hand, a skilled technique is required for the contact and separation between the tungsten electrode and the base material, In the latter case, it is a noncontact type that generates arc naturally by applying a high-frequency high frequency to a tungsten electrode. This is a commonly used method for TIG welding.

As described above, a high-frequency high-frequency signal applied between the tungsten electrode and the base material acts as a noise in the TIG welding using the high-frequency arc generating method, and the noise of the high-frequency signal causes the voltage and current It is very difficult to monitor the change in real time. However, as described in Korean Patent No. 10-0525013 (published on October 31, 2005), the voltage is firstly attenuated A technique has been developed in which a high voltage is cut off by a voltage attenuator composed of a varistor and a low frequency signal having passed through a low pass filter is passed through an insulating interface circuit to enable monitoring of TIG welding.

However, in the conventional welding monitoring method as described above, after the welding operation is completed, only the post-treatment (after treatment) monitoring that identifies the occurrence time of the welding defect and the cause of the welding is possible Therefore, there is a problem that it is not possible to contribute to the aspect of minimizing the occurrence rate of weld defect and greatly improving the productivity, by venturing the operator's attention from time to time during the welding work at the work site. Thus, There is a problem in that it can not provide a possible monitoring method.

On the other hand, in addition to the actual welding work on the base material, various other types of welding work including TIG welding, various auxiliary tools such as surface treatment before welding, finishing after welding, The work is carried out in the field together with the welding work. In the conventional monitoring method, it is not possible to automatically obtain the data on the welding operation, There is a problem that it is difficult to perform more detailed and systematic work management and process management throughout the welding work.

Particularly, in the conventional welding monitoring method, only the noise due to the high frequency is cut off when an arc is generated, and a high-voltage static electricity, which is generated in the inside of the welding machine main body during arc generation and becomes another noise during the welding monitoring process, There is a problem that a large error occurs in the voltage value and the current value measured at the welding work due to the noise interference caused by the welding operation. Therefore, the welding quality and the productivity are improved based on the more accurate analysis data, But also an undesirable problem has arisen.

Korea Patent No. 10-0525013

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above problems, and it is an object of the present invention to provide a welding torch and a base material, The voltage data input from the measurement cable connected to each electrode cable to the CPU via the high frequency shielding surge module and the voltage sensing module and the sensor cable of the current sensor connected to one electrode cable To monitor the voltage and current fluctuations occurring during the welding operation in real time using the current data input to the CPU through the CPU and the upper and lower limits of the allowable voltage and current values according to the type of the base material and the welding method Can be set using a setting knob and a monitor, and the voltage value When the current value is within the predetermined range, the green lamp of the tower lamp is lighted, and when the voltage value and the current value are out of the predetermined range, the red lamp of the tower lamp is lighted, In addition to basic functions that allow you to identify the time and cause of welding failure even if expensive nondestructive testing is not performed by transmitting and storing all of these processes in real time to the main computer in real time, And to provide a welding monitoring apparatus and a monitoring method capable of reducing the incidence of welding defects to a maximum extent and significantly improving productivity by venturing the operator's attention from time to time.

In addition, the present invention is characterized in that a current sensor is connected to a power cable of a transmission mechanism used for a pre-welding surface treatment, a post-welding finishing process or a welding process, and a sensor cable extending from the current sensor is connected to a monitoring device By additionally connecting to the CPU, it is possible to automatically obtain, together with the data on the welding operation, how many times the auxiliary operations other than the welding operations have been carried out for a certain number of times, In addition, the noise generated by the high frequency is blocked by the surge module when the arc is generated, and the static electricity blocking layer formed by applying the MS polymer to the inner surface of the wall panel constituting the casing of the welder main body To the high-voltage static electricity that causes another noise in the welding monitoring process. This makes it possible to measure the voltage and current values of the welding operation more precisely without any errors and furthermore applies the temperature sensor and the humidity sensor to the monitoring device so that temperature and humidity data By providing more comprehensive feedback data, it is possible to improve welding quality and productivity based on more precise and detailed analysis data. Therefore, it is possible to provide weld monitoring Apparatus, and a method of monitoring.

According to the present invention, there is provided a welding monitoring apparatus comprising: an electrode cable extending from a welding machine main body to a welding torch and a base material side, And the voltage sensing module is connected to the CPU together with the sensor cable of the current sensor, and the current sensor is connected to the voltage sensor module via the high frequency cutoff surge module. The surge module, the voltage sensing module, and the CPU are installed inside the device case. The CPU is connected to a monitor provided on the door panel on the front side of the device case. Thus, A monitoring device capable of outputting a variation status on a monitor screen in a graph form, In the door panel of the base unit case, there are provided a setting knob for setting the upper and lower limits of the voltage and current on the monitor via the CPU, and a digital knob for displaying the voltage and current values in the welding operation, And a tower lamp connected to the CPU is installed on the outer upper surface of the device case. The voltage of the welding lamp is calculated by the CPU, and the voltage value and current value of the tower lamp are set in a range of a predetermined upper limit and lower limit And when the voltage value and the current value are out of the range of the predetermined upper limit line and the lower limit line, the red light is turned on and the alarm is sent out.

In addition, the monitoring device is further provided with a detecting means for judging whether or not the transmission mechanism used for the surface treatment before the welding of the base material, the post-welding finishing treatment or the supplementary treatment during the welding is in operation, The sensor cable of the electric current sensor for the electric motor is connected to the CPU inside the device case together with the sensor cable of the current sensor for the electrode cable, And a digital indicator for displaying a current value of the computed transmission mechanism is additionally provided. The surge module further includes a pair of input and output terminals for connecting the voltage measurement cable to the voltage sensing module, A capacitor for reducing AC power and an RC noise removing circuit are sequentially wired, A capacitor electrode for reducing AC power and a pole for RC noise elimination circuit are connected to each other by a pole grounding method. An ESC layer is formed on the inner surface of the wall panel of the casing of the welder by coating MS polymer And the monitoring device is disposed close to the outer surface of the wall panel. On the outer upper surface of the device case, all data inputted and processed through the CPU in a state of being connected to the CPU, A temperature sensor and a humidity sensor connected to the CPU are installed inside or outside the device case, and a temperature value and a humidity value input from the respective sensors to the CPU are connected to a monitor Is displayed as a numerical value on the screen of the display device.

In the welding monitoring method according to the present invention, the power switch of the monitoring apparatus is turned on, and then the upper limit and lower limit of the voltage value and the current value are set to the target of the welding operation A surge module for high frequency cutoff and a voltage sensing module are connected to the measurement cable connected to the electrode cable extending from the welder main body to the welding torch and the base material side after the setting step, A measurement step of performing arithmetic processing on the voltage data at the time of the welding operation inputted through the sensor cable and the current data at the welding operation inputted through the sensor cable of the current sensor connected to one of the electrode cables, The voltage value and the current value during the welding operation, which are calculated in the measuring step, When it is within the range of the line, the green lamp of the tower lamp provided to the monitoring device is turned on. When the voltage value and the current value are out of the range of the predetermined upper limit and lower limit, the red lamp of the tower lamp is lighted, Wherein the measuring step and the monitoring step are repeated in real time during the welding work of the base material, wherein the voltage value and the current value during the welding operation, which are calculated in the measuring step, Is displayed in real time as graph and numerical values through the monitor screen and digital indicator provided on the monitoring device. On the other hand, the normal operation signal that the voltage value and the current value during the welding operation are within the predetermined range, All of the input and computed inputs to the CPU, including the abnormal operation signal, Data is characterized in that through an antenna provided on the monitor device in real time sent to the main computer.

In addition, a work selection step of determining, by the CPU, whether or not voltage data and current data according to the welding operation are inputted is additionally applied between the setting step and the measurement step. In the work selection step, When the data and the current data are input, the process goes to the measurement step. When the data is not inputted, the transmission mechanism detection step of determining whether the transmission mechanism is in operation is performed by the CPU. And the sensor cable of the current sensor connected to the power cable of the transmission mechanism is connected to the CPU of the monitoring device. In the power transmission mechanism sensing step, When usage is detected, an incidental signal is transmitted to the main computer via the antenna of the monitoring device Meanwhile, when the current value of the transmission mechanism is displayed numerically through the digital indicator of the monitoring device and the operation stop signal is transmitted to the main computer via the antenna of the monitoring device when the use of the transmission mechanism is not detected, The welding monitoring method is performed by forming an electrostatic shielding layer on the inner surface of the wall panel constituting the casing of the welder body by applying MS polymer so that the monitoring device is not affected by the static electricity generated from the welder main body The monitoring device is further provided with a temperature sensor and a humidity sensor. The temperature value and the humidity value input from the respective sensors through the CPU in real time are displayed numerically on the monitor screen of the monitoring device, To be transmitted to the main computer via the antenna of the monitoring device And a gong.

According to the present invention, the upper limit and the lower limit of the allowable voltage value and the current value are set in advance according to the kind of the base material and the welding method, and then the voltage value and the current value measured in the welding operation are within a predetermined range When the voltage value and the current value exceed the preset range, the red lamp of the tower lamp is lighted and the alarm is sent out. By real-time transmission and storage, it is possible to identify the time and cause of welding failure even when expensive nondestructive inspection is not carried out, and the operator's attention is frequently circulated during the welding operation at the worksite, It is possible to reduce the size of the product as much as possible and greatly improve the productivity.

In addition to this, it is possible to automatically acquire the number of times the auxiliary operation other than the welding operation has been carried out and the data on the welding operation, so that a more detailed and systematic work management And process control. It also completely blocks the high-voltage static electricity which causes another noise in the welding monitoring process, so that the voltage value and the current value according to the welding operation can be measured more accurately without error And provides a wide range of feedback data including the temperature and humidity data around the work site, thereby improving welding quality and productivity based on more accurate and detailed analysis data Actually contribute to securing competitiveness And can provide a very useful effect.

1 is a wiring diagram showing a state in which a welding monitoring apparatus according to the present invention is installed together with a TIG welding machine;
2 is a front view of a welding monitoring device according to the invention;
3 is an external perspective view of a welding monitoring apparatus according to the present invention;
4 is a schematic internal wiring diagram of a welding monitoring apparatus according to the present invention.
5 is a circuit diagram of a surge module used in the present invention.
6 is an enlarged sectional view of the portion " A "
7 is a photograph showing an example of a monitor screen applied to the welding monitoring apparatus of the present invention.
8 is a flowchart showing a welding monitoring method according to the present invention.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

1, the welding monitoring apparatus 10 according to the present invention includes a welding torch 7 and a base material 9 from a distribution board 3 provided at the lower end of a welding machine main body 2 of a welding machine 1 A voltage measuring cable 12 is connected to each of the pair of electrode cables 5 extending to each other and a current sensor 13a is connected to one electrode cable 5 of the electrode cable 5, Each of the measurement cables 12 is connected to the monitoring means inside the device case 11 together with the sensor cable 13 extending from the current sensor 13a.

Although the connecting portions 12a connecting the measuring cables 12 to the electrode cables 5 are placed outside the switchboard 3 in order to more clearly show the wiring state of the cables in the drawing, It is most preferable that the connection portion 12a is located inside the switchboard 3. The current sensor 13a may be any kind of device capable of measuring the current flowing through the corresponding electrode cable 5 It is preferable to use a coil type DC 500A current sensor product in which the electrode cable 5 is penetrated.

1, the monitoring device 10 of the present invention is applied to the TIG welding machine 1 as a representative example. However, the monitoring device 10 of the present invention can be applied to a TIG welding machine such as GMAW (MIG welding, CO ₂ welding) , It can be applied to various welding works such as SMAW (manual welding), SAW (submerged automatic welding), PLASMA welding, LASER welding and the like. In FIG. 1, which is a typical application example of TIG welding, argon The gas hose 6 extending from the gas tank 4 storing the inert gas such as the inert gas through the distribution panel 3 at the lower end of the welder main body 2 is connected to the welding torch 7, The numeral 8 indicates a filler to be introduced into the joint surface of the base material 9.

As shown in FIGS. 2 and 3, the monitoring device 10 according to the present invention includes a door panel 11a on the front surface of a device case 11, which is manufactured in a rectangular box shape, A monitor 15 is provided at a central portion of the door panel 11a and a rotary setting knob 17 is installed at a lower side of the monitor 15 (right side in the drawing) A digital indicator 16 is provided on the upper side of the monitor 15. A tower lamp 18 (red light 18a and green lamp 18b) provided on both left and right sides of the upper surface of the apparatus case 11 And a cable terminal 12b for connecting the measurement cable 12 and the sensor cable 13 are provided below the one side surface (the left side surface in the drawing) of the device case 11, (13b) are provided.

In addition, a control unit provided inside the apparatus case 11 and capable of monitoring the change of voltage and current due to the welding operation in real time includes a surge module for interrupting the high frequency, A voltage sensing module 21 and a CPU 20. Each of the measurement cables 12 is connected to a voltage sensing module 21 through a high frequency cutoff surge module 22 The voltage sensing module 21 is connected to the CPU 20 together with the sensor cable 13 of the current sensor 13a.

The surge module 22 and the voltage sensing module 21 correspond to the high frequency signal preprocessing device and interface of the prior art document (Korean Patent Registration No. 10-0525013) mentioned in the above description of the prior art Recently, surge modules with excellent functions, which are provided with a high frequency cutoff function for the purpose of protecting sensitive electronic equipment, have been marketed in various types. Therefore, if an appropriate product is selected and applied, .

5, the surge module 22 includes a pair of input terminals In + and In- for connecting the voltage measurement cable 12 to the voltage sensing module 21, and output terminals Out + A capacitor 10nF and an RC noise canceling circuit 10KOhm and 10nF are sequentially connected between the AC power supply capacitor 10nF and the RC noise reducing capacitor 10nF, Removal circuit (10KOhm, 10nF), and one pole is connected by a pole grounding (PE) method.

When the welding voltage is applied to the input terminals In + and In- through the respective voltage measurement cables 12, the AC power reduction capacitor 10nF A signal in a state in which high frequency components are almost removed as it passes through the RC noise removing circuits 10KOhm and 10nF is transmitted to the output terminals Out + and Out-, and the transmission signal is outputted to the voltage sensing module 21 Is measured by the CPU 20 as a voltage value at the time of welding work, which is a very simple and efficient high frequency cutoff method compared with the method described in the prior art document.

The CPU 20 is connected to the monitor 15 by using the setting knob 17 as an input means so that the upper limit and lower limit of the allowable voltage value and the current value can be determined by the CPU 20 2, the setting knob 17 is provided with an upper limit setting knob (High Guide in the drawing) and a lower limit setting knob (in the drawing, Low The tower lamp 18, the antenna 19, and the digital indicator 16 are connected to the output terminal of the CPU 20.

The tower lamp 18 lights up the green light 18b when the voltage value and the current value during the welding work calculated and processed by the CPU 20 are within a predetermined upper limit and lower limit, And when the current value is out of the range of the predetermined upper limit and lower limit, the red light 18a is turned on and the alarm (warning sound) is transmitted. The antenna 19 is input and processed through the CPU 20 And transmits all data to the main computer (not shown) in real time. The indicator 16 performs a function of displaying the voltage value and the current value at the time of welding operation, .

The CPU 20 of the monitoring apparatus 10 may be connected to the main computer using a local communication network such as LAN without using the wireless communication method by the antenna 19 as required, It is preferable to apply the wireless communication method when welding work using each welding machine 1 is carried out simultaneously in a state where dozens or more welding machines 1 are disposed in the welding machine 1 The main computer may collectively collect, analyze, and store the data signals transmitted from several to several monitoring devices 10, such as a LAN .

As other constituent elements of the present invention, as shown in Fig. 1, Fig. 3 and Fig. 4, electric components such as an electric grinder used for surface treatment before welding, finishing after welding or complementary treatment during welding of base material 9 The sensing means is provided with a current sensor 13a connected to the power cable 14a of the transmission mechanism 14 and a current sensor 13b connected to the power cable 14a of the transmission mechanism 14. [ The current sensor 13a for the transmission mechanism 14 is preferably an AC 50A product as the coil type current sensor in which the power cable 14a is passed as described above Do.

The sensor cable 13 of the current sensor 13a for the transmission mechanism 14 is connected to the CPU 20 in the device case 11 together with the sensor cable 13 of the current sensor 13a for the electrode cable 5 Two voltage measuring cables 12 and two current sensor cables 13 can be connected to the lower portion of one side (left side in the drawing) of the device case 11 for this purpose A total of four cable terminals 12b and 13b are provided so that the digital indicator 16 is also provided with two indicators 16 for indicating the voltage value and the current value according to the welding operation A total of three indicators 16 including one indicator 16 (E-Tool Amp. In the drawing) for displaying the current values of the transmission mechanism 14 and the transmission mechanism 14 as numerical values are connected to the door panel 11a, and two or more transmission mechanisms 14 may be used depending on the type of welding operation. In this case, The number of those according to the number of the mechanism 14, the sensor cable 13 and the indicator 16 will also increase.

4, a temperature sensor 24 and a humidity sensor 25, which are connected to the CPU 20, are further installed inside (or outside) the device case 11 6, the inner surface of the wall panel 2a constituting the casing of the welder main body 2, as shown in Fig. 6, By forming the electrostatic shielding layer 2b by applying the MS polymer to the substrate 1, it is possible to completely block not only the high frequency noise at the time of arc generation but also the noise due to the high voltage static electricity.

The MS polymer is a modified silicone which collects the merits of silicone and urethane, and is widely used for undercoating work for soundproofing and a method of automobile lower panel. In the present invention, it is used as an electrostatic shielding agent, It is possible to provide an excellent electrostatic shielding performance even with a thin thickness of about 1 mm. Therefore, even if the casing structure of the welder main body 2 is changed or a separate and troublesome installation work is not performed, It is possible to easily form the electrostatic barrier layer 2b.

The monitoring device 10 according to the present invention can be mounted on the wall panel 2a of the welder main body 2 by forming the electrostatic shielding layer 2b by applying the MS polymer on the inside of the wall panel 2a constituting the casing of the welder main body 2. [ It is possible to prevent the welding monitoring operation from being interfered by the high-voltage static noise even if it is installed in close contact with the outer surface of the welding apparatus main body 2 a It is possible to reduce the space as much as possible, which is advantageous in terms of efficient use of space on the worksite.

7 is a photograph showing a screen of the monitor 15 of the monitoring apparatus 10 according to the present invention. It is a graph showing the relationship between the voltage value and the current value fluctuation occurring in the welding operation between the predetermined upper limit line and the lower limit line A total work time, a welding work time, a machine work time by the transmission mechanism 14, and a number of times of welding work A small inspection window is provided which can clearly understand the setting conditions of the welding temperature, the current temperature and the humidity, the upper guide and the lower guide, 9, an input window for inputting material, size and worker is additionally provided with a SETUP button and an EXIT button which are operated in a touch screen manner.

The configuration of the screen of the monitor 15 shown in FIG. 7 is also only one typical example that can be applied to the present invention. The configuration and arrangement of the screen of the monitor 15 are not limited to those shown in FIG. 7, Alternatively, instead of the function of setting the upper limit and lower limit of the voltage value and the current value using the setting knob 17, the corresponding function may be performed on the screen 15 itself by the touch screen method, The current value and the current value of the transmission mechanism 14 are provided on the screen of the monitor 15 so that the digital indicator 16 is omitted.

Hereinafter, the welding monitoring method of the present invention using the monitoring device 10 having the above-described configuration will be described in detail with reference to the flowchart of FIG.

First, in order to perform the monitoring method of the present invention, the power switch of the monitoring device 10 is turned on, and then the voltage value and the voltage value are measured using the setting knob 17 and the monitor 15 provided in the monitoring device 10 The setting step of setting the upper limit and the lower limit of the current value in advance according to the type of the base material 9 and the welding method to be subjected to the welding operation must be performed first.

Normally, in each welding operation, the allowable voltage value and the current value reference are determined in accordance with the type, size (dimension), and the like of the base material 9. Therefore, the upper and lower limits of the required voltage value and current value And if necessary, the corresponding work manual is produced as an electronic file and stored in the CPU 20 of the monitoring device 10, and then displayed on the monitor 15 screen provided with the touch screen function, It is possible to automatically input and set the upper and lower limits of a specific numerical value as soon as the type and the welding method of the welding machine are selected.

The worker starts the welding work on the base material 9 and the electrode cable 5 extending from the welder main body 2 to the welding torch 7 and the base material 9 respectively Voltage data indicating the start of the welding operation is inputted from the connected measuring cable 12 to the CPU 20 through the high frequency shielding surge module 22 and the voltage sensing module 21 and the voltage data The current data informing the start of the welding operation via the sensor cable 13 of the current sensor 13a connected to one electrode cable 5 is also input to the CPU 20 so that the corresponding voltage data and current data are supplied to the CPU 20 ) To the measurement step of performing arithmetic processing.

If the voltage value and the current value during the welding operation calculated in the present step are within the predetermined upper and lower limits, the monitoring device 10 may perform the measurement operation at the same time as the start of the welding operation, The red lamp 18a of the tower lamp 18 is turned on when the voltage value and the current value are out of the range of the predetermined upper limit and lower limit, And a monitoring step of sending an alarm at the same time is performed. The monitoring step and the monitoring step are repeated in real time until the welding operation of the base material 9 is completed, thereby implementing the welding monitoring method according to the present invention.

In addition, the voltage value and the current value during the welding operation, which have been calculated in the measuring step, are outputted in real time as graphs and numerical values through the screen of the monitor 15 provided on the monitoring device 10 and the digital indicator 16, A normal operation signal that the voltage value and the current value at the time of operation are within the preset range and all the data inputted and processed by the CPU 20 including the abnormal operation signal that the voltage value and the current value are out of the predetermined range Is transmitted in real time to the main computer via the antenna 19 provided in the monitoring device 10. [

As a more preferred embodiment, the CPU 20 further applies a job selection step of determining whether the voltage data and the current data according to the welding operation are input between the setting step and the measurement step, When the voltage data and the current data according to the welding operation are input, the control unit goes to the measurement step. When the data is not input, the control unit 20 determines whether the transmission mechanism 14 is in operation .

As described above, the transmission mechanism 14 is a mechanism such as an electric grinder used for surface treatment before welding, post-welding finishing treatment or complementary treatment during welding of the base material 9, The sensor cable 13 of the current sensor 13a connected to the power cable 14a of the monitoring device 10 is connected to the CPU 20 of the monitoring device 10, It can be judged.

Accordingly, when the use of the transmission mechanism 14 is sensed through the transmission mechanism sensing step, the incidental operation signal is transmitted to the main computer via the antenna 19 of the monitoring device 10, When the use of the transmission mechanism 14 is not sensed, the current value of the transmission mechanism 14 is displayed numerically through the digital indicator 16 of the monitoring device 10 via the antenna 19 of the monitoring device 10, Signal to be transmitted to the main computer.

7, it is possible to accurately calculate the total work time in which the actual work has been performed, and it is also possible to calculate the total work time by the welding work time (Welding Work Time) (Machine Work Time) by the power transmission mechanism 14, and at the same time, the welding count of the welding operation can be automatically counted.

On the other hand, when the temperature sensor 24 and the humidity sensor 25 are additionally installed in the monitoring device 10, the temperature value and the humidity value input from the respective sensors through the CPU 20 are monitored 15) Displayed numerically on the screen, and the data is transmitted and stored in real time to the main computer via the antenna 19 separately from the progress of the welding monitoring, so that the temperature and humidity around the worksite It is desirable to utilize it as an analysis of its impact.

According to the present invention configured as described above, the upper limit and the lower limit of the allowable voltage value and the current value are set in advance by the setting knob 17 and the monitor 15 in accordance with the type of the base material 9 and the welding method , The green lamp 18b of the tower lamp 18 is turned on when the voltage value and the current value measured in the welding operation are within the predetermined range and when the voltage value and the current value are out of the predetermined range, The red light 18a of the lamp 18 is turned on and an alarm is sent out. All of these processes are dataized and transmitted to the main computer in real time and stored. Thus, even when the non-destructive inspection is not performed, The cause can be identified. At the same time, the operator's attention is frequently raised during the welding work at the worksite, thereby reducing the occurrence rate of the welding defect to the maximum, Can be improved.

In addition, the current sensor 13a is connected to the power cable 14a of the transmission mechanism 14 used for the pre-welding surface treatment of the base material 9, the post-weld finishing treatment, or the supplementary treatment during welding, The sensor cable 13 extending from the sensor 13a is further connected to the CPU 20 of the monitoring device 10 so as to determine how many times the auxiliary operation other than the welding operation has been performed It can be automatically obtained with the data on the welding operation, so that the entire working time in which the actual working is performed is divided into the welding working time and the auxiliary working time, and a more detailed and systematic work Management and process management becomes possible.

In addition, the noise due to high frequency is cut off by the surge module 22 while the arc is generated, and the static electricity blocking layer 2b is formed on the inner surface of the wall panel 2a constituting the casing of the welder main body 2 by application of the MS polymer Pressure static electricity causing another noise in the welding monitoring process can be completely blocked so that the voltage value and the current value due to the welding operation can be measured more accurately without any error, The humidity sensor 25 may be additionally applied to the monitoring device 10 to obtain a wide range of feedback data including temperature and humidity data around the work site and thereby provide more accurate and detailed analysis data, By significantly improving quality and productivity, it can contribute substantially to securing foreign competitiveness.

1: Welding machine 2: Welding machine main body 2a: Wall panel
2b: electrostatic shielding layer 3: switchboard 4: gas tank
5: Electrode cable 6: Gas hose 7: Welding torch
8: sparing material 9: base material 10: monitoring device
10a: Device table 11: Device case 11a: Door panel
12: Measurement cable 12a: Connection part 12b, 13b: Cable terminal
13: sensor cable 13a: current sensor 14: transmission mechanism
14a: Power cable 15: Monitor 16: Indicator
17: Setting knob 18: Tower lamp 18a: Red light
18b: green light 19: antenna 20: CPU
21: voltage sensing module 22: surge module 23: cable line
24: Temperature sensor 25: Humidity sensor

Claims (11)

delete A measurement cable 12 for voltage is connected to each of the electrode cables 5 extending from the welder main body 2 to the welding torch 7 and the base material 9 respectively and one of the electrode cables 5 5 are connected to a current sensor 13a provided with a sensor cable 13 and each of the measurement cables 12 is connected to a voltage sensing module 21 through a high frequency cutoff surge module 22 The voltage sensing module 21 is connected to the CPU 20 together with the sensor cable 13 of the current sensor 13a and the surge module 22 and the voltage sensing module 21 and the CPU 20 The CPU 20 is installed inside the apparatus case 11 and connected to the monitor 15 provided on the front side door panel 11a of the apparatus case 11 so that the voltage generated during the welding operation A monitoring device (10) capable of outputting a real time variation of a current in the form of a graph on a screen of a monitor (15)
A setting knob 17 for setting the upper limit and the lower limit of the voltage and the current on the monitor 15 via the CPU 20 and the setting knob 17 for setting the upper limit and the lower limit of the voltage and the current on the door 15a of the CPU 20 And a digital indicator 16 for displaying the voltage value and the current value at the time of the arithmetically operated welding work are respectively provided. A tower lamp 18 connected to the CPU 20 is provided on the outer upper surface of the device case 11, Respectively,
The tower lamp 18 lights up the green light 18b at a time point when the voltage value and the current value during the welding work calculated and processed by the CPU 20 are within the predetermined upper and lower limits, The red light 18a is turned on and the alarm is sent at the time when the current value is out of the range of the predetermined upper limit and lower limit,
The monitoring device 10 is additionally provided with a sensing means for determining whether or not the transmission mechanism 14 used for the pre-welding surface treatment, the post-welding finishing treatment, or the supplementary treatment during welding of the base material 9 is in operation, The sensing means is the sensor cable 13 of the current sensor 13a connected to the power cable 14a of the transmission mechanism 14,
The sensor cable 13 of the current sensor 13a for the transmission mechanism 14 is connected to the CPU 20 in the device case 11 together with the sensor cable 13 of the current sensor 13a for the electrode cable 5 And a digital indicator 16 for displaying the current value of the transmission mechanism 14 calculated and processed by the CPU 20 in numerical values is additionally provided on the door panel 11a of the device case 11 A welding monitoring device. The surge module according to claim 2, wherein the surge module includes a pair of input terminals (In +, In-) and output terminals (Out +, Out-) connecting the voltage measurement cable (12) A capacitor 10nF and an RC noise canceling circuit 10KOhm and 10nF are sequentially connected between the AC power supply capacitor 10nF and the RC noise reduction circuit 10KOhm, 10nF) one pole is connected to the pole ground (PE) system. The monitoring device (10) according to claim 2, wherein an electrostatic shielding layer (2b) is formed on the inner surface of the wall panel (2a) constituting the casing of the welder body (2) Is disposed close to the outer surface of the panel (2a). 3. An apparatus according to claim 2, wherein an antenna (19) for transmitting in real time to the main computer all data inputted and processed through the CPU (20) in a state connected to the CPU (20) Is installed in the welding apparatus. The humidity sensor according to claim 2, wherein a temperature sensor (24) and a humidity sensor (25) connected to the CPU (20) are provided inside or outside the device case (11) And the inputted temperature value and humidity value are displayed numerically on the screen of the monitor (15). delete delete A method for monitoring a voltage and current fluctuation occurring during a welding operation,
The power switch of the monitoring apparatus 10 is turned on and then the upper limit and lower limit of the voltage value and the current value are set to the target of the welding operation using the setting knob 17 and the monitor 15 provided in the monitoring apparatus 10. [ A setting step of setting in advance according to the type of the base material 9 that becomes the base material 9,
After the setting step, the high-frequency shielding module 22 and the high-frequency shielding module 22 are respectively connected to the measuring cable 12 connected to the electrode cable 5 extending from the welder main body 2 to the welding torch 7 and the base material 9, The voltage data of the welding operation inputted through the voltage sensing module 21 and the sensor cable 13 of the current sensor 13a connected to one electrode cable 5 of the electrode cable 5 A measuring step of calculating the current data at the time of operation by the CPU (20) of the monitoring device (10)
When the voltage value and the current value during the welding operation calculated in the measuring step are within the range of the predetermined upper limit and lower limit, the green lamp 18b of the tower lamp 18 provided in the monitoring apparatus 10 is turned on, And a monitoring step of lighting the red lamp 18a of the tower lamp 18 and sending an alarm when the voltage value and the current value are out of the range of the predetermined upper limit and lower limit,
The measuring step and the monitoring step are repeated in real time during the welding work of the base material 9, and the voltage value and the current value during the welding operation, which are calculated in the measuring step, (15) screen and a digital indicator (16), while the normal operation signal that the voltage value and the current value during the welding operation are within a predetermined range and the corresponding voltage value and current value are outputted in a predetermined range All the data input to and processed by the CPU 20 including the abnormal operation signal indicating that the mobile terminal 20 has departed from the monitoring device 10 is transmitted in real time to the main computer via the antenna 19 provided in the monitoring device 10,
A work selection step of determining whether voltage data and current data according to a welding operation are inputted by the CPU 20 is additionally applied between the setting step and the measuring step, When the data and the current data are input, the control unit proceeds to the measurement step. When the data is not inputted, the transmission mechanism detection step is performed in which the CPU 20 determines whether or not the transmission mechanism 14 is operated.
The transmission mechanism 14 is used for surface treatment before the welding of the base material 9 or post-weld finishing treatment or supplementary treatment during welding. The current sensor 13a connected to the power cable 14a of the transmission mechanism 14 The sensor cable 13 of the monitoring device 10 is connected to the CPU 20 of the monitoring device 10,
When the use of the transmission mechanism 14 is sensed in the transmission mechanism sensing step, an incidental signal is transmitted to the main computer via the antenna 19 of the monitoring device 10, while the digital indicator The current value of the transmission mechanism 14 is numerically displayed through the antenna 19 of the monitoring device 10 and the operation stop signal is transmitted to the main computer via the antenna 19 of the monitoring device 10 when the use of the transmission mechanism 14 is not detected Wherein the welding process is carried out by the welding process. The welding monitoring method according to claim 9, wherein the monitoring device (10) comprises: an electrostatic shielding layer (2b) formed by applying an MS polymer on the inner surface of a wall panel (2a) constituting a casing of the welder main body Is performed in a state in which it is not subjected to interference caused by static electricity generated from the welder main body (2). The humidity monitoring system according to claim 9, wherein the monitoring device (10) further comprises a temperature sensor (24) and a humidity sensor (25) Is displayed numerically on the screen of the monitor (15) of the monitoring device (10) while being transmitted to the main computer via the antenna (19) of the monitoring device (10).

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