KR102387653B1 - Real-time welding quality prediction system through distance measuring device - Google Patents

Abstract

The present invention relates to a real-time welding quality prediction system through a distance measuring device, and more specifically, to a system for predicting welding quality based on heat input by monitoring, in real time, the position of a welding torch through a distance measuring device composed of an accelerometer, a gyroscope and an ultra-wide band (UWB). The real-time welding quality prediction system through a distance measuring device comprises: a distance measuring device (100) including an accelerometer (12) which is provided on one side of a welding torch (500) for performing welding to measure the acceleration value of each axis of the welding torch and a gyroscope (13) which measures the direction angle (f) of the welding torch, measuring the moving distance (c) of the welding torch through the acceleration value of each axis, and calculating a welding length (d) through the measured moving distance © and the direction angle of the welding torch; a welding variable sensor part (200) including a current sensor (21) for measuring the current value of the welding process, a voltage sensor (22) for measuring the voltage value, and a temperature sensor (23) for measuring the temperature between the layers of an object to be welded; and a data analysis device (300) calculating heat input using the welding length (d) of the welding torch measured by the distance measuring device (100) and the current and voltage values measured by the welding variable sensor part (200), determining the quality suitability by comparison with a database (35), which is the suitability standard of the welding process, and storing the result. The present invention can measure the welding length and speed using an accelerometer, a gyroscope, and a UWB, and determine the welding quality within a welding route based on the analysis result of the measured values.

Description

Real-time welding quality prediction system through distance measuring device}

The present invention relates to a real-time welding quality prediction system through a distance measuring device, and more particularly, by monitoring the position of a welding torch in real time through a distance measuring device composed of an accelerometer, a gyroscope and an Ultra Wide Band (UWB) in real time. It relates to a system for predicting welding quality based on heat quantity.

In general, welding refers to a method of joining metal materials by applying heat and pressure to each other to melt the metal materials in contact with each other.

Depending on the thickness of the metal material, there are two types of welding work: thin plate welding and relatively thick thick plate welding, depending on the thickness of the metal material. However, in shipbuilding, heavy industry, and construction sites where relatively thick thick plates are used as a material, it is difficult to connect with only one pass, so multi-layer welding, which welds the same welded parts in stages, is usually used. will be performed

In addition, there are various variables in the welding process, for example, the material of the welding object, the material of the welding rod, the amount of heat input expressed by voltage, current, and speed, the position of the welding, the stage of pass welding, and the skill of the operator are representative. The quality of the heat input of the process is closely related to safety.

Specifically, the factors affecting the heat input are welding voltage, current, and speed. The welding heat input is proportional to the product of voltage and current and inversely proportional to the speed. The welding speed is the length of the welding rod consumed per unit time. As soon as possible, the heat input of welding is reduced.

Welding defects that can appear when the welding heat input is excessive include melt melting, under-cut, welding strength and the impact value of the weld metal. There are welding cracks due to speed.

As a specific example, it has been frequently investigated that the cause of sudden destruction in ships, ship equipment and offshore structures is a welding defect, and it has been found that there are cases in which poor welding in important parts of the structure causes the collapse of the entire structure, Defects were mainly caused by factors during the welding process.

Therefore, in order to minimize welding defects, real-time monitoring of process management according to the type of work, systematic data management, and a quality monitoring system for welding quality evaluation are essential, but various types of base materials, locations of various types of welds, and large structures such as scrubs When internal welding has a narrow space and a complex structure, manual welding tends to be used rather than automatic configuration through a machine.

However, the conventional manual welding cannot measure the factors affecting the amount of heat input, and it is difficult to evaluate the welding quality during operation because the welding quality can be evaluated after the welding process is finished. There was a problem in that it was difficult to confirm the stage of the pass.

In order to solve the problem of welding quality evaluation of manual welding, Republic of Korea Patent Publication No. 10-1643187 “Real-time arc welding monitoring and evaluation device” measures, collects and stores welding current or arc voltage data over time. Although the technology for doing has been announced,

In measuring the heat input, which is a major variable of welding quality, there is no information on the welding distance, so the measurement of heat input is inaccurate.

In addition, the Republic of Korea Patent Publication No. 10-0561087 “monitoring device for arc welding” provides an appropriate quality determination value expressed in pre-entered welding current, welding voltage, wire supply speed, and rising voltage value and an appropriate value measured in real time during welding. Although the technology for real-time evaluation, management, and monitoring by comparing quality discrimination values has been announced,

Because it is difficult to apply the welding distance required for heat input calculation to the appropriate quality determination value entered in advance due to the variety of the type of base material and the weld zone, and the irregular welding time and distance, the method of measuring the welding distance in real time for proper quality determination is needed

Therefore, there is a need for a real-time welding quality prediction system through a distance measuring device capable of obtaining and monitoring major welding variables in real time for proper quality determination as well as measuring the three-dimensional welding distance information of the welding area for calculating the amount of heat input.

Republic of Korea Patent Publication No. 10-1643187 (2016.07.21.) Republic of Korea Patent Publication No. 10-0561087 (2006.03.08.)

The present invention was created to solve the above problems, and an object of the present invention is to measure the welding length and speed by using an accelerometer, a gyrometer, and a UWB provided in a welding torch, and perform welding as a result of analyzing the measured values. It is possible to provide a real-time welding quality prediction system through a distance measuring device through monitoring of a welding torch position variable that can determine the welding quality in the path.

Objects of the present invention are not limited to the objects mentioned above, and other objects not mentioned will be clearly understood by those of ordinary skill in the art from the following description.

In order to achieve the above object, an accelerometer 12 provided on one side of the welding torch 500 for performing welding to measure an acceleration value of each axis of the welding torch and a gyrometer for measuring the direction angle f of the welding torch ( 13), and measuring the moving distance (c) of the welding torch through the acceleration value of each axis, and calculating the welding length (d) through the measured moving distance (c) and the direction angle of the welding torch a distance measuring device 100; Welding variable sensor unit 200 including a current sensor 21 for measuring the current value of the welding process, a voltage sensor 22 for measuring the voltage value, and a temperature sensor 23 for measuring the interlayer temperature of the welding object ; and calculating the amount of heat input from the welding length (d) of the welding torch measured by the distance measuring device 100 and the current and voltage values measured by the welding variable sensor unit 200, and the suitability standard for the welding process It is possible to provide a real-time welding quality prediction system through a distance measuring device, characterized in that it includes; a data analysis device 300 for determining the quality suitability by comparison with the database 35 and storing the result.

At this time, the distance measuring device 100 measures the direction angle f that is the inclination degree of the welding torch 500 using the gyrometer 13 , and the length of the welding torch 500 and the Measuring the position of the end of the welding torch 500 according to the direction angle f, and applying the measured end of the welding torch 500 to the moving distance c of the welding torch 500, the welding It is characterized by measuring the welding length (d) to be welded at the end of the torch (500).

In addition, the distance measuring device 100 includes a UWB 14, and the UWB 14 periodically measures a straight line distance between the UWB anchor 50 located outside the distance measuring device 100, and the UWB A linear distance (a) between the UWB anchor 50 and the distance measuring device 100a before moving around the anchor 50 and a linear distance between the UWB anchor 50 and the distance measuring device 100b after moving (b) and the value measured by the moving distance (c) of the welding torch, and the UWVB anchor 50, the distance measuring device 100a before moving, and the distance measuring device 100b after moving through the inner angle g of the triangle A trajectory is calculated through the moving direction of the welding torch 500 , and the calculated trajectory is used to correct the position of the welding torch 500 in real time.

And, the welding process includes a welding process step according to the type of work, and the data analysis device 300 applies the welding process suitability standard corresponding to the welding process step to the database 35, a monitor for outputting one or more of the welding process step and the current value, the voltage value, the heat input, and the quality suitability judgment result, and stores the result of the quality suitability judgment in the database 35, and the quality When the suitability determination result is suitable, the success criteria for the next welding process are applied to the database 35 .

In addition, a control signal is received from the remote control device 60 located outside the data analysis device 300 so as to control the data analysis device 300 , and the result of quality suitability judgment for the welding process is described above. It is characterized in that it comprises a communication unit for transmitting to the user device 400 located outside the data analysis apparatus (300).

The present invention uses an accelerometer, a gyrometer, and a UWB provided in a welding torch to measure the welding length and speed, and as a result of analyzing the measured values, real-time welding through a distance measuring device that can determine the welding quality in the welding path It has the effect of providing a quality prediction system.

1 is a block diagram of the configuration of a monitoring system according to the present invention.
2 is a schematic diagram of a welding length measurement method according to the present invention.
3 is a schematic diagram of a position correction method through UWB according to the present invention.
4 is a block diagram of heat input measurement of the data analysis apparatus according to the present invention.
5 is a block diagram illustrating a monitoring flowchart according to the present invention.
6A is an example of data output and non-conformity determination of the display unit according to the present invention.
6B is an example of data output and conformity determination of the display unit according to the present invention.
6C is another example of data output by the display unit according to the present invention.

Advantages and features of the present invention, and a method of achieving them, will become apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in a variety of different forms, and only these embodiments allow the disclosure of the present invention to be complete, and common knowledge in the technical field to which the present invention belongs It is provided to fully inform the possessor of the scope of the invention, and the present invention is only defined by the scope of the claims.

With reference to the accompanying drawings will be described in detail for the implementation of the present invention. Irrespective of the drawings, like reference numbers refer to like elements, and "and/or" includes each and every combination of one or more of the recited items.

Although the first, second, etc. are used to describe various elements, these elements are not limited by these terms, of course. These terms are only used to distinguish one component from another. Accordingly, it goes without saying that the first component mentioned below may be the second component within the spirit of the present invention.

The terminology used herein is for the purpose of describing the embodiments, and is not intended to limit the present invention. In this specification, the singular also includes the plural unless specifically stated otherwise in the phrase. As used herein, “comprises” and/or “comprising” does not exclude the presence or addition of one or more other components in addition to the stated components.

Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used with the meaning commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, terms defined in a commonly used dictionary are not to be interpreted ideally or excessively unless clearly defined in particular.

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

An important aspect of the present invention is to measure the welding length and speed using an accelerometer, a gyrometer, and a UWB provided in the welding torch, and a welding torch position variable that can determine the welding quality in the welding path as a result of analyzing the measured values A method for providing a welding process management and quality prediction system through monitoring is presented.

1 is a block diagram of the configuration of a monitoring system according to the present invention.

As shown, an accelerometer 12 provided on one side of a welding torch 500 for performing a welding process to measure an acceleration value of each axis of the welding torch and a gyrometer 13 for measuring the direction angle f of the welding torch ), and measuring the moving distance (c) of the welding torch through the acceleration value of each axis, and calculating the welding length (d) through the measured moving distance (c) and the direction angle of the welding torch The distance measuring device 100 transmits the measured data to the communication unit 33 of the data analysis device 300 , and may turn the device on/off according to the needs of the operator through the power supply unit 11 .

And, a welding variable sensor unit 200 including a current sensor 21 for measuring the current value of the welding process, a voltage sensor 22 for measuring the voltage value, and a temperature sensor 23 for measuring the temperature between the layers of the welding object ) transmits the data measured during the welding process to the communication unit 33 .

In addition, the amount of heat input is calculated using the data measured during the welding process through the calculation unit 32, and the calculated heat input value is stored in advance by the manager of the operation according to the type of the process. ) to check whether the quality is suitable, and the result value is stored in the database 35 and displayed on the display unit 31 so that the operator can check it. do.

Data stored in the database 35 is a user device 400 using a storage medium such as a worker's mobile device, PC, memory card, hard disk, etc. located outside the data analysis apparatus 300 through the communication unit 33 and It is possible to receive data by being connected, it is possible to store quality standards in the database 35 , and a remote control device 60 capable of operating the data analysis device 300 by receiving a control signal is also available.

2 is a schematic diagram of a welding length measurement method according to the present invention.

As shown, as the welding torch 500 moves during the welding process, the distance measuring device 100 moves and the path is measured by the welding torch movement distance (c), and based on the welding torch movement distance (c). It becomes possible to predict the welding length (d).

However, since the environment of the welding site is not an environment suitable for attaching the sensor, the distance is different as much as the length of the torch, and the welding angle f of the welding torch 500 that performs the welding operation is the welding surface of the welding object. Because it is not constant due to various external factors such as (e) and working posture, the welding angle (f) of the welding torch is measured with an accelerometer (12) in order to measure the welding length (d) through the welding torch movement distance (c). corrected through

The position of the distance measuring device 100 is displayed as an acceleration vector in the absolute coordinate system through the accelerometer 12, the position is calculated by double integration, and the angle is measured through the gyrometer 13 at the calculated position, By applying the torch length for the welding process, it is possible to know the end position of the welding torch.

Accordingly, since the end of the welding torch 500 is the welding surface e due to the characteristics of the welding process, the welding length d can be measured through the distance measuring device 100 .

3 is a schematic diagram of a position correction method through UWB.

As shown, the UWB anchor 50 can be installed at a fixed position outside the distance measuring device 100 , and can communicate with the UWB 14 included in the distance measuring device 100 through the wired/wireless communication unit 10 . The distance between the UWB anchor 50 and the distance measuring device position 100a before movement is measured as a, and the distance between the UWB anchor 50 and the distance measuring device position 100b after the movement is measured as b. A triangle formed through the moved distance c measured by the device 100 is created on the absolute coordinate system.

The generated triangle uses the law of cosines to obtain the interior angle of a triangle when the lengths of the three sides are known to calculate the included angle (g). It can be used to estimate the movement trajectory of welding because the distance moved by the in-between angle (g) per unit time is known by calculating the transmission period as a minute time.

Utilizing the characteristic that the welding direction is constant for each process, that is, welding such as circular welding and straight welding has a fixed angle and movement distance depending on the welding process, and the change is monotonous, the accelerometer and gyroscope This is a method of reducing the error of the movement distance c of the torch by correcting the position of the distance measuring device 100 based on the movement trajectory estimated by using UWB to the position measured through .

4 is a block diagram of a heat input amount measurement of an operation unit according to the present invention.

로 나타낼 수 있다.As shown, the amount of heat input is calculated using the welding length d measured by the distance measuring device 100 and the current value and voltage value data measured by the welding variable sensor unit 200, and the welding quality determination standard is The amount of heat input is defined as the amount of heat given from the outside of the weld, and is defined as the electric energy provided to the weld per 1 cm of unit length. ), current I(A, Ampere), welding time and welding length (d) through the distance measuring device 100, when the welding speed calculated through v(cm/min)

can be expressed as

5 is a block diagram illustrating a monitoring flowchart according to the present invention.

As shown, welding data of one or more of the welding length and welding trajectory of the object to be welded according to the type of welding operation, data measurement unit period, average and maximum/minimum value of heat input, current value, voltage value, interlayer temperature, and welding process step Step (S10) for storing welding quality standards by inputting the welding operation information including and storing it in the database 35;

Measuring a welding start time based on the time when welding is started and current is supplied to the welding object (S20);

Measuring data for comparison with the welding quality standard stored in the database 35 through the distance measuring device 100 and the welding sensor unit 200 and storing the data in the database 35 (S30);

The data measured through the welding sensor unit 200 and the amount of heat input calculated through the calculation unit 32 are stored in the database 35 and compared with the welding quality standards stored in the database 35 to determine whether the welding quality is suitable or not. to save the result and output the result of determining whether the welding quality is suitable or not to the display unit 31 in real time, but output a warning to the display unit 31 so that the operator can know when the welding quality is unsuitable to supplement the work. assisting to do so (S40);

Measure the completion time of welding based on the point in time when welding is stopped and no current is supplied to the object to be welded, and compare the welding length (d) measured until the completion time through the distance measuring device 100 with the welding length based on welding quality and outputting the determination result to the display unit 31, but outputting a notification to the display unit 31 so that the operator can know when the welding quality is judged unsuitable to assist in supplementing the work (S50);

The final stage of the welding process step is detected to determine the completion of the welding process, and when a subsequent welding process step remains, the subsequent welding process step is output to the display unit 31, and the quality standard data for the subsequent welding process step is is applied to the database 35, and when the welding process step satisfies the last step, outputting the welding process completion to the display unit 31 (S60);

When the welding process of the welding object is completed, the welding data measured based on the welding process start time and the completion time is stored in the database 35 and transmitted to the user device through the communication unit 33 (S70); distance through A real-time welding quality prediction system is made through the measuring device.

6A to 6C are examples of data output and conformity determination of the display unit and other examples of data output according to the present invention.

As shown, the welding data is displayed as a graph over time, and the user can set the main measurement variable to immediately respond to the main variable.

Although embodiments of the present invention have been described with reference to the above and the accompanying drawings, those of ordinary skill in the art to which the present invention pertains can practice the present invention in other specific forms without changing its technical spirit or essential features. You will understand that there is Therefore, it should be understood that the embodiments described above are illustrative in all respects and not restrictive.

10: Wired and wireless communication department
11: power supply
12 : Accelerometer
13: gyroscope
14: UWB
21: current sensor
22: voltage sensor
23: temperature sensor
31: display unit
32: arithmetic unit
33: communication department
34: power supply
35: database
50: UWB anchor
60: remote control device
a : Distance between UWB anchor and distance measuring device before moving
b : Distance between UWB anchor and distance measuring device after movement
c : moving distance of welding torch
d: welding length
e: weld face
f : direction angle of welding torch
g: Cabinet
100: distance measuring device
200: welding variable sensor unit
300: data analysis device
400: user device
500: welding torch

Claims (5)

It is provided on one side of the welding torch 500 for performing the welding process and includes an accelerometer 12 for measuring the acceleration value of each axis of the welding torch and a gyrometer 13 for measuring the direction angle f of the welding torch, Distance measuring device 100 for measuring the moving distance c of the welding torch through the acceleration value of each axis, and calculating the welding length d through the measured moving distance c and the direction angle of the welding torch );
Welding variable sensor unit 200 including a current sensor 21 for measuring the current value of the welding process, a voltage sensor 22 for measuring the voltage value, and a temperature sensor 23 for measuring the temperature between the layers of the welding object ; and
The amount of heat input is calculated using the welding length (d) of the welding torch measured by the distance measuring device 100 and the current and voltage values measured by the welding variable sensor unit 200, and the suitability standard for the welding process is and a data analysis device 300 that compares the database 35 to determine the quality suitability and stores the result.
The distance measuring device 100,
Using the gyrometer 13, the direction angle f, which is the inclination degree of the welding torch 500, is measured, and the welding torch according to the length of the welding torch 500 and the direction angle f. 500), the measured end of the welding torch 500 is applied to the moving distance c of the welding torch 500, and the welding length to be welded at the end of the welding torch 500 (d) Real-time welding quality prediction system through a distance measuring device, characterized in that for measuring. delete The method of claim 1,
The distance measuring device 100 includes a UWB 14,
The UWB 14 periodically measures the linear distance between the UWB anchor 50 located outside the distance measuring device 100,
A linear distance (a) between the UWB anchor 50 and the distance measuring device 100a before moving around the UWB anchor 50, and a linear distance between the UWB anchor 50 and the distance measuring device 100b after moving. (b), the moving distance (c) of the welding torch, the UWB anchor 50 and the distance measuring device 100a before and after moving the UWB anchor 50 using the interior angle (g) of the triangle formed by the distance measuring device 100b Calculate the trajectory through the moving direction of the welding torch 500,
A real-time welding quality prediction system through a distance measuring device, characterized in that the calculated trajectory is used to correct the position of the real-time welding torch (500). The method of claim 1,
The welding process includes a welding process step according to the type of welding operation,
The data analysis device 300 applies the suitability criteria of the welding process corresponding to the welding process step to the database 35,
a monitor for outputting one or more of the welding process step and the current value, the voltage value, the heat input amount, and the quality suitability determination result;
The result of the quality suitability judgment is stored in the database 35, and when the quality suitability judgment result is suitable, the suitability standard for the next step welding process is applied to the database 35 through a distance measuring device. Real-time welding quality prediction system. The method of claim 1,
The data analysis device 300,
Receives a control signal from the remote control device 60 located outside the data analysis device 300 so as to control the data analysis device 300, and analyzes the data analysis result of the quality suitability judgment for the welding process Real-time welding quality prediction system through a distance measuring device, characterized in that it comprises a communication unit for transmitting to the user device (400) located outside the apparatus (300).

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