KR102594693B1 - Feeder control system - Google Patents

Abstract

The present invention relates to a feeder control system, which performs supply of welding wire, voltage supply, current supply, and gas supply to perform electric welding. The feeder control system includes power supply status, wire supply speed, and supply voltage amount. , a status display unit that displays status information including supply current amount, gas supply amount, remaining gas amount value, whether the welding holder is activated, and connection status with a preset user terminal, and is provided at a preset location to monitor temperature, harmful gas concentration, oxygen concentration, and noise. A sensor unit that senses environmental information including size, humidity, and dust amount, and the status display unit and information collected from the sensor unit are used to determine the status of the feeder control system and the welding performance environment and determine the user's welding stability. It is characterized by comprising a monitoring unit and a control unit that controls the amount of voltage, current, gas, and welding wire supplied by the feeder control system in response to the signal received from the monitoring unit.

Description

Feeder control system{FEEDER CONTROL SYSTEM}

The present invention relates to a method of controlling a welding feeder, and more specifically, to a feeder control system that automatically supplies welding wire and supplies it by constantly adjusting set voltage, current, and gas output during welding.

A welding machine for welding generally generates an electric arc by passing a certain voltage and current between the welding rod and the base material to be welded, and at the same time ejects carbon dioxide (CO ₂ ) through a gas nozzle provided at the tip of the welding torch to purify the air around the object to be welded. The most commonly performed welding method is welding to prevent oxidation and nitridation of the weld area by blocking it.

In the above welding method, partial welding is generally performed using a welding rod, but when the object to be welded is large and only a welding rod is used, the welding length that the welding rod can perform is shorter than the required welding length, so the welding rod must be replaced. If welding cannot be continued and welding is not done with care after replacing the welding rod, a weak part may remain. Therefore, if the welding area or welding length of the object to be welded is long, it is ideal to perform welding using a welding wire that can perform continuous welding. am.

To realize this, the welder can perform continuous welding without the burden of supplying welding materials through a feeder that uses rollers to supply welding wire to the welder at a constant speed.

However, if the voltage, current, and carbon dioxide supply required for welding are not within a certain range, welding is not performed properly and there are risks that may lead to safety accidents.

In addition, even if the welding feeder operates safely, the environment in which welding is performed is often underground or in a closed environment rather than outside, so many welders are defenseless against environmental accidents such as suffocation or toxic gas poisoning rather than welding-related accidents. It is exposed,

Therefore, research is required on a feeder control system that senses surrounding environment information in addition to stable supply of welding wire, voltage, current, and gas, and can be wirelessly connected to the user's terminal and controlled remotely.

Korean Patent No. 10-1467205

The purpose of the present invention is to provide convenience for the welder's continuous welding work by supplying welding wire at a constant speed and voltage, current, and gas at constant values to the welder.

In addition, the purpose is to ensure the stability of the environment in which welding is performed by sensing environmental information such as temperature, humidity, dust amount, harmful gas concentration, and oxygen concentration in the feeder.

In addition, the purpose is to prevent safety accidents and the spread of safety accidents caused by the feeder by controlling the operation of the feeder control system according to the status information of the feeder and the environmental information of the point where the feeder is located.

In addition, by classifying the welding stability of the user who performed welding after connecting to the preset user terminal, the limit on working time according to the user's welding stability and the data at the time when the 3-axis changes in voltage, current, and welding holder are large are calculated. The purpose is to improve the user's welding stability.

The feeder control system according to an embodiment of the present invention performs supply of welding wire, voltage supply, current supply, and gas supply to perform welding. The feeder control system includes power supply status, wire supply speed, and supply. A status display unit that displays status information including voltage amount, supply current amount, gas supply amount, remaining gas amount value, whether the welding holder is activated, and connection status with a preset user terminal. It is provided at a preset location and displays temperature, harmful gas concentration, and oxygen concentration. , a sensor unit that senses environmental information including noise level, humidity, and dust amount, the status display unit, and information collected from the sensor unit is used to determine the status of the feeder control system and the welding performance environment and determine the user's welding stability. It may include a monitoring unit that determines and a control unit that controls the amount of voltage, current, gas, and welding wire supplied by the feeder control system in response to the signal received from the monitoring unit.

In addition, the status display unit includes a user terminal connection unit that collects connection status information and whether the connection between the feeder control system and the preset user terminal is approved, a rotation detection sensor and a welding wire detection sensor on the roller that supplies the welding wire. A supply status collector that senses the rotation speed of the roller and the presence of the welding wire for a preset time, a voltage current supply status collector that collects the amount of current and voltage supplied in response to a signal from the welding holder, and a gas supply. It may include a gas supply status collection unit that receives remaining gas amount data and supplied gas amount data from the device, and a status information transmission unit that transmits the status information to the preset user terminal, the screen of the feeder control system, and the monitoring unit. .

In addition, the supply status collection unit uses an infrared sensor that senses the presence of the welding wire between the rollers and a rotation speed sensor provided on the rotation axis of the roller to measure the length of the supplied welding wire, the length of the remaining welding wire, and Calculate the amount of welding wire consumed during a preset time, and if the status information is outside the preset allowable range, the status information transmitter transmits a signal requesting temporary suspension of the entire operation of the feeder control system to the control unit. And, a work stoppage notification can be transmitted to the preset user terminal.

In addition, the monitoring unit calculates a welding stability value (W _s ) to determine the user's welding stability according to the following [Equation 1],

[Equation 1]

(Here, t _w·f is the wire supply time, M _t is the thickness of the welding base material, H _v is the 3-axis change weight of the welding holder, W _t is the wire thickness, t _t·w is the total welding time, and α- _v is the voltage Change weight, α _I means current change weight)

In response to the calculated welding stability value (W _s ), it can be divided into 6 levels of welding stability and transmitted to the preset user terminal.

In addition, the monitoring unit classifies the welding stability of the user who performed welding for a preset time, and provides recommended work time, maximum workable time, and hourly voltage and current to the preset user terminal in response to the classified welding stability. The change amount and the 3-axis position change amount of the welding holder by time are transmitted, and if the user exceeds the maximum workable time, a command to stop operation of the feeder control system can be sent to the control unit.

According to the present invention, convenience can be provided for the welder's continuous welding work by supplying welding wire at a constant speed and supplying voltage, current, and gas at constant values to the welder.

In addition, by sensing environmental information such as temperature, humidity, dust amount, harmful gas concentration, and oxygen concentration in the feeder, the stability of the environment in which welding is performed can be secured.

In addition, by controlling the operation of the feeder control system according to the status information of the feeder and the environmental information of the point where the feeder is located, it is possible to prevent safety accidents and the spread of safety accidents caused by the feeder.

In addition, by classifying the welding stability of the user who performed welding after connecting to the preset user terminal, the limit on working time according to the user's welding stability and the data at the time when the 3-axis changes in voltage, current, and welding holder are large are calculated. The user's welding stability can be improved.

Figure 1 is a block diagram of a feeder control system according to an embodiment of the present invention.
Figure 2 is a diagram showing an intermediate block diagram of a feeder control system according to an embodiment of the present invention.

Specific details, including the problem to be solved by the present invention, the means for solving the problem, and the effect of the invention, are included in the examples and drawings described below. The advantages and features of the present invention and methods for achieving them will become clear by referring to the embodiments described in detail below along with the accompanying drawings.

The scope of the present invention is not limited to the embodiments described below, and various modifications can be made by those skilled in the art without departing from the technical gist of the present invention.

Hereinafter, the feeder control system of the present invention will be described in detail with reference to the attached FIGS. 1 and 2.

First, Figure 1 is a diagram showing a block diagram of a feeder control system according to an embodiment of the present invention, and Figure 2 is a diagram showing an intermediate block diagram of a feeder control system according to an embodiment of the present invention. .

Referring to FIG. 1, the feeder control system according to an embodiment of the present invention may include a status display unit 110, a sensor unit 120, a monitoring unit 130, and a control unit 140.

The feeder control system 100 of the present invention can supply welding wire at a constant speed and supply voltage, current, and gas at preset values to perform welding.

The status display unit 110 displays status information including power supply status, wire feeding speed, supply voltage amount, supply current amount, gas supply amount, remaining gas amount value, whether the welding holder is activated, and connection status with a preset user terminal. can do.

Here, whether or not the welding holder is activated is determined by using a grip-type button that transmits a gas supply signal, a feeder operation signal, and a current and voltage supply signal when the user performs welding provided on the welding holder or torch. This may mean whether operations for transmitting wire supply and gas supply signals are performed.

In addition, the preset user terminal may mean a PC, laptop, smartphone, tablet PC, etc. capable of wired or wireless communication, and is connected to the feeder control system 100 to perform tasks and receive notifications and send and receive data. Therefore, the most ideal terminal for the user may be a smartphone or tablet PC.

Meanwhile, the power supply status refers to whether the power supply status of the battery in the feeder control system 100 is receiving power from an external power source or an internal battery, and whether power is supplied using the internal battery. When running, it may mean the current remaining battery percentage and power supply time status.

In addition, the remaining gas amount value is calculated by converting the remaining gas amount value in the gas supply device connected to the feeder control system 100 into data and transmitting the remaining gas amount value when a module compatible with the feeder control system 100 exists. Numerical values may be received and displayed on the status display unit 110 and a preset user terminal.

In addition, the remaining gas amount value is compatible with the feeder control system 100 in the gas supply device connected to the feeder control system 100, and if there is a module that converts the remaining gas amount value into data, the dataized remaining gas amount is received. This can be transmitted to the status display unit 110 and a preset user terminal.

Meanwhile, the status display unit 110 will be described in more detail with reference to FIG. 2.

Referring to FIG. 2, the status display unit 110 includes a user terminal connection unit 111, a supply status collection unit 112, a voltage and current supply status collection unit 113, a gas supply status collection unit 114, and status information. It may include a transmitter 115.

The user terminal connection unit 111 may collect connection status information and whether connection is approved between the feeder control system 100 and a preset user terminal.

Here, the user terminal connection unit 111 is connected using wired or wireless communication when first connected to a preset user terminal, but connecting using Bluetooth, a type of wireless communication, may be the most ideal connection for welding work. there is.

In addition, the user terminal connection unit 111 becomes the subject of the communication connection and activates a screen window on the screen outside the feeder control system 100 to ask whether to approve the connection of other user terminals, including the preset user terminal, to select the user. Accordingly, approval or rejection of a communication connection with a preset user terminal or another user terminal may be performed.

The supply status collection unit 112 may provide a rotation detection sensor and a welding wire detection sensor on the roller that supplies the welding wire to sense the rotation speed of the roller and the presence of the welding wire for a preset time.

Here, the supply status collection unit 112 supplies the roller in response to the rotation speed of the roller sensed by an infrared sensor that senses the presence of a welding wire between the rollers and a rotation speed measurement sensor provided on the rotation axis of the roller. The length of the welding wire, the length of the remaining welding wire, and the amount of welding wire consumed during a preset time can be calculated.

Here, the preset time refers to the time range for the user to calculate the amount of welding wire consumption, and the amount of welding wire consumed during the user's welding time is the amount of the roller measured for a preset time around the circumference of the welding wire cross section. It can be calculated by multiplying the number of revolutions.

In addition, the length of the remaining welding wire can be calculated from the total length of the initial welding wire input by the user into the feeder control system 100 through the difference in the length of the total supplied welding wire according to the total number of rotations of the roller. .

The voltage and current supply status collection unit 113 can collect the amount of current and voltage supplied in response to the signal from the welding holder.

More specifically, it may mean collecting the amount of current and voltage supplied from the feeder control system 100 according to the welding holder activation signal for performing welding in the welding holder.

Here, the amount of current and voltage supplied from the feeder control system 100 may be supplied based on the amount of current and voltage preset by the user.

The gas supply status collection unit 114 may receive remaining gas amount data and supplied gas amount data from the gas supply device.

Here, in the case of an electronic gas supply device including a module that measures the remaining gas amount and output gas amount in the gas storage device connected to the feeder control system 100 and converts it into data, the feeder control system 100 and the wired or Remaining gas data and supplied gas amount can be received from a preset user terminal through a wireless communication connection.

In addition, gas supply through the feeder control system 100 is performed only when the welding holder is activated, and the feeder is controlled so that gas is not supplied to the outside when the user does not confirm gas use. Gas safety accidents can be prevented by setting the default value of the gas supply module that supplies gas to the welding holder in the system 100 to the locked state.

The status information transmitting unit 115 may transmit status information to a preset user terminal, the screen of the feeder control system 100, and the monitoring unit 130.

More specifically, the status information transmitting unit 115 determines whether the feeder control system 100 is powered, which is the status information collected by the status display unit 110, the current available power amount (battery amount) status, and the welding wire. Presence or absence, welding wire supply speed, supply voltage amount, supply current amount, supply gas amount, remaining gas amount, whether the welding holder is activated, connection status between the preset user terminal and the feeder control system 100 is monitored by the preset user terminal and the above. It can be transmitted to unit 130.

Here, when the status information is outside the preset allowable range, the status information transmitter 115 transmits a signal requesting temporary suspension of the entire operation of the feeder control system 100 to the control unit 140, and A stop notification can be sent to a preset user terminal.

At this time, the preset allowable range of the status information, the allowable range of the power supply state means when the remaining power is 10% or more, and the allowable range of the welding wire supply speed is 1 to 16 m/min (m per minute) ), the allowable range of the supply voltage or current amount is within an error range of ±70% based on the voltage or current set by the user, the allowable range of the gas supply amount is a supply amount within 5 to 50 l/min, and the remaining gas amount is allowed. The range value is 50l or more, and the range in which the communication response rate is 200ms or less when connected to a preset user terminal is set as the allowable range, and the allowable range of individual items is set according to the type of welding wire or welding environment by the feeder control system (100 ) Alternatively, the setting value of the allowable range can be changed using a preset user terminal connected to communication with the feeder control system 100.

The sensor unit 120 is provided at a preset location outside the feeder control system 100 and can sense environmental information including temperature, harmful gas concentration, oxygen concentration, noise level, humidity, and dust amount.

Here, the sensor unit 120 is provided at the top or inner central location of the feeder control system 100 and can sense external environmental information.

In addition, the sensed environmental information is transmitted to the monitoring unit 130, and the environmental information on the current user's work is received through the feeder control system 100 or a preset user terminal connected to the feeder control system 100. You can check it.

The monitoring unit 130 uses the information collected from the status display unit 110 and the sensor unit 120 to determine the status and welding performance environment of the feeder control system 100 and determine the user's welding stability. You can.

More specifically, the monitoring unit 130 receives and monitors the status information and environmental information collected by the status display unit 110 and the sensor unit 120, and the status information and environmental information are preset and allowable. If the range is exceeded, a signal to stop operation of the feeder control system 100 may be transmitted to the control unit 140.

In addition, the monitoring unit 130 can calculate a welding stability value (W _s ) to determine the user's welding stability according to the following [Equation 1].

[Equation 1]

(Here, t _w·f is the wire supply time, M _t is the thickness of the welding base material, H _v is the 3-axis change weight of the welding holder, W _t is the wire thickness, t _t·w is the total welding time, and α- _v is the voltage Change weight, α _I means current change weight)

Here, the total welding time (t _t·w ) starts from the moment the welding operation is started through the user's preset terminal after the power supply of the feeder control system 100 and the user's preset terminal are connected and ends. It means the time until the point of performance, and the wire supply time (t _w·f ) is the total rotation time of the roller among the total welding time (t _t·w ), the time when the welding wire is supplied and welding is performed. It can be judged as follows.

In addition, the welding base material thickness (M _t ) and the wire thickness (W _t ) can be input directly by the user into the feeder control system 100 or input numerical values through a connected preset user terminal.

At this time, it can be used by connecting a thickness gauge that digitally measures the weld base material thickness (M _t ) to the external connector of the feeder control system 100 and immediately transmits the measured value to the feeder control system 100.

In addition, in the case of the wire thickness (W _t ), a thickness measuring sensor is provided at a location where the welding wire passes, the welding wire thickness is measured through the sensor, and the measured value is sent to the feeder control system 100 in real time. You can receive it.

Meanwhile, the voltage change weight (α- _v ) and the current change weight (α _I ) are the actual voltage supplied when the target supply voltage and supply current set by the user activate the welding holder of the feeder control system 100. The amount of change in quantity and current can be measured, the measured change amount can be automatically calculated as a ratio, and the change weight can be assigned according to [Table 1] below.

[Table 1]

In addition, the 3-axis change weight (H _v ) of the welding holder is weighted according to the change rate of the 3-axis sensor provided inside the welding holder, and the change amount of the 3-axis sensor is calculated from the time when welding performance in the welding holder is activated. By detecting, the 3-axis change weight (H _v ) can be assigned according to [Table 2] below.

[Table 2]

_{Here , β _}

For example, when welding begins and the user activates the welding holder to supply welding wire, gas supply, voltage supply, and current supply, the value of the 3-axis sensor is (10, 11, 13), and the welding holder is activated. If the x-axis change up to the end of the event is up to +17% (11.7), the y-axis change is up to -5% (10.5), and the z-axis change is up to +30% (16.9), the weight for each axis is β _x =1.5, β _y =1, β _z =10, and the 3-axis change weight (H _v ) can be calculated as 15 (1.5*1*10=15).

Here, the maximum amount of change for each axis means an absolute value. For example, if the x-axis change occurs from -25% to +19%, the maximum amount of change in the x-axis may be -25%.

Meanwhile, the voltage change weight (α- _v ), the current change weight (α _I ), and the 3-axis change weight (H _v ) are applied regardless of the number of times the user activates the welding holder to perform welding. Weights can be assigned based on the amount of change with the largest absolute value.

Through the above process, the feeder control system 100 calculates the welding stability value (W _s ) calculated according to [Equation 1] from the time the user performs welding holder activation, and the calculated In response to the welding stability value (W _s ), six levels of welding stability can be classified according to Table 3 below and transmitted to the feeder control system 100 and a preset user terminal.

[Table 3]

Here, the monitoring unit 130 operates the feeder control system 100 in the control unit 140 when the user activates the welding holder by exceeding the maximum workable time provided according to the user's welding stability. You can stop a task by sending a stop command.

In addition, it is possible to improve the user's welding stability by managing work time according to the user's welding stability as classified and providing voltage, current, and 3-axis position change amount during welding to a preset user terminal.

In this way, the monitoring unit 130 calculates the welding stability value of the user who performed welding for a preset time through [Equation 1], and then classifies the welding stability according to [Table 3]. In response to the user's welding stability, the recommended work time, maximum workable time, voltage and current change by time, and 3-axis position change of the welding holder by time can be transmitted to the preset user terminal.

The control unit 140 may control the amount of voltage, current, gas, and welding wire supplied by the feeder control system 100 in response to the signal received from the monitoring unit 130.

In addition, when an overall operation pause or stop signal received from the status display unit 110 and the monitoring unit 130 is received, the entire operation of the feeder control system 100 can be stopped within a time set by the user. .

Here, the time set by the user can be set from a minimum of 3 seconds to a maximum of 5 minutes, and since it is related to stopping, the initial value is set to 30 seconds, and it is ideal to set it to a time of less than 2 minutes.

In addition, when receiving an immediate stop signal from the preset user terminal or a stop signal input through an emergency stop button provided in the feeder control system 100, the control unit 140 does not apply the time set by the user. All operations within the feeder control system 100 and the operations of voltage, current, and gas supply can be stopped immediately.

Through the above process, the feeder control system supplies welding wire, voltage, current, and gas supply to the welding holder at a constant speed, and provides status information of the feeder control system 100 supplied in real time to the user's preference. You can receive by connecting to a set terminal. In addition, the sensor unit 120 is provided outside the feeder control system 100 to sense environmental information in the environment where the feeder control system is currently located, so that the user can check whether the environment is safe to perform welding work. Here, after the preset user terminal and the feeder control system 100 are connected, the welding stability is determined using the welding history information performed by the user, and the working time is limited and normal to the preset user terminal according to the user's welding stability. By providing 3-axis change data of voltage, current, and welding holder when it is out of range or has a large change, it can improve the user's welding stability and encourage safe welding work by eliminating unreasonable work. In addition, if any of the status information or environmental information data received from the monitoring unit 130 exceeds the normal range, a signal is transmitted to the control unit 140 to stop the operation of the feeder control system 100, thereby preventing safety accidents. Prevention and remote control using the user terminal can be performed.

According to one embodiment of the present invention, convenience can be provided for the welder's continuous welding work by supplying welding wire at a constant speed and voltage, current, and gas at constant values to the welder.

In addition, by sensing environmental information such as temperature, humidity, dust amount, harmful gas concentration, and oxygen concentration in the feeder, the stability of the environment in which welding is performed can be secured.

In addition, by controlling the operation of the feeder control system according to the status information of the feeder and the environmental information of the point where the feeder is located, it is possible to prevent safety accidents and the spread of safety accidents caused by the feeder.

In addition, by classifying the welding stability of the user who performed welding after connecting to the preset user terminal, the limit on working time according to the user's welding stability and the data at the time when the 3-axis changes in voltage, current, and welding holder are large are calculated. The user's welding stability can be improved.

As described above, although one embodiment of the present invention has been described with limited examples and drawings, one embodiment of the present invention is not limited to the above-described embodiment, which is based on common knowledge in the field to which the present invention pertains. Anyone who has the knowledge can make various modifications and variations from this description. Accordingly, one embodiment of the present invention should be understood only by the scope of the claims set forth below, and all equivalent or equivalent modifications thereof shall fall within the scope of the spirit of the present invention.

100: Feeder control system
110: Status display unit
111: User terminal connection part
112: Delivery status collection department
113: Voltage current supply status collection unit
114: Gas supply status collection unit
115: Status information transmitter
120: sensor unit
130: monitoring unit
140: control unit

Claims (5)

The feeder control system that performs welding wire feeding, voltage supply, current supply, and gas supply to perform welding,
A status display unit that displays status information including power supply status, wire feeding speed, supply voltage amount, supply current amount, gas supply amount, remaining gas amount value, whether the welding holder is activated, and connection status with a preset user terminal;
A sensor unit provided at a preset location to sense environmental information including temperature, harmful gas concentration, oxygen concentration, noise level, humidity, and dust amount;
a monitoring unit that determines the status and welding performance environment of the feeder control system and the user's welding stability using the information collected from the status display unit and the sensor unit; and
A control unit that controls the amount of voltage, current, gas, and welding wire supplied by the feeder control system in response to the signal received from the monitoring unit;
Including,
The status display unit,
a user terminal connection unit that collects whether connection is approved and connection status information between the feeder control system and the preset user terminal;
A supply status collection unit that provides a rotation detection sensor and a welding wire detection sensor on the roller feeding the welding wire to sense the rotation speed of the roller and the presence of the welding wire for a preset time;
A voltage current supply status collection unit that collects the amount of current and voltage supplied in response to the signal from the welding holder;
a gas supply status collection unit that receives remaining gas amount data and supplied gas amount data from the gas supply device; and
a status information transmitting unit that transmits the status information to the preset user terminal, a screen of the feeder control system, and the monitoring unit;
Includes,
The delivery status collection department,
The length of the supplied welding wire, the length of the remaining welding wire, and the welding wire used for a preset time using an infrared sensor that senses the presence of the welding wire between the rollers and a rotation speed sensor provided on the rotation axis of the roller. Calculate consumption,
The status information transmitter,
If the status information is outside the preset allowable range, transmitting a signal requesting temporary suspension of the entire operation of the feeder control system to the control unit,
A work stoppage notification is sent to the preset user terminal.
The monitoring unit,
The welding stability value (W _s ) for determining the user's welding stability is calculated according to the following [Equation 1],
[Equation 1]

(Here, t _wㆍf is the wire supply time, M _t is the thickness of the welding base material, H _v is the 3-axis change weight of the welding holder, W _t is the wire thickness, t _tㆍw is the total welding time, and α- _v is the voltage Change weight, α _I means current change weight)
The voltage change weight (α- _v ) and the current change weight (α _I ) correspond to the change ratio of the target supply voltage and current amount set by the user in response to activation of the welding holder and the actual voltage and current amount. It is granted,
The 3-axis change weight (H _v ) of the welding holder is calculated as the product of the weight for each axis given in response to the ratio of the change amount of the 3-axis sensor provided inside the welding holder,
In response to the welding stability value (W _s ), welding stability is divided into 6 levels and the welding stability, recommended work time, and maximum work time are transmitted to the preset user terminal,
The monitoring unit,
Classifying the welding stability of the user who performed welding for a preset time,
In response to the classified welding stability, the recommended work time, maximum workable time, voltage and current change by time, and 3-axis position change of the welding holder by time are transmitted to the preset user terminal,
A feeder control system characterized in that, when the user exceeds the maximum workable time, a command to stop operation of the feeder control system is transmitted to the control unit. delete delete delete delete