KR20040082793A - Automatic monitoring device of welding carriage - Google Patents
Automatic monitoring device of welding carriage Download PDFInfo
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- KR20040082793A KR20040082793A KR1020030017473A KR20030017473A KR20040082793A KR 20040082793 A KR20040082793 A KR 20040082793A KR 1020030017473 A KR1020030017473 A KR 1020030017473A KR 20030017473 A KR20030017473 A KR 20030017473A KR 20040082793 A KR20040082793 A KR 20040082793A
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- Prior art keywords
- welding
- carriage
- abnormal operation
- detection module
- welding carriage
- Prior art date
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- 238000003466 welding Methods 0.000 title claims abstract description 97
- 238000012806 monitoring device Methods 0.000 title 1
- 230000002159 abnormal effect Effects 0.000 claims abstract description 21
- 238000001514 detection method Methods 0.000 claims description 19
- 238000011065 in-situ storage Methods 0.000 claims description 12
- 238000012544 monitoring process Methods 0.000 abstract 2
- 238000010586 diagram Methods 0.000 description 3
- 230000005856 abnormality Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0282—Carriages forming part of a welding unit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0294—Transport carriages or vehicles
Abstract
Description
본 발명은 캐리지 용접시 나타나는 주행면 이탈이나 제자리 용접 등의 이상동작들을 조기에 감지할 수 있는 기능을 가진 용접캐리지의 이상동작 자동검출장치에 관한 것이다.The present invention relates to an apparatus for automatically detecting abnormal operation of a welding carriage, which has a function of detecting an abnormal operation such as a deviation from a running surface or in situ welding during welding.
기존의 용접캐리지는 간단한 설치 및 운영상의 이점으로 인하여 작업자 한 사람당 용접캐리지를 3∼4대 혹은 그 이상 운용할 수 있으나 작업자가 항상 용접장비를 감시해야 하는 문제가 있었다.Conventional welding carriage can operate three to four or more welding carriages per worker due to the simple installation and operation advantages, but the operator always had to monitor the welding equipment.
특히 용접캐리지가 주행중 용접 와이어(wire), 쇠조각, 공구류 등 큰 이물질에 걸리거나 돌출된 작업부재에 부딪칠 경우 또는 용접캐리지에 연결된 케이블이 꼬이거나 어떤 힘에 의해 뒤로 잡아당겨지거나 하면 용접캐리지가 더 이상 앞으로 나아가지 못하고 제자리에서 바퀴가 헛돌며 한 위치를 계속 용접하는 경우가 발생하거나 주행면을 이탈하면서 용접하는 현상이 발생한다.In particular, if the welding carriage is caught by a large foreign object such as welding wire, metal pieces, tools, etc., or hits the protruding work member while traveling, or the cable connected to the welding carriage is twisted or pulled back by some force, the welding carriage No longer moving forward, the wheel is spinning in place and welding continues at one position or welding while leaving the running surface.
이러한 이상동작이 발생했을 경우에는 심각한 용접불량으로 인해 품질 및 생산성이 저하하며, 수정작업에 따른 막대한 시간과 비용이 소요된다.When this abnormal operation occurs, the quality and productivity are lowered due to the severe welding failure, and enormous time and cost are required for the corrective work.
특히 장비의 특성상 작업자가 항시 감시하고 있어야 하는데, 조선산업 등의 경우에는 작은 격자공간의 블록들로 이루어져 있어 작업자가 모든 용접캐리지를 지속적으로 감시하기가 매우 어려운 실정이다.In particular, the nature of the equipment should be monitored by the operator at all times. In the shipbuilding industry, it is very difficult for the worker to continuously monitor all the welding carriages because it consists of blocks of small lattice space.
한편 종래에 있어서도 특허공개 제2002-26913호 및 실용신안등록 제246026호, 그리고 특허공개 제98-68640 호 등과 같이 용접캐리지에 근접거리센서나 초음파센서, 적외선센서 등을 부착하여 주행면 이탈을 감지하려고 여러번 시도하였으나 용접시 발생하는 고열과 흄, 각종 먼지 등으로 인해 센서의 기능이 저하되고, 신뢰성이 떨어져 현재는 전혀 사용하지 못하고 있는 실정이다.On the other hand, in the prior art, it detects the deviation of the traveling surface by attaching a proximity distance sensor, an ultrasonic sensor, an infrared sensor, etc. to the welding carriage, such as Patent Publication No. 2002-26913, Utility Model Registration No. 246026, and Patent Publication No. 98-68640. Although many attempts have been made, the function of the sensor is deteriorated due to high heat, fume, and various dusts generated during welding, and the current situation is not used at all because of its low reliability.
본 발명은 상기와 같은 문제점을 해결하기 위한 것으로, 그 목적이 용접시 나타나는 주행면 이탈이나 제자리 용접 등의 이상동작들을 조기에 감지할 수 있도록 하는 용접캐리지의 이상동작 자동검출장치를 제공하는 데에 있는 것이다.The present invention is to solve the above problems, the object of the present invention is to provide an automatic detection of abnormal operation of the welding carriage to detect the abnormal operation, such as running surface deviation or in-situ welding during welding early It is.
도 1a는 용접캐리지의 용접경로 이탈현상을 나타낸 사시도Figure 1a is a perspective view showing the welding path departure phenomenon of the welding carriage
도 1b는 용접캐리지의 제자리용접상태를 나타낸 사시도Figure 1b is a perspective view showing the welding position in place of the welding carriage
도 2는 본 발명의 한 실시예의 구성도2 is a block diagram of an embodiment of the present invention
도 3은 동 실시예의 센싱시스템의 입·출력 구성도3 is an input / output configuration diagram of the sensing system of the embodiment.
도 4a는 동 실시예의 용접캐리지의 사시도4A is a perspective view of a welding carriage of the same embodiment
도 4b는 동 실시예의 용접캐리지의 밑면도4B is a bottom view of the weld carriage of the embodiment
도 5a는 용접경로이탈시 용접전류와 데이터갯수와의 관계그래프Figure 5a is a graph of the relationship between the welding current and the number of data when the welding path deviated
도 5b는 제자리용접시 용접전류와 데이터갯수와의 관계그래프5B is a graph of the relationship between the welding current and the number of data during spot welding
도 5c는 제자리용접시의 이동거리와 시간과의 관계그래프Figure 5c is a graph of the relationship between the moving distance and time in place welding
<도면의 주요부분에 대한 부호의 설명><Description of the symbols for the main parts of the drawings>
1 : 용접토치(Torch)1: Welding Torch
2 : 조작패널2: operation panel
3 : 가이드롤러(Guide Roller)3: Guide Roller
7 : 제자리용접 감지모듈 혹은 독립 주행바퀴7: In situ welding detection module or independent driving wheel
8 : 경로이탈 감지모듈 혹은 접촉센서 모듈8: Deviation detection module or contact sensor module
9 : 전류 센서9: current sensor
10 : 용접캐리지10: welding carriage
20 : 센싱시스템20: sensing system
30 : 와이어 피더(Wire Feeder)30: Wire Feeder
40 : 용접기40: welding machine
상기의 목적을 달성하기 위한 본 발명은 제자리 주행을 검출하기 위해 주행바퀴와는 별도로 설치된 제자리용접 감지모듈(7)과 주행벽면에 접촉하는 가이드롤러 부위의 경로이탈 감지모듈(8)을 장착한 용접캐리지(10)와, 용접시 아크전류를 측정하기 위해 용접토치부 혹은 와이어 공급장치에 설치되는 전류센서(9), 상기 각 감지모듈(7)(8) 및 센서(9)들로부터의 신호를 입력받아 용접이상동작을 자동으로 판별하는 센싱시스템(20), 그리고 용접기(40)를 포함하는 것을 특징으로 한다.The present invention for achieving the above object is a welding equipped with a spot welding detection module (7) installed separately from the driving wheel and the path deviation detection module (8) of the guide roller portion in contact with the running wall to detect the driving in place Signals from the carriage 10 and the current sensor 9, each of the sensing modules 7 and 8 and the sensors 9, which are installed in the welding torch or the wire supply device to measure the arc current during welding. It characterized in that it comprises a sensing system 20, and a welder 40 to automatically determine the welding abnormal operation received.
본 발명의 다른 특징은 상기 제자리용접 감지모듈(7)로 용접캐리지의 구동바퀴들과는 별도의 독립주행바퀴를 몸체의 하단부에 설치하여 주행시 용접에 의한 열 및 구동모터의 영향을 받지 않고 독립적으로 회전함으로써 이때의 신호를 감지하면 용접캐리지가 이동하고 있는지 아니면 제자리에서 헛돌고 있는지를 파악할 수 있는 것에 있다.Another feature of the present invention is that the in-situ welding detection module (7) by installing independent driving wheels separate from the driving wheels of the welding carriage at the lower end of the body by rotating independently without the influence of heat and driving motor by welding during driving By detecting the signal at this time, it is possible to determine whether the welding carriage is moving or moving in place.
본 발명의 또 다른 특징은 상기 경로이탈 감지모듈(8)로 가이드롤러(3) 부분에 기구적 동작에 의한 접촉센서를 장착하여 주행벽면 접촉시와 주행벽면에서 멀어졌을 때의 신호를 판단하면 주행면 이탈을 감지할 수 있는 것에 있다.Another feature of the present invention is to mount the contact sensor by the mechanical movement to the guide roller (3) portion of the path departure detection module (8) to determine the signal at the time of contact with the traveling wall and when away from the traveling wall It's about being able to detect surface deviation.
이하 그 구체적인 기술내용을 첨부도면에 의거하여 더욱 자세히 설명하면 다음과 같다.Hereinafter, the specific technical details will be described in more detail with reference to the accompanying drawings.
즉, 도 2에는 본 발명에 따른 한 실시예의 용접캐리지의 이상동작 자동검출장치의 구성도가 도시되어 있다.That is, Figure 2 is a block diagram of the automatic detection device for abnormal operation of the welding carriage of one embodiment according to the present invention.
도 2와 같이 본 발명의 이상동작 자동검출장치는 제자리 주행을 검출하기 위해 주행바퀴와는 별도로 설치된 제자리용접 감지모듈(7)과 주행벽면에 접촉하는 가이드롤러 부위의 경로이탈 감지모듈(8)을 장착한 용접캐리지(10)와, 용접시 아크전류를 측정하기 위해 용접토치부 혹은 와이어 공급장치에 설치되는 전류센서(9), 상기 각 감지모듈(7)(8) 및 센서(9)들로부터의 신호를 입력받아 용접이상동작을 자동으로 판별하는 센싱시스템(20), 그리고 용접기(40) 등으로 구성된다.As shown in FIG. 2, the apparatus for automatically detecting abnormal operation of the present invention includes a spot welding detection module 7 installed separately from the driving wheel and a path deviation detection module 8 of the guide roller in contact with the traveling wall to detect the driving in place. From the mounted welding carriage 10 and the current sensor 9, each of the detection module (7) (8) and the sensors (9) which are installed in the welding torch or wire supply device for measuring the arc current during welding It consists of a sensing system 20, and a welder 40, etc. to automatically determine the welding abnormal operation by receiving a signal of.
이와 같은 본 발명에 있어서 캐리지(10)에 있는 용접시작 단추가 눌려지면 용접 시작신호가 센싱시스템(20)에 전달되며, 센싱시스템(20)은 이 신호를 받아 이상동작 감지 프로그램을 동작시키게 된다.In the present invention as described above, when the welding start button on the carriage 10 is pressed, the welding start signal is transmitted to the sensing system 20, and the sensing system 20 receives this signal to operate the abnormal motion detection program.
이를 위하여 센싱시스템(20)에는 외부와 디지털 입·출력 및 아날로그 입·출력이 가능한 여러 개의 포트를 가지고 있고, 이러한 신호들을 제어하기위해 16-bit 원칩(One-chip) 마이크로프로세서(Microprocessor)를 사용하고 있으며, 이에 대한 간략한 센싱시스템(20)의 입·출력 신호 구성은 도 3과 같다. 캐리지(10)나 각 감지모듈(7,8) 및 센서(9)로부터 경로이탈신호(S1), 용접전류신호(S2), 제자리용접신호(S3)가 센싱시스템(20)에 전달되면 센싱시스템(20)은 이상 동작감지 프로그램을 수행하여 용접 이상 동작이 검출되면 즉시, 캐리지(10)나 주변장치 등에 용접중단신호(S4), 캐리지정지신호(S5), 알람 및 경보 신호(S6) 등을 출력하게 된다.To this end, the sensing system 20 has multiple ports capable of external and digital input / output and analog input / output, and uses a 16-bit one-chip microprocessor to control these signals. The input / output signal configuration of the brief sensing system 20 is as shown in FIG. 3. When the path departure signal S1, the welding current signal S2, and the in-situ welding signal S3 are transmitted from the carriage 10 or each of the sensing modules 7 and 8 and the sensor 9 to the sensing system 20, the sensing system 20. 20, if the welding abnormal operation is detected by performing the abnormal motion detection program, the welding stop signal S4, the carriage stop signal S5, the alarm and the alarm signal S6, etc., to the carriage 10 or the peripheral device, etc. immediately. Will print.
그리고 본 발명에 있어서 용접시 나타나는 아크전류 및 독립주행바퀴의 신호는 정상적인 주행일 때에 용접전류의 크기와 변동폭이 일정범위내에서 유지되며, 도 5a와 같이 용접 경로 이탈시에 용접전류가 감소하고, 도 5b와 같이 제자리용접일 경우에 용접전류가 증가하게 된다.In the present invention, the arc current and the signal of the independent driving wheel appearing during welding maintain the magnitude and fluctuation range of the welding current within a certain range during normal driving, and the welding current decreases when the welding path deviates as shown in FIG. 5A, In the case of in-situ welding as shown in FIG. 5B, the welding current increases.
따라서 정상적인 용접전류와 비교하여 상대적으로 상한·하한 전류 리미트(Limit) 값을 설정하면 용접 경로 이탈 및 제자리 용접을 감지할 수 있다.Therefore, by setting the upper and lower current limit values relative to the normal welding current, it is possible to detect the welding path deviation and in-situ welding.
또한 제자리용접 감지모듈의 주행바퀴로부터는 엔코더신호를 검출하는데, 일정 시간단위 주기로 펄스의 수를 검출하면 현재의 용접캐리지 속도 및 정상주행 여부를 알 수 있다.In addition, an encoder signal is detected from the driving wheel of the in-situ welding detection module. When the number of pulses is detected at a predetermined time unit period, the current welding carriage speed and normal driving can be known.
그리고 가이드롤러(3) 부위에 장착된 경로이탈 감지모듈(8)에서는 정상적인 주행면 접촉시 ON 혹은 OFF 신호를 발생하는데, 주행면에서 멀어지면 신호의 반전이 일어나므로 주행면 이탈을 감지할 수 있다.In addition, the path deviation detection module 8 mounted at the guide roller 3 generates an ON or OFF signal when a normal driving surface is touched, and when the distance is far from the driving surface, the signal is inverted so that the driving surface deviation can be detected. .
따라서 센싱시스템(20)은 이러한 여러종류의 신호들을 복수의 입력으로 받아 처리하게 되며, 최종적으로 용접캐리지(10)의 이상유무를 판단하게 된다. 만약 도 1a 및 도 1b와 같은 주행경로 이탈이나 제자리 용접 등의 이상동작이 감지되면, 도 3에서와 같이 센싱시스템(20)은 용접캐리지(10)의 동작 및 용접을 중지시키고, 알람을 발생시키며 센싱동작을 멈추고 대기상태가 된다.Therefore, the sensing system 20 receives and processes these various types of signals as a plurality of inputs, and finally determines whether there is an abnormality in the welding carriage 10. 1A and 1B, if an abnormal operation such as driving path deviation or in-situ welding is detected, the sensing system 20 stops the operation and welding of the welding carriage 10 and generates an alarm as shown in FIG. The sensing operation stops and waits.
이상에서 설명한 바와 같이, 본 발명에 의하면 용접중 실시간으로 용접캐리지의 이상 동작을 자동 감지하여 용접캐리지의 동작을 정지시켜 줌으로써 용접 불량에 따른 수정 작업 비용 및 작업 시간을 감소시킬 수 있게 되고, 후처리 작업 감소로 인한 생산성 증대에 기여할 수 있게 되며, 단순 기능 위주의 용접캐리지에 지능을 부여해 줌으로써 용접캐리지의 기능성을 증대시킬 수 있게 됨은 물론 작업자 1명이 동시에 다수의 용접 캐리지를 관리함에 있어 작업자가 장비를 계속적으로 감시해야 하는 수고를 덜어 줌으로써 장비 관리의 효율성 증대의 효과를 얻을 수 있게 된다.As described above, according to the present invention, by automatically detecting the abnormal operation of the welding carriage in real time during welding and stopping the operation of the welding carriage, it is possible to reduce the correction work cost and the working time due to the welding failure, and post-processing It can contribute to productivity increase due to reduced work, and it is possible to increase the functionality of the welding carriage by giving intelligence to the welding carriage focused on simple functions, and the operator can manage the equipment at the same time. By eliminating the need to constantly monitor, the efficiency of equipment management can be increased.
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KR1020030017473A KR20040082793A (en) | 2003-03-20 | 2003-03-20 | Automatic monitoring device of welding carriage |
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KR1020030017473A KR20040082793A (en) | 2003-03-20 | 2003-03-20 | Automatic monitoring device of welding carriage |
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