KR20150068513A - Energy Management System for Digital welding machine and method therefor - Google Patents

Abstract

The present invention relates to an energy management system for a digital welding machine and a method, which establishes the amount of energy used per process and the amount of CO_2 used with DB and manages energy efficiency of a welding process through real time measurement and analyzation. Welding productivity is expected to grow through the minimization of a heat input and the occurrence of spatter through an optimized arc length estimation SW development; the enhancement of management effectiveness can be achieved by shortening a period of job management through a real time process management SW development; quality increase is accomplished through the realization of optimized welding quality with minimum consumption power; and production costs can be reduced through the realization of the minimization of consumable materials through a digital wire feed control SW.

Description

TECHNICAL FIELD [0001] The present invention relates to a digital welding machine and method therefor,

The invention digital welder energy management system to manage energy efficiency of the welding process through the digital welder energy management system and method, and more particularly the process-specific energy consumption, and real-time measurement and analysis by building a CO ₂ amount to the DB on the And methods.

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

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

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

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

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

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

In order to solve such a problem, the present invention provides a digital welding machine energy management system and method for managing the energy efficiency of a welding process by real-time measurement and analysis by constructing a DB using energy consumption and CO ₂ consumption by process .

The digital welder energy management system according to an embodiment of the present invention is a system in which when a welding worker starts a welding work through a welder feeder, the welding worker matches the welder identification information to identify the feeder identification information, the welder start time, The solenoid valve time and the crater use information are received by the welding machine for transmitting the welding data and the welding data transmitted from the welding machine and stored in the database to be managed and the welding operation is performed through each welding machine using the welding data And an energy management server for monitoring the amount of energy, providing energy usage statistical information, and transmitting an alarm signal to the manager terminal or the worker terminal when there is noxious gas information from the welder.

As an example related to the present invention, the energy management server may calculate the amount of power consumption based on at least one item of used power, welding time, and welder efficiency.

As an example related to the present invention, the energy management server may store the starting time of the welding machine on the basis of the time when the welding machine is turned on, and calculate the difference between the starting time of the welding machine operation and the current market value to calculate the welding machine operation time .

As an example related to the present invention, the energy management server can calculate the CO ₂ gas consumption amount by using the predetermined amount of CO ₂ gas and the operating time per minute of the solenoid.

As an example related to the present invention, the energy management server can calculate the wire usage amount by summing up the amount of the primary welding wire and the amount of the secondary welding wire.

As an example related to the present invention, the energy management server can calculate the CO ₂ emission amount per process as a result of dividing the fuel calorific value by the petroleum conversion tonnage.

The energy management server records the identification information of each welder connected on-line, the energy management server records the currently connected welder IP and the port, And the energy management server may transmit a control item for controlling the welding machine.

As an example related to the present invention, the energy management server designates a welder ID of a digital welder client, a digital welder feeder ID, an IP address, and a connection port to designate power ON / OFF, crater enable / disable, Setting, and waveform configuration.

As an example related to the present invention, an energy management server provides a welding schedule information according to a work instruction using a terminal device held by an administrator or a worker, and the energy management server is a terminal device And the energy management server is provided with at least one item of welding time, welding time, voltage, current, consumed power, consumed wire, and consumed CO ₂ The energy management server provides energy management status in real time and the safety management situation information can be matched with the factory layout information and can be provided in real time.

The present invention is expected to improve the welding productivity by minimizing the heat input and spatter generation through development of the optimum arc length estimation SW, and it is possible to improve the management efficiency through the development of the real time process management SW, It is possible to reduce the cost by realizing the welding quality and realizing the quality and minimizing the cost of consumable material through the digital wire feed control SW.

In addition, the present invention can provide a welding standard pattern by converting the welding setting for each process into a DB, and it is possible to realize safety management of the operator through implementation of the noxious gas control / alarm SW.

1 is a view for explaining a configuration of a digital welding machine energy management system according to the present invention.
2 is a flowchart illustrating an energy management method for a digital welder according to the present invention.
3 is an interface screen diagram provided through a PC according to the present invention.
4 is an interface screen diagram provided through a portable terminal device according to the present invention.

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

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

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

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

Hereinafter, a digital welding machine energy management system according to the present invention will be described in detail with reference to the accompanying drawings.

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

1, the digital welding machine energy management system includes a welding machine 100, an energy management server 200, an administrator or a worker terminal device 300, and a communication network 400. The welding machine 100 is a digital welding machine.

When the welding worker starts the welding work through the welder feeder, the welding machine 100 matches the welding machine identification information to find the feeder identification information, the welder start time, the wire start time, the voltage, the current, the solenoid valve time, And transmits the welding data.

The energy management server 200 receives and manages the welding data transmitted from the welding machine 100, stores the welding data in the database, and monitors the amount of energy required when the welding operation is performed through each welding machine using the welding data. And provides an alarm signal to the manager or the worker terminal device 300 when the hazardous gas information is present from the welding machine 100. [

The energy management server 200 calculates the amount of power consumption based on at least one of the usage power, the welding time, and the welding machine efficiency.

The efficiency of the welding machine 100 is briefly described as about 50% for the DC welding machine, about 80% for the AC welding machine, and varies depending on the welding machine. The loss of the power due to the no- %, But AC welding machine need not be considered.

The power is expressed by an accumulated value of power per hour, and is calculated by the following equation.

(W / h) = {Primary Voltage (V) x1 Current (A) x Second Time (sec)} / 3600+ {Secondary Voltage (V) x2 Current (A)

The energy management server 200 stores the start time of the welding machine on the basis of the time point at which the welding machine is turned on and calculates the difference between the welding start time and the current time value to calculate the welding machine operation time.

Welding machine running time = current time - Welding machine start time

The energy management server 200 calculates the CO ₂ gas consumption amount by using the preset CO ₂ gas consumption amount and the solenoid operating time per minute.

CO ₂ gas consumption (ℓ) = reference value x (SOL time / 60), where SOL time refers to solenoid operating time.

The energy management server 200 calculates the amount of wire usage by summing up the primary welding wire usage and the secondary welding wire usage.

WFS = aL + bl2

Where WFS is the wire feeding speed, L is the wire protrusion length, I is the welding current, and a and b are the proportional constants. The wire protrusion length L is calculated as 20 mm, and the wire usage calculation is calculated using the wire feed rate (speed = distance / time).

The energy management server 200 calculates the CO ₂ emission amount per process as a result of dividing the calorific value of the fuel by the petroleum conversion tonnage.

Here, the toe of petroleum conversion is defined as 107 Kcal and is a unit that can be conveniently used with a calorific value very close to the net calorific value of 1 ton of crude oil, and Toe = fuel calorific value (Kcal) / (107 Kcal). In the case of toe conversion, the total calorific value of the "energy calorie conversion standard" is used to convert, for example, 2300 Kcal / (107 Kcal) is calculated as Toe of 1 KWh of power consumption, and the result is 0.00023 toe. Here, multiplying the toe of the fuel by the carbon emission factor yields the CO ₂ emissions per process. To convert to TCO ₂ , multiply the TC value (carbon dioxide molecular weight) / carbon atom amount) in the above equation. For example, when the TCO ₂ of a power consumption of 1 KWh is calculated, TC = 0.00023 * 0.47 = 0.001081 and TCO ₂ = 0.001081 * (44/12) = 3.7 (TCO ₂ ).

The digital welding machine energy management method as described above will be described as follows.

2 is a flowchart illustrating an energy management method for a digital welder according to the present invention.

As shown in FIG. 2, the energy management server 100 records the identification information of each welder connected on-line (S110), and writes the currently connected welder IP and port (S120).

The energy management server 200 receives and records current state information provided from each welding machine 100 and transmits a control item for controlling the welding machine 100 in operation S140.

The energy management server 200 designates a welding welder ID, a digital welder feeder ID, an IP address, and a connection port of a digital welder client through a PC or a portable terminal device so that the power ON / OFF setting, Crater setting / , Alarm setting, waveform setting.

The energy management server 200 provides the welding schedule information according to the work instruction using the terminal device held by the manager or the worker. The energy management server 200 is a terminal device And the energy management server 200 provides at least one of the welding time, the welding time, the voltage, the current, the consumed power, the consumed wire, and the consumed CO ₂ And the energy management server 200 matches the safety management status information with the factory layout information so that the energy management server 200 can check the energy management status in real time.

3 is an interface screen diagram provided through a PC according to the present invention. 4 is an interface screen diagram provided through a portable terminal device according to the present invention.

(DWIS Ver 1.0) web via a manager or worker terminal 300 such as a PC or a smart phone, as shown in FIGS. 3 and 4, and then inputs the welder ID of the digital welder client, the digital welder feeder It is an interface screen in which the power ON / OFF setting, Crater setting / no setting, voltage / current setting, alarm setting and waveform setting can be set by designating ID, IP address and connection port. The interface screen is used to display the welding schedule. It is an interface screen for registering the welding schedule per day according to the work instruction. It is the interface screen in which the digital welding client's real-time energy usage status (welding time, welding time, voltage, Consumed wire, and consumed CO ₂ ), and select the digital welder client to select the energy It is an interface screen for checking usage statistics. It is an interface screen for outputting the real-time safety management situation of the application site on the factory layout and an interface screen for outputting the CO ₂ pollution degree by time. The digital welder client is selected, An interface screen for selecting CO ₂ emission statistics, an interface screen for selecting a digital welding client, and an interface screen for searching the power status of the main body by selecting a date to be searched.

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

100: Welding machine
200: Energy management server
300: Manager or worker terminal
400: communication network

Claims (9)

When the welding worker starts the welding work through the welder feeder, feeder identification information, welder start time, wire start time, voltage, current, solenoid valve time, and crater use information are transmitted to welder welding machine; And
Wherein the control unit receives the welding data transmitted from the welding machine and stores the welding data in the database and monitors the amount of energy consumed when the welding operation is performed through each welding machine using the welding data, And an energy management server for transmitting an alarm signal to the manager terminal device or the worker terminal device when the harmful gas information exists from the welding device.
The method according to claim 1,
Wherein the energy management server calculates an amount of power consumption based on at least one item of usage power, welding time, and welder efficiency.

The method according to claim 1,
Wherein the energy management server stores the welding start time of the welder on the basis of a time point at which the welding power is turned on and calculates the welding time of the welder by calculating a difference between the welding start time and the current time value, .
The method according to claim 1,
Wherein the energy management server calculates a CO ₂ gas consumption amount by using a preset CO ₂ gas consumption amount and a solenoid operating time per minute.
The method according to claim 1,
Wherein the energy management server calculates the wire usage amount by summing the primary welding wire usage amount and the secondary welding wire usage amount.
The method according to claim 1,
Wherein the energy management server calculates a CO ₂ emission amount for each process as a result of dividing the calorific value of the fuel by the petroleum converted tonnage.
The energy management server records the identification information of each welder having an online connection;
The energy management server recording the currently connected welder IP and port;
The energy management server receiving and recording current state information provided from each welder; And
Wherein the energy management server comprises transmitting a control item for controlling the welder.
8. The method of claim 7,
The energy management server can set a power ON / OFF setting, a crater setting / no setting, a voltage / current setting, an alarm setting, and a waveform setting by designating a welder ID of a digital welder client, a digital welder feeder ID, How to manage energy in a digital welder.
8. The method of claim 7,
The energy management server provides a welding schedule information according to a work instruction using a terminal device held by an administrator or an operator,
Wherein the energy management server provides daily welding schedule information according to a work instruction by using a terminal device held by a manager,
Wherein the energy management server provides energy usage status including at least one of a welding time, a welding time, a voltage, a current, a consumed power, a consumed wire, and consumed CO ₂ in real time,
Wherein the energy management server provides safety management status information to factory layout information so that it can be checked in real time.

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