RU2681589C2 - Method of automation of welding production processes - Google Patents

Abstract

FIELD: welding.SUBSTANCE: invention relates to the field of automation of production processes associated with the use of electric arc welding. Method is carried out using a hardware-software complex, a server and at least one welding machine, the method includes the input to the server information about the manufactured products, the composition of products, assembly units, welding operations, technological maps of operations, control cards products, information on blanks and consumables, information on welding parameters in accordance with the technological map and data on the distribution of tasks between the performers, the application of bar codes on the blanks and consumables, the registration of the contractor in the hardware-software complex under account thereof, the choice of the task by the contractor and execution thereof. By means of the server, the results of the quality check of the operation are recorded, and a product passport is formed using a hardware-software complex.EFFECT: use of the invention allows to improve the quality of technological operations, to carry out remote monitoring and control in real time, as well as complete documentation of the manufacturing process of the product.1 cl, 2 dwg

Description

Technical field

The present invention relates to systems of production processes associated with the use of electric arc welding, and can be used to improve the quality of technological welding operations, increase the transparency of welding production, document welding processes, simultaneous real-time remote monitoring and control of many autonomous welding machines distributed in space.

State of the art

A number of systems for controlling welding machines distributed over a territory are known from the prior art.

Known "System and method for providing a distributed architecture of welding means" [US Pat. US Pat. No. 6,624,388, publ. 08/01/2002]. The system includes at least one welding machine operatively connected to a network server, a network interface and a network for exchanging data with at least one remote system. A remote system includes at least one remote interface for exchanging data with a network architecture.

The disadvantage of this system is the lack of authorization of the welder during the welding operation, which does not allow to connect the personality of the welder, identification of the welding machine, welding parameters and data on the operation performed, and thereby reduce the influence of the human factor on the quality of the operation.

The well-known "System and method of welding, providing a distributed architecture" [Pat. US US 2002/001888, publ. 08/01/2002].

The system includes welding machines operatively connected to the server and the network interface, a network architecture that interacts with at least one remote system, including at least one remote interface for interacting with a network architecture, in which the remote system has access at least one HTTP socket to establish a web connection with the welder and download at least one application from the welder.

The disadvantage of this system is the lack of authorization of the welder during the welding operation, which does not allow to connect the personality of the welder, identification of the welding machine, welding parameters and data on the operation performed, and thereby reduce the influence of the human factor on the quality of the operation.

Closest to the claimed technical solution is the patent "System and method for monitoring and control characteristics of manual welding" [Pat. US No. US 2015056585, publ. 02/26/2015].

A method in which hardware and software are configured to collect and process data in real time.

The disadvantage of this method is that the current welding parameters are tied to the identification number of the welding machine. At the same time, the absence of a rigid connection between the welder’s authorization, identification of the welding machine, welding parameters and data on the operation performed does not allow reducing the influence of the human factor on the quality of the operation being performed.

SUMMARY OF THE INVENTION

The interrelated tasks to which the claimed invention is directed are:

1. increasing transparency and documenting production processes associated with the use of electric arc welding;

2. improving the quality, reducing the likelihood of marriage and the appearance of hidden defects, reducing the influence of the human factor on product quality during operations;

3. providing the ability to remotely monitor welding processes and perform welding operations in real time;

4. providing the ability to remotely monitor the availability of manufactured parts and products in real time;

5. Ensuring the possibility of automated collection of personalized information about the work of welders (use of working time, violation of the work schedule, violation of technological parameters, real labor costs during the operation, the quality of the work performed and the percentage of defects found according to the results of control, etc.);

6. providing the ability to remotely monitor the condition of welding equipment (technical, operational, serviceable, efficient, etc.) in real time;

7. providing the possibility of automated planning of maintenance work on welding equipment;

8. providing the possibility of automated metering of consumption and planning needs for welding materials used in production (welding wire, flux, gas, etc.).

These interrelated tasks are solved due to the fact that the hardware of the hardware-software complex according to this method consists of at least one welding machine (block 1.4.), Additionally equipped with a remote monitoring and control unit (block 1.1.); Computer server (block 1.6.); Computer databases (block 1.9.); at least one computer user (block 1.10.) if necessary, ensure work within the enterprise (block 2.10.); A computer-web server (block 1.7.) And at least one workstation of a remote user (block 1.8.) (If necessary, ensure work with the hardware-software complex from mobile devices, including outside the enterprise, block 2.8 .).

All of the listed elements of the hardware of the hardware-software complex have a software component that provides the logic of their work, and interact with each other through a local area network, which can have sections of wired and wireless communications. The wireless network section in this way organizes a Wi-Fi router (block 1.5.) Or another device. Remote user workstations (block 1.8.) (Devices that work with Internet pages and sites through web browsers located on the enterprise or outside) using this method can interact with a computer-web server 1.7.) As if it were a local wired or wireless network, and over the Internet.

Brief Description of the Drawings

The invention is illustrated by drawings.

In FIG. 1 shows a diagram of the hardware of a hardware-software complex for implementing the method.

In FIG. 2 shows a diagram of the software part of the hardware-software complex for implementing the method.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1 shows a diagram of the hardware of a hardware-software complex for implementing the method.

The hardware of the hardware-software complex according to this method consists of: at least one welding machine (block 1.4.), Additionally equipped with a remote monitoring and control unit (block 1.1.); Computer server (block 1.6.); Computer databases (block 1.9.); at least one computer user (block 1.10.); A computer-web server (block 1.7.), If necessary, to ensure work with the hardware and software complex from mobile devices, including outside the enterprise (block 2.8.), For example, via the Internet; at least one workstation of a remote user (block 1.8.) connected to a computer-web server (block 1.7.) via the Internet.

All of the listed hardware elements interact with each other through a local area network, which can have sections of wired and wireless communications. A wireless network section is organized by a Wi-Fi router (block 1.5.) Or another device! Remote user workstations can interact with a computer-web server (block 1.7.) Both over a local wired or wireless network, and over the Internet.

The composition of the hardware for this method:

1 Block 1.4. Welding equipment (at least one welding machine).

2 Block 1.1. Remote monitoring and control unit.

3 Block 1.2. User Identity Block.

4 Block 1.3. Block identification of materials and products.

5 Block 1.5. Wi-Fi router.

6 Block 1.6. Computer server.

7 Block 1.9. Computer database.

8 Block 1.10. Computer user (at least one).

9 Block 1.7. Computer web server.

10 Block 1.8. Computer remote user.

11 Local Area Network (LAN).

Welding equipment (block 1.4.) - welding equipment (block 1.4.), Additionally equipped with blocks for remote monitoring and control (block 1.1.), User identification (block 1.2.), Identification of materials and products (block 1.3.), And other blocks if necessary, expand the functionality. The blocks are structurally made in the form of printed circuit boards with sealed electronic components, placed in the housing of the welding equipment, receive electrical power from the welding equipment and are electrically connected between themselves and the welding equipment by cables. It is possible to expand the functionality by connecting additional circuit boards that perform the necessary functions.

The remote monitoring and control unit (BUMU, block 1.1.) Is a set of electronic modules:

1 wireless module

2 microprocessor control module,

3 data acquisition module,

4 module for limiting the adjustment of welding parameters. The wireless module is designed to create a wireless network and organize the interchange of data between the microprocessor control module and the computer server (block 1.6.) Through the wireless network. Wireless network setup and data transmission channel setup are carried out during commissioning. The wireless module stores the settings in non-volatile memory and each time the welding equipment is turned on (block 1.4.), It is automatically connected to the corresponding wireless network and sends and receives information data packets.

The microprocessor control module provides the logic of the software part of the module.

The data collection module provides reception of signals and information about the state of welding equipment (block 1.4.) - operating mode, self-diagnosis data, values of welding parameters, etc., and its peripheral devices (personal user ID reader, barcode reader, etc.) for subsequent sending to the computer server (block 1.6.).

The module for restricting welding parameter adjustments provides the reception of information about the specified ranges of values of the welding parameters (arc voltage, wire feed speed, etc.), sets the specified welding parameters for the welding equipment, limiting the possible range of adjustments of the welding parameters available to the welder using standard welding controls equipment (block 1.4.), and blocking / authorization of welding.

The user identification block (BIP, block 1.2.) Is designed to identify the welder who starts the operation of welding equipment. The hardware of the user identification unit is a reader of identification information from the carrier of the user's personal identification key (welder pass, plastic card, etc.). The identification information read from the carrier of the user's personal key is transmitted to the remote monitoring and control unit for further processing.

The unit for identification of materials and products (BIMI. Block 1.3.) Is designed to identify parts of the product that are in operation and welding materials (wire, etc.) with which work is being performed. The hardware of the unit for identification of materials and products is a device that provides scanning of bar codes applied to welding materials and blanks of parts of products. The information read by the scanner is transmitted by the software part of the unit to the remote monitoring and control unit for subsequent processing.

A WI-FI router (block 1.5.) In the mode of an access point or a repeater provides the creation of a wireless network of a hardware-software complex. Wi-Fi router (block 1.5.) Is connected to a computer server via a local area network.

The type and number of Wi-Fi routers (block 1.5.) In the hardware-software complex can vary and is determined by the location of the welding equipment in space.

The operability of the wireless network is ensured by the software, operating mode and settings of the Wi-Fi router (block 1.5.) And the wireless module, which is part of the hardware of the remote monitoring and control unit (block 1.1.) Installed in the welding equipment (block 1.4.) . Wireless network settings are configured during commissioning of the equipment.

A computer server (block 1.6.) - a computer working around the clock, receiving and processing data from welding equipment, forwarding this data via a local area network to a computer database (block 1.9.), As well as generating and sending data packets to welding equipment . A computer server (block 1.6.) Is connected via a local area network to a computer database (block 1.9.) For the possibility of transmitting data received from welding equipment (block 1.4.) And a Wi-Fi router (block 1.5.) To receive current data from welding equipment (block 1.4.).

A computer database (block 1.9.) Is a computer running around the clock, on which special software is launched and runs, which ensures long-term storage and use by the hardware-software complex of all information obtained during the performance of work on this method.

Information received from the server, entered by users and stored in the database of the hardware-software complex, is used to ensure the functioning and management of the hardware-software complex, as well as to perform various necessary calculations and report generation. The architecture of the hardware-software complex allows combining on one productive computer two components - a computer server (block 1.6.) And a computer database (block 1.9.). The database of the hardware and software complex can be deployed to a computer server (block 1.6.) Provided that special software is launched on the computer server (block 1.6.) That provides management, creation and use of the database of the hardware and software complex.

A computer user (block 1.10.) - at least one computer on which a set of special software is installed and (or) granted access to a computer-web server y (block 1.7.), And designed to provide users (various enterprise services) with a hardware-software complex. A set of special software for a computer user provides users with a fixed set of interfaces for interacting with the hardware and software complex depending on access rights, position held and the range of duties of the employee-user of the hardware and software complex. A computer user (block 1.10.) Is connected via a local area network to a computer database (block 1.9.) To access information and modify information stored in the database of the hardware-software complex, to control the functioning of the hardware-software complex, and for visualization of information stored in the database of the hardware-software complex.

A computer-web server (block 1.7.) - a computer running around the clock, on which special software is launched and runs, providing remote access for users to work with the hardware-software complex via the Internet.

A computer of a remote user (block 1.8.) - mobile devices, personal computers, or other computing devices configured to work by this method.

A local area network can be performed, for example, with fiber optic cables, and serves to communicate hardware with each other.

In FIG. 2 shows a diagram of the software part of the hardware-software complex for implementing the method.

The software part consists of the following blocks:

1. Software (in Fig. 2 software) installed on the welding equipment (block 1.4.), Containing the following blocks:

- block 2.2. software unit for remote monitoring and control (PBUMU),

- block 2.1. user identification software block (PBIP),

- block 2.3. software block identification of materials and products (PBIMI).

2. Wi-Fi router software.

3. Block 2.5. Software computer server (software computer server).

4. Block 2.4. Software computer database (software computer database).

5. Block 2.9. User computer software (user computer software).

6. Block 2.7. Remote computer software (remote computer software).

7. Block 2.6. Computer-web-server software (computer-web-server software).

8. Software for organizing the work of a local area network (LAN).

Block 2.2. The software unit for remote monitoring and control (PBUMU) is a set of software modules that interact with each other:

1 Wireless software module;

2 Software module microprocessor control;

3 Data acquisition software module;

4 Software module for limiting the adjustment of welding parameters.

The software module of the wireless communication module receives information packets from the microprocessor control module, converts data packets for transmission in a wireless network, as well as sends them to the microprocessor control module.

The program block of the microprocessor control module provides the logic of the remote monitoring and control unit: receiving information from the data acquisition module, generating information packets from them, with a certain frequency, sent to the wireless module and then to the computer server (block 1.6.); long-term accumulation and storage of information received from the data acquisition module in internal non-volatile memory in the absence of communication between the wireless communication module and the computer server (block 1.6.), and sending the accumulated information during restoration; receiving data from a computer server (block 1.6.) through a wireless communication module about technologically specified ranges of values of welding parameters (arc voltage, wire feed speed, etc.) and making it impossible for the welders to violate the welding process technology by transmitting control commands to the restriction module adjustments of welding parameters.

The software block of the data acquisition module provides: software filtering and processing of signals received by the hardware, processing of information protocols of various peripheral devices (barcode scanner, personal identification key reader, etc.), data transfer to the microprocessor control module.

The software block of the welding parameters adjustment restriction module provides the generation of signals on discrete and analog output channels, as well as the generation of commands sent via digital data channels to implement remote control of the operation of welding equipment: blocking or enabling welding, setting unchanged welding parameters, imposing restrictions on possible range of adjustments of welding parameters available to the welder by means of standard welding controls borudovaniya, et al.

Block 2.1. The user identification software block (PBIP) provides the transfer of identification information by the read hardware from the carrier of the user's personal identification key (welder pass, plastic card, etc.) to the remote monitoring and control unit for subsequent processing.

Block 2.3. The software block for identification of materials and products (PBIMI) provides the transfer of information from the barcode scanner to the remote monitoring and control unit (block 1.1.) For subsequent processing.

Software of a Wi-Fi router - can be the usual software for a Wi-Fi router (block 1.5.), Configured and supplemented with the necessary components for working with this method.

Block 2.5. The software of the computer server (software of the computer server) provides:

1. reception, processing and sending for storage in the database of the hardware-software complex, information received from the remote monitoring and control unit (block 1.1.) From the welding equipment (block 1.4.).

2. formation and sending of information packets containing welding equipment control commands, according to a special algorithm that takes into account factors such as the type of equipment, tasks assigned to the user who is authorized by the welding equipment (block 1.4.), The operation selected for execution, permissible values of welding parameters in accordance with a technological map, the duration of a shift, etc.

It can be ordinary server software, configured and supplemented with the necessary components for working with this method.

Block 2.4. Computer-database software (computer-database software) - can be ordinary database software, configured and supplemented with the necessary components for working with this method.

Block 2.9. Computer user software (computer user software) is a special software for workplaces of employees of various enterprise services, providing:

1. providing an interface for working with the hardware and software complex to various users with differentiation of access rights;

2. input (editing) of information in the database of the hardware-software complex of information about equipment, users, manufactured parts and products, welding operations technologies, results of product control, distribution and assignment of tasks to work performers, assigned operating modes of welding equipment, etc.

3. visualization of the state (technical, operational, serviceable, efficient, etc.) of welding equipment in real time, as well as the values of welding parameters set using standard controls (voltage, wire feed speed, welding mode, program number, number of cycles and etc.), the values of the welding parameters during welding, etc.

4. providing an interface for building various reports:

4.1. snapshots of the working time of equipment and welders - reports containing information on the distribution of the working time and downtime (pause) of welding equipment and welders in the working shift, affecting the wages of the metalworker, the total time of work and downtime of welders, the total time of work, downtime and equipment malfunctions, about the percentage of workload of equipment and welders, etc.

4.2. equipment passport - a report containing information about the equipment: type, production and commissioning dates, malfunctions and failures in operation, operating hours, maintenance and repair, etc.

4.3. welder passport - a report containing information about the career, professional skills of the welder, the quality of work performed, etc.

4.4. product passport - a report containing information: which welder, when, according to which technology and using what welding equipment and materials, welded the product details, which inspector evaluated the work, etc.

4.5. consumption of welding consumables - a report containing information about the used welding consumables, consumption of materials for the period, forecasting requirements for materials, etc.

4.6. defect forecast - a report containing information about the forecast of possible places of occurrence of defects that require closer attention during control operations

4.7. production forecast - a report containing information on the predicted production time of the products, the time spent on the operation and the cost of operations and parts of the product.

It depends on the type and type of computer network existing at the enterprise, and can be the usual web server software (block 1.7.), Used to build a computer network with Internet access, configured and supplemented with the necessary components for working on the network using to this method.

Block 2.7. The computer software of the remote user (the computer software of the remote user) allows mobile devices of remote users (block 1.8.) To work with the hardware-software complex using this method.

Block 2.6. Computer-web-server software (computer-web-server software) - depends on the type and type of computer network existing at the enterprise, and can be the usual web server software (1.7.) Used to build a computer network with output to the Internet, configured and supplemented with the necessary components for working on the network in this way.

The software for organizing the work of a local area network (LAN) - depends on the type and type of local area network existing at the enterprise, and can be the usual software used to build a local area network, configured and supplemented with the necessary components for organizing the work of the network to this method.

The hardware-software complex works as follows.

To implement the method, the production room is equipped with welding equipment (block 1.4.), Which can work as part of a hardware-software complex or upgrade existing equipment, deploy a wireless Wi-Fi network and a local area network (it is possible to use an existing network), equipment is acquired or allocated, necessary for the operation of the hardware-software complex.

Computer networks and equipment are configured, information necessary for the operation of the hardware-software complex is entered. Entering the necessary information and managing the operation of the hardware and software complex is carried out by authorized users, depending on their job responsibilities.

When entering the information necessary for the operation of the hardware-software complex, employee accounts (unique login and password, as well as access level in accordance with official duties) are entered into the computer database (block 1.9.). Each employee who works with welding equipment (block 1.4.) Is given a personal identification key carrier (welder pass, plastic card, etc.) to authorize the user when working with the welding machine (block 1.4.).

In the process of preparing the production, to fulfill the order for the manufacture of parts, the responsible technical services of the enterprise carry out the technological preparation of production, in which the following information is determined and entered into the database (software part) of the computer database (block 2.4.): Manufactured products, composition of products , assembly units, welding operations, operation flow charts, product control cards, information on blanks and consumables and stick barcodes on them, information on welding parameters in tvetstvii with technological map, etc.

In the process of direct production, the persons responsible for the implementation of the plan, the organization and control of production, distribute tasks among the executors (welders, engineering services, managers responsible for the relevant area of work, etc.), assign priorities and deadlines and enter all this information into database (software) computer-database (block 2.4.) for subsequent use.

Executors of tasks (welders, controllers, etc.) from a computer user (block 1.10.) Enter the hardware and software complex under their accounts, study the tasks assigned to them, select one task to be performed at the moment and begin to execute. Contractors can refuse to complete the task, indicating the reason.

Before starting work, the welders are authorized on the welding machine, the remote monitoring and control unit (block 1.1.) Installed on the welding machine (block 1.4.) Sends data to the computer server (block 1.6.), Where the special software is the computer server ( block 2.5.), depending on the task selected by the welder, calculates and sends, for installation in the welding equipment (block 1.4.), welding parameters in accordance with the technology. Without authorization, work on the welding machine (block 1.4.) Is impossible. If it is necessary to control the welding materials used, the welder reads the barcode from the materials charged into the machine and the barcode from the workpiece of the product. After completing the task, the executors from the computer user (block 1.10.) Report on the results of work using the corresponding interface of the hardware-software complex.

The production technology for each operation sets the acceptable ranges of values of the welding parameters, in which the required quality of the weld is ensured, so that the welder can adjust the parameters to the current welding conditions (distance of the weld from the electrode connected to the product, ambient temperature, metal surface condition and etc.).

If necessary, it is possible to adjust the allowable range of adjustment of welding parameters by making changes to the process flow chart of the relevant technical services.

Documentation of product manufacturing processes is expressed in the formation of a product passport by a complex. The product passport contains detailed specifications, as well as complete information for each component: information on the performers (technologists, craftsmen, welders, controllers), information on consumables used in the production process, actual welding modes, technological operational cards, control cards, actual manufacturing schedule.

Registration and long-term storage of detailed information about welding processes, transparency and visibility of the welding process by documenting the complex process of manufacturing parts of the product, the possibility of applying a reasonable and probable administrative effect, motivates specialists to more carefully and responsibly approach their duties, which ultimately helps to increase quality of products and reduce the likelihood of marriage and the appearance of hidden defects during opera welding stations.

Registration of the results of checking the quality of the operation performed by the service of the enterprise, taking into account the tight binding of the fact of the operation to a specific welder, provides the ability to automatically collect operational information on the quality of work of each welder, as well as get a slice of the working time of each welder.

Increasing transparency and documenting production processes associated with the use of electric arc welding is ensured by fixing and long-term storage in the database of the hardware and software (block 2.4.) A set of facts of the work of each welder on a particular welding machine (block 1.4.) During a specific operation in accordance with the specific welding parameters specified by the production technology.

Improving the quality, reducing the likelihood of marriage and the appearance of hidden defects, reducing the influence of the human factor on product quality during operations is ensured by hardware limitations, in accordance with the developed production technology (technological operational cards), the welders' ability to adjust the values of welding parameters by standard equipment controls .

Providing the possibility of real-time remote monitoring (monitoring) of the welding process and welding operations, the readiness of the parts and products produced, the quality of the welders, the condition of the welding equipment, the possibility of automated planning of maintenance work on welding equipment, the possibility of automated metering and planning needs for welding materials used in production is provided by special software for a computer user (block 2.9.) and a computer-web server (block 2.6.). The prohibition of the installation by the welder of process parameters that do not correspond to the production technology helps to eliminate the bad faith factor during the process operation, which could be manifested in the conscious use of welding parameters to increase performance indicators, which results in a defective weld, and, often, defects in such welds can detected only with the use of special control methods (ultrasonic testing, fluoroscopy).

The technical result consists in improving the quality of the process operations by the welder, reducing the likelihood of marriage and the appearance of latent defects in welding operations, fully documenting the manufacturing process of the product.

Claims (1)

A method for automating the welding process of manufactured products, carried out using a hardware-software complex, a server and at least one welding machine, comprising inputting to the server information about manufactured products, composition of products, assembly units, welding operations, process flow charts, product control cards, information on workpieces and consumables, information on welding parameters in accordance with the flow chart and data on the distribution of tasks between performers and applying barcodes to the product blanks and consumables, after which the performer is registered in the hardware and software complex under his account, the performer selects the task and performs it, and before welding starts, the performer is authorized on the welding machine, the data of which is sent to the server, through which allowable ranges of values of welding parameters are set on the welding machine in accordance with the flow chart, and by means of hardware-software Plexus provides a prohibition of setting process parameters that do not correspond to the flow chart, while the scanner reads the barcode from the material data entered in the welding machine and the barcode from the workpiece of the product part and, through a hardware-software complex, collects and transfers data to the server, determines the logic of the remote monitoring and control, and after welding, the results are entered into the hardware-software complex under the account of the contractor, while through the server, the results of the quality control of the operation are recorded, using the hardware-software complex, a product passport is generated containing the detailed specification, information on each component of the product, and the received information is sent via the hardware-software complex to the server in which the storage and storage are carried out incoming information.

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