RU2782534C1 - Local automated welding operation monitoring system - Google Patents

Abstract

FIELD: controlling.

SUBSTANCE: invention relates to the field of monitoring production processes and can be used, e.g., for monitoring welding operations. System consists of three subsystems interconnected via a wireless access network Wi-Fi. The central subsystem herein constitutes a hardware and software complex including an automated workstation of the engineer, an application and database server, an access card reading apparatus, a scanning and printing apparatus, an uninterruptible power supply unit, a wireless access point, and a network switch, interconnected into a local network. The data processing and monitoring subsystem constitutes a hardware and software complex including an automated workplace of the technician, an automated workplace of the specialist, a mobile automated workplace, and wireless access points interconnected into a local network. The recording subsystem includes a recorder and a welding parameter meter with a current sensor, a wire consumption sensor, and a gas flow rate sensor.

EFFECT: higher reliability of recording the parameters of the welding and expand the process capabilities of the system.

5 cl, 1 dwg

Description

The invention relates to computer systems for controlling welding and controlling production processes, and can be used to control the conduct of welding work during the construction and operation of construction and repair facilities, control the performance of work on non-destructive quality control, collect primary information for subsequent use in electronic document management during the formation as-built and permissive documentation, formation and maintenance of permissive and as-built documentation in electronic form in accordance with the existing requirements of as-built documentation in terms of welding and non-destructive testing of welding quality.

The technical solution is known from the prior art [patent RU 2284885 C2. System and method providing a distributed structure of welding. IPC B23K 9/10, G05B 19/418, G06F 15/16. Copyright holder: Dze Lincoln Electric Company (US), application No. 2003125867/02 dated 01/22/2002, published: 10/10/2006 in Bull. No. 28], which includes at least one welding machine operatively connected to a network server, a network interface and a network for data exchange with at least one remote system. The remote system includes at least one remote interface for communication with the network architecture. The remote system is configured to access at least one HTTP socket to communicate with the welder over the network, download at least one application from the welder, and access at least one welding application socket via, over at least one application for exchanging information between the welding machine and the remote system. At least one application includes at least one of a welding configuration component, a welding monitoring component, and a welding control component. A method for providing a distributed welding architecture includes the steps of connecting a welding machine to a network interface. At least one socket is used to establish a network connection via a network interface with a remote system: an HTTP socket or a welding application socket, where the HTTP socket is used for communication via the Web. A welding application socket is used to exchange information between a welding machine and a remote system and provide a welding protocol for communicating with remote systems. The data structure providing the welding protocol includes at least one of the following fields: options/flags field, message sequence field, message status field, data length field, data field, server command field, server command identifier field, command arguments field server field, host field, host address field, property/method identifier field, and property/method arguments field.

The disadvantages of this invention are the lack of authorization of the welder during the welding operation, which does not allow to link the identity of the welder and data on the quality of the operation performed, as well as the inability to take into account regulatory documents regulating non-destructive quality control and the formation of permits and as-built documentation in accordance with the current requirements of regulatory documents in the field of welding during construction, reconstruction and overhaul of capital construction projects.

Closest to the considered technical solution is the invention [RU 2681589 C2. A method for automating welding processes at an enterprise. IPC B23K 9/10, B23K 9/32. Copyright holder: Ellroy LLC (RU), application No. 2016140314 dated 10/12/2016, published: 03/11/2019 in Bull. No. 11], which describes a hardware-software complex, the hardware of which consists of at least one welding machine, additionally equipped with a remote monitoring and control unit, a computer server, a computer database, at least one user computer ( if it is necessary to ensure work within the enterprise), a computer web server and at least one workstation (module) of a remote user. All of the listed elements of the hardware part of the hardware-software complex have a software component that provides the logic of their operation, and interact with each other through a local area network, which may have sections of wired and wireless communication. The wireless section of the network according to this method is organized by a Wi-Fi router or other device. Remote workstations of users can interact with the computer-web-server both over a local wired or wireless network, and over the Internet.

The disadvantages of this technical solution are the impossibility of autonomous operation of individual blocks of the invention while maintaining the minimum required functionality, as well as the absence of hardware recording components included in the hardware and software complex, which allow automating and ensuring reliable reading of the parameters necessary for the analysis and evaluation of non-destructive testing of welding quality .

The technical result of the invention are:

- increasing the reliability of recording the quality parameters of the welding being performed;

- ensuring compliance with the requirements of continuous quality control of welding;

- automation of the formation and maintenance of permits and executive documentation;

- ensuring autonomous operation of individual parts of the welding control system.

The technical result is achieved by the fact that the local automated welding control system includes

the central subsystem, the data processing and monitoring subsystem and at least one welding parameters recording subsystem, which is made in the form of a welding parameters recorder with the ability to connect to welding equipment by means of measuring units, interconnected using a wireless local area network Wi-Fi using wireless access points and a welding parameter meter connected to the welding parameter recorder, which is configured to be connected to the welding machine or to the welding wire feeder and welding torch, wherein the welding parameter meter includes a current sensor, a welding wire flow sensor and a gas flow sensor, moreover, the central subsystem is made in the form of a hardware-software complex, which includes an engineer's workstation in the form of an appropriate personal computer with software, an application and database server in the form of an appropriate personal computer. th computer, a device for reading access cards for welders connected via USB to a personal computer of the said workstation of an engineer, a device for scanning and printing executive and permit documentation, an uninterruptible power supply for the said computers and devices, which are appropriately connected by means of a network switch to each other by wires and with the mentioned point of wireless access to the local Wi-Fi network. At the same time, the data processing and monitoring subsystem is made in the form of a hardware-software complex with the possibility of independent operation from the central subsystem for a period determined by the amount of accumulated data on the progress of welding work, including an automated workplace for the foreman in the form of an appropriate personal computer with software, a specialist workstation in the form of an appropriate personal computer with software and a mobile workstation in the form of a tablet computer with software, wherein said mobile workstation and workstations of a foreman and specialist are connected through said wireless access point to a local Wi-Fi network.

In addition, one subsystem for recording welding parameters is made with the ability to connect welding equipment to one machine.

In addition, the welding parameters meter is equipped with an external current sensor, a connector for connecting a remote welding wire consumption meter and a connector for connecting to a welding parameters recorder.

Moreover, the mentioned computers and devices of the central subsystem can be connected to each other in a local network via a wireless Wi-Fi network or via a wired connection.

The invention is illustrated graphically, where the figure shows an enlarged block diagram of the proposed local automated welding control system.

The positions on the figure indicate: 1 - central subsystem, 2 - data processing and monitoring subsystem, 3 - registration subsystem, 4 - application and database server, 5 - engineer workstation, 6 - access card reader, 7 - scanning and printing, 8 - wireless access points, 9 - network switch, 10 - workstation of the master, 11 - mobile workstation, 12 - recorders of welding parameters.

Implementation of the invention

The local automated system for welding control (hereinafter referred to as the system) includes three subsystems: central (1), data processing and monitoring (2) and registration (3).

The central subsystem provides automation of business processes for the activities of a welding engineer and an engineer of the department responsible for maintaining permits and as-built documentation in terms of incoming inspection, approval procedures, welding and non-destructive quality control of welded joints, as well as system configuration management (users , construction sites, sites, welding equipment).

The data processing and monitoring subsystem provides automation of business processes in terms of the activities of specialists in the area of welding operations and work on non-destructive quality control of welded joints, as well as obtaining, processing and monitoring data on the values of the parameters of the welding equipment operation mode during welding operations.

The registration subsystem provides automation of business processes in terms of the authorization of welders to work with welding equipment. The registration subsystem is presented in the form of six independent sets of devices for interfacing with welding equipment and reading indicators of welding modes.

Interaction of subsystems is carried out through a wireless access network, provided that the access points of the subsystems are removed at a distance of no more than 200 meters.

The central subsystem (1) is a hardware and software complex that automates the work of the department responsible for maintaining permits and executive documentation for incoming inspection, approval procedures, performing welding and non-destructive testing of the quality of welded joints, as well as managing the system configuration (hereinafter - OGM). The central subsystem can operate in a mode independent of other subsystems (including in their absence), providing the functionality of automating the maintenance of permits and as-built documentation for the construction object.

A subsystem for processing and monitoring data (2) is connected to the central subsystem (1) via a Wi-Fi wireless access network using a wireless access point (8) and subject to the condition of removal of no more than 200 meters from the transceiver (not shown in the figure). ) subsystems for processing and monitoring data (2) and maintaining line of sight.

The automated workplace of an engineer (5) of the central subsystem (1) is designed to organize access for employees with the functional duties of welding engineers and engineers of the OGM to the functionality of the system software.

The application and database server (4) is a centralized data storage system that ensures their safety and availability in the mode necessary to support the process of welding and installation work at construction sites.

The scanning and printing device (7) is intended for printing executive and permit documentation generated in the system software, as well as for scanning documents for downloading in the system software.

The access card reader (6) is designed to create authentication cards for welders authorized to work on a construction site.

An uninterruptible power supply unit (not shown in the figure) is designed to provide power to the application server and database (4) and communication equipment of the central subsystem (1) in cases of a short-term power outage. The main task of the device is to ensure the correct suspension of the application server and database (4), eliminating the loss or corruption of data.

The wireless access point (8) is designed to establish communication with the data processing and monitoring subsystem (2), provided that the transceiver of the data processing and monitoring subsystem (2) is located at a distance of no more than 200 m in line of sight.

The network switch (9) provides high-speed interaction between the engineer's workstation (5) and the application and database server (4) within the central subsystem (1).

Computers and devices of the central subsystem can be connected to each other in a local network via a wireless Wi-Fi network or via a wired connection.

The data processing and monitoring subsystem (2) is a hardware and software complex that automates the collection and processing of information on the progress of welding and non-destructive testing of welded joints at the production site. The data processing and monitoring subsystem (2) can operate independently of the central subsystem (2) during the period specified in the technical characteristics of the system, determined by the amount of accumulated data and the scheduled work planning horizon in the OGM.

The automated workplace of the foreman (10) provides the foreman with access to the corresponding system functionality, as well as intermediate storage and processing of information at the production site during periods between synchronizations with the central subsystem (1).

The automated workplace of the master (10) is connected to the Wi-Fi wireless access network.

The automated workplace of a specialist (not shown in the figure) is designed to provide access for specialists involved in the production of welding and non-destructive testing of welded joints to the functionality of the system software. In the system, the automated workplace of a specialist is intended for specialists in construction control and the quality control service of a construction organization, for employees of the non-destructive testing laboratory performing non-destructive testing of welded joints at the site.

The automated workplace of a specialist (not shown in the figure) is connected to the Wi-Fi wireless access network via the built-in Wi-Fi module.

The mobile workstation (11) is designed to provide access to the functionality of the system software from the territory of the welding production site, connected to the Wi-Fi wireless access network deployed at the production site. Access to the functionality of the system software is provided by a regular browser of the operating system.

The wireless access point (8) of the data processing and monitoring subsystem (2) is designed to organize a Wi-Fi wireless access network and provides connection for welding parameters recorders (12), mobile workstation (11), specialist workstation, central subsystem (1 ) (when its wireless access point (8) is within 200 meters in line of sight).

The registration subsystem (3) is a set of equipment interfaced with the welding equipment for collecting and transmitting to the subsystem for processing and monitoring data (2) on welding modes, it implements the authentication of welders and the control of welding tasks.

One set of the registration subsystem (3) is used to connect one welding equipment (not shown in the figure).

The welding parameters recorder (12) is the central node of the recording subsystem (3). Measuring units installed on welding equipment are connected to it, and the welder interacts with the system through it.

Two types of welding parameter meters can be used in the system.

The first type welding parameter meter includes a built-in current sensor, a wire flow sensor, a gas flow sensor. This type of meter is necessary for recording the parameters of welding equipment equipped with a EURO torch connection and in cases where the welding process takes place in an inert gas environment. It connects to the welding machine or feeder and welding torch.

The second type welding parameter meter is equipped with an external current sensor, suitable for recording the parameters of welding equipment and welding power sources that require an external sensor. It has connectors for connecting a remote welding wire consumption meter, for connecting to a welding parameters recorder and for connecting a cradle movement control device.

A remote wire consumption meter is required to control wire consumption in automatic welding machines of the AGW-2 type.

The device for controlling the movement of the cradle is necessary to control the speed of movement of the cradle in automatic welding machines of the AGW-2 type.

Local automated welding control system works as follows.

OGM welding engineers using software in the central subsystem (1) enter data on welding tasks into the system in accordance with the design documentation. The foreman directly at the place of work in the system software using the automated workplace of the foreman (10) of the data processing and monitoring subsystem (2) distributes welding tasks between the welders.

Welders, using personal authorization tools, are authenticated on the welding parameters recorders (12) included in the system kit and connected directly to the welding equipment in a configuration determined by the type of welding equipment; after passing the authentication, the welder selects welding tasks and proceeds to its execution (in case of an authorization error or in the absence of welding tasks, the welding parameters recorder (12) will not allow the use of welding equipment).

The welding parameters recorder (12) records the welding parameters, events occurring during the welding process, and transfers them to the system software database. Upon completion of the welding process, the welder puts a mark on the welding parameters recorder (12) of completion.

The foreman, specialists of the non-destructive testing laboratory, building control specialists, upon completion of the welding of parts, receive tasks through the system software for carrying out their actions to control the quality of the work and perform them in accordance with the regulations and performance marks with fixing the necessary parameters in the system software. All registered data and results of the work of specialists are stored by the system software on the application and database server (4).

Based on the results of the work, the OGM welding engineer in the central subsystem (1) can generate the necessary as-built documentation in accordance with the approved forms using the engineer's workstation (5), the system software and the scanning and printing device (7).

When carrying out acceptance tests of a local automated welding control system, the automated workstation of an engineer (5) was made in the form factor of a laptop based on Lenovo IdeaPad L340-17IRH with pre-installed system software. Access to the software of the local automated welding control system was carried out through the Microsoft Edge browser, which is included in the set of basic application software for the operating system of the engineer's workstation (5).

The application and database server (4) was made in the ATX form factor based on an ICL Ray P111 electronic computer for desktop or floor placement, while maintaining a distance of at least 10 cm from all sides of the case to ensure free air circulation.

The scanning and printing device (7) was implemented on the basis of the Brother 2540 multifunction printer in a desktop version. The access card reader (6) was made on the basis of the EM-H-PRG-USB RFID programmer.

An uninterruptible power supply (not shown in the figure) is based on the Ippon smart power pro 11 euro 1200 model. Wireless access points (8) are based on Mikrotik RBGROOVEGA-52HPACN. The network switch (9) was made on the basis of Mikrotik 1000M 1SFP+RB4011IGS+5HACQ2HND-I.

The master workstation (10) was implemented in a laptop form factor based on Lenovo IdeaPad L340-17IRH with pre-installed system software. The subsystem software was accessed through the Microsoft Edge browser, which is included in the set of basic application software for the wizard's workstation operating system.

A specialist workstation (not shown in the figure) was implemented in the form factor of a laptop based on the Lenovo Thinkpad E14-IML model with preinstalled system software connected to a Wi-Fi wireless access network at the production site. Access to the subsystem software was carried out through the Microsoft Edge browser, which is included in the set of basic application software for the operating system of the specialist's workstation.

The mobile workstation (11) was made in the form factor of a tablet based on the Runbo P12 model, connected to a Wi-Fi wireless access network deployed at the production site.

The power release unit was implemented on the basis of a three-phase four-contact Schneider Electric electromagnetic starter.

Claims (8)

1. A local automated system for controlling welding operations, comprising a central subsystem, a subsystem for processing and monitoring data, and at least one subsystem for recording welding parameters, which is made in the form of a recorder, interconnected via a wireless local area network Wi-Fi using wireless access points welding parameters with the ability to connect to welding equipment by means of measuring units and a welding parameter meter connected to the welding parameters recorder, which is configured to be connected to a welding machine or to a welding wire feeder and a welding torch, wherein the welding parameter meter includes a current sensor, a sensor welding wire flow rate and gas flow sensor, characterized in that the central subsystem is made in the form of a hardware-software complex, including an automated workstation of an engineer in the form of an appropriate personal computer with software, an application and database server in the form of an appropriate personal computer, a reader for welders' access cards connected via USB to a personal computer said engineer's workplace, a device for scanning and printing as-built and permitting documentation, an uninterruptible power supply for said computers and devices, which are appropriately connected to each other and to the mentioned wireless access point to the local Wi-Fi network by means of a network switch, while the data processing and monitoring subsystem is made in the form of a hardware-software complex with the possibility of independent operation from the central subsystem for a period determined by the amount of accumulated data on the progress of welding operations, including an automated workplace for the foreman in the form of an appropriate personal computer with software, an automated work a place of a specialist in the form of an appropriate personal computer with software and a mobile workstation in the form of a tablet computer with software, wherein said mobile workstation and workstations of a foreman and specialist are connected through said wireless access point to a local Wi-Fi network. 2. The system according to claim 1, characterized in that one subsystem for recording welding parameters is configured to be connected to one welding equipment. 3. The system according to claim 1, characterized in that the welding parameters meter is equipped with an external current sensor, a connector for connecting a remote welding wire consumption meter and a connector for connecting to a welding parameters recorder. 4. The system according to any one of paragraphs. 1-3, characterized in that the said computers and devices of the central subsystem are interconnected in a local network via a Wi-Fi wireless network. 5. The system according to any one of paragraphs. 1-3, characterized in that the said computers and devices of the central subsystem are interconnected in a local network via a wired connection.

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