SU912441A1 - Welding process control apparatus - Google Patents

Description

(54) DEVICE FOR MANAGING THE WELDING PROCESS

one

The invention relates to welding production and can be used to automatically control and control a group of systems for contact and arc welding.

The closest to the technical essence of the present invention is a device for controlling the process of resistance spot welding, comprising a device for controlling a welding machine, drivers, OR logic circuits, power valves, compression force reducers, comparison circuits, DC sources, inverters unit registers, the switch, the processor, to one input of which the output of a random access memory is connected, and to the second - the output of the interface unit, in which the first input is connected to the output of the analog-digital signal a converter whose input is connected to the output of an analog signal switch. The latter has one input connected to the output of the welding process parameter sensors and another to the second output output, the output of the processor interrupt device whose input is connected to the synchronizer output is connected to the processor input, and also contains a network tie-in unit, to the input of which the phase voltages of the power supply line of the welding machines are connected, and whose input is connected to the input of the processor interrupt device, sensors The network, air and water pressure, the inputs of which are connected respectively to the supply lines of welding machines with electricity and to devices for stabilizing the pressure of air and water in the pipeline 10 liters, and the outputs to the inputs of the analog signal switchboard, the control unit of the welding equipment, the input which is connected to the welding machine, and the outputs to the input of the processor interrupt device 15 and the interface of the interface unit, the unit for creating control commands for the welding equipment, the input of which is connected to the output of the interface module The analog and discrete outputs of which are connected to the inputs of the welding machine's control unit, and the other two discrete inputs to the inputs of the air and water pressure stabilization device in the mains, as well as the signaling unit for the strength of the welded structure, equipment faults and electrode stripping, connections to the output mate block 1.

However, this device is ineffective for controlling a large number of welding plants (several tens). This is related to that. that the group control algorithm of the device does not take into account the mode of operation of the welding equipment (welding of the product, selection of the mode, certification of equipment). The device does not allow to evaluate the impedance of the secondary circuit of welding installations - one of the most important indicators of their technical condition. In this device, the sampling frequency of the mode parameter sensors is constant, whereas for continuous seam and arc welding, it is advisable to select the sensor polling period taking into account the welding speed.

The purpose of the invention is to improve the quality of welding joints by increasing the accuracy of monitoring the mode parameters and the technical condition of the welding units. The goal is achieved in that a device for controlling the welding process, comprising a processor with operational memory, its device and through an interrupt unit with synchronization units with the power supply network of the welding units and monitoring the condition of the welding equipment connected to the welding unit, to the processor also through the unit The interfaces are connected to the welding equipment state control unit, the power supply control unit of the welding units with electricity, water, air and protective gas, the signal unit to increase the strength of the welded structure and equipment operability, the mode parameter control unit and the control command generation unit connected to the welding unit and the synchronizer, and the mode parameter control unit is connected to the welding unit through the sensor unit for the mode parameter parameters, the service priority selection unit of the welding units the work of the welding installation, the unit for setting the polling period of the sensor parameters and the impedance control unit of the secondary circuit of the welding unit The output of the latter is connected to the mode control unit, the first and second inputs of the impedance control unit of the secondary circuit of the welding unit are connected respectively to the welding unit and the sensor unit of mode parameters, the first output of the welding service priority selector unit is connected to the network unit the power supply of the welding units, the second output and the first input of the priority selection unit are connected respectively to the inputs and outputs of the interface unit, the second input of the selector unit the priority is with the synchronizer output, and the third input is with the output of the welding recorder

installation and with the input of the interface unit, the first input of the unit specifying the polling period of the mode parameter sensors is connected to the output of the interface unit, the second input is connected to the output of the sensor module of mode parameters, and the output of the task block is connected to the input of the mode parameter control unit and the second synchronizer input .

The unit for selecting the priority of welding units is made on four OR circuits, two registers, four AND circuits, an OR NOT circuit, and an input signal input module, the outputs of the latter being the first and second outputs of the block, and its inputs are connected to the outputs of the AND circuits the first inputs of the first and second circuits AND are connected to the first register, the inputs of the last are connected to the outputs of the first and second OR circuits, the first inputs of the OR circuits are connected to the first input of the unit, and the second inputs of the OR circuits are connected to the outputs of the operation mode and welding registers The third and fourth OR outputs are connected to the second register, and its inputs are to the first inputs of the third and fourth AND schemes, the second inputs of these schemes are OR-NOT connected to the first and second outputs of the third and fourth circuits. And the second input of the first and second circuits And connected to the outputs of the synchronizers.

The block for specifying the polling period of the mode parameter sensors contains a matching and serially connected register, a digital-to-analog converter, a multiplying device and an analog signal converter to a private signal, the output of the latter being the output of the block, the polling reference, the input-matching of the period polling, the register input is the first input of the same block, and the other input of the multiplying device is connected to the coordinator.

The impedance measurement unit of the secondary circuit of the welding installation contains a series-connected voltage sensors and an adder, as well as an inverter, the last input is the second input of the specified block, the output of the same block is connected to the output of the adder, the second input of the last is connected to the inverter, the first input of the measuring unit is connected with voltage sensor input.

The drawing shows a functional diagram of a device for controlling welding processes.

The device contains a processor 1, a random access memory 2, an interrupt device 3, a synchronization unit 4 with the power supply network of welding units, a welding equipment condition monitoring unit 5, an interface unit 6, a power supply control unit 7 for welding lines using electricity, water, air and protective gas , unit 8 for signaling the strength of the welded structure and equipment malfunction, unit 9 for monitoring the mode parameters, unit 10 for generating control commands, synchronizer 11, unit 12 for the parameter sensors mode , the welding priority setting unit 13 of the welding installations, the recorder 14 of the operating mode of the welding installation, the block 15 specifying the polling period of the sensor parameters of the mode and the block 16 of the impedance control of the secondary circuit of the welding installation 16. The drawing shows the welding setup 17. The dotted line around the blocks 14 and 17 indicates that the recorder of the operating mode of the welding unit 14 is installed at the workplace of the welder directly on the welding unit 17. Other welding units are connected to the device By additionally introducing into the device blocks 5, 9, 10, I, 12, 14, 15 and 46, one for each controlled welding installation. The service priority selection unit of the welding units 13 consists of OR 18-21 logic circuits, registers 22 and 23, logic circuits 24-27, OR OR NOT 28 logic, and module 29 for inputting initiative signals. The unit 15 for setting the polling mode sensor parameter period consists of a register 30, a digital-to-analog converter 31 of a multiplying device 32, a coordinator 33 and an analog signal converter 34 into a frequency signal. The impedance measurement unit 16 of the secondary circuit of the welding installation comprises a voltage sensor 35, an adder 36 and an inverter 37. The elements of the device are connected as follows. One input of the processor 1 is connected to the output of the random access memory 2, the second to the output of the interrupt device 3, and the third to the output of the interface block 6. The inputs of the interrupter device 3 are connected to the output of the anchor unit to the power supply network of the welding units 4 and the first output of the unit 5 to control the state of the welding equipment. The input of the synchronization unit 4 with the power supply network of the welding units is connected to the first output of the input module 29 of the initiative signals of the unit 13. The input of the welding state control unit 5 is connected to the welding unit 17. The inputs of the interface unit 6 are connected to the second output of the state control unit 5 welding equipment, the output of the control unit for supply lines of welding installations with electricity, water, air and protective gas 7, the output of the control parameters block 9, the output of the module 29 for inputting initiative signals unit 13 and the output of the recorder 14 of the operating mode of the welding unit, and the output of the interface unit 6 are connected to the input of the strength alarm unit of the welded structure about equipment failure 8, the input of the control command generation unit 10, the first input of the logic circuit OR 18-21 of the unit 13 and the register input 30 of the block 15. The inputs of the control unit, parameters of mode 9 are connected to the output of the sensor block of parameters of mode 12, the output of the analog signal converter to the frequency signal 34 of block 15, and the output of the adder 36 of block 16. First output of the unit 10 form control commands are connected to the first input of the synchronizer 11, and the second output is connected to the welding unit 17. The second input of the synchronizer 11 is connected to the output of the analog signal converter to the frequency signal 34 of the unit 15, and the output of the synchronizer 11 to the first inputs of logic circuits 24 and 26 block 13. The output of block 12 of mode parameter sensors is connected to the input of matcher 33 of block 15, the input of inverter 37 of block 16, and its input is connected to the welding unit 17. The second inputs of logic circuits OR 18 and 20 of block 13 are connected to the output of the recorder ma operation of the welding system 14, the second inputs of OR logic circuits 19 and 21 of unit 13 connected to the output welding operation mode setting recorder (not shown). To the first inputs of logic circuits N 25 n 27 the output of the synchronizer of the welding unit is connected (not shown in the drawing). The input of the voltage sensor 35 of the block 16 is connected to the input of the secondary circuit of the welding installation 17. In the block 13 of the priority selection of the maintenance of welding installations, the outputs of the logic circuit OR 18 and 19 are connected to the inputs of the register 22, the outputs of the logic circuit OR 20 and 21 are connected to the inputs of the register 23, the outputs of the register 22 are connected to the second inputs of the AND 24 and 25 logic circuits, the outputs of the register 23 are connected to the second inputs of the AND 26 and 27 logic circuits, the outputs of the And 24-27 logic circuits are connected to the inputs of the input module of the initiative signals 29, the outputs of the And 24 logic circuits 25 are connected to the inputs of the OR-NOT 28 logic circuit, the output of which is connected to the third inputs of the AND 26 and 27 logic circuits. In block 13, the priority of servicing welding stations has the number of logic circuits OR OR circuits 2 n, where n is the number of controlled welding installations. The drawing shows an example of block 13 for item 2. In block 15, specifying the period for polling the sensor parameters, the output register 30 is connected to the input of a digital-to-analog converter 31, the output of which is connected to the first input of the multiplying device 32, the second input of which is connected to the output of the correlator 33, and the output of multiplying device 32 is connected to the input of an analog signal-to-frequency converter 34. In block 16 for measuring the impedance of the secondary circuit of a welding installation, a voltage sensor 35 is connected to the first input an adder and 36, the second input of which is connected to the output of the inverter 37. The device operates as follows. When the welding pedal 17 is turned on, the control command generation unit 10 via the synchronizer 11 outputs to the welding service priority selection unit 13 a request signal for servicing this welding installation. The priority of servicing welding units is chosen according to their work regime. The mode of operation of the welding unit: the welding of the product, the selection of the parameters of the mode and certification - is set by the welder on the recorder 14 of the operating mode of the welding unit. The operating mode code of the welding machine is fed through interface 6 to processor 1 to select a data processing program. In addition, this code is supplied to the unit 13 for the selection of the priority of service of welding plants, in which, using a logic circuit OR 18, the register bit 22 is set to the unit corresponding to this setting when welding a product or using the logic circuit OR 20, the bit corresponding to this setting is set to one d register 23 in the selection of parameters of the mode and certification of this welding installation. The service request signal from the welding installation in question passes through the logic circuit 24 of block 13 to the input of module 29 for inputting the initiative signals of block 13, if register 22 of block 13 is the bit corresponding to this setting / equal to one, i.e. welding mode of the product. At the same time, the module for inputting the initiative signals 29 of the block 13 generates a request signal for servicing the synchronization unit with the power supply network of the welding units 4. In block 4, this signal is gated with a pulse whose front coincides with the beginning of each period of the mains voltage. Thus, the service request signal can be supplied to the interrupt device 3 only at the beginning of the mains voltage period. On this signal, the interrupt device 3 switches the processor 1 to the maintenance of the welding units. The processor 1, through the interface unit 6, reads the contents of the module 29 for inputting the initiative signals of the unit 13 and, using the received code, determines the address of the welding installation requiring maintenance. If the installation in question is not in the welding mode of the product, the request signal for processing data from this installation will be passed to the input module 29 to input the initiative signals of block 13 through the logic circuit 26 of block 13, which is controlled by the register 23 of block 13 corresponding to this setting, only in the presence of a logical unit signal at the output of the logic circuit OR-NOT 28 of block 13. This condition is fulfilled only in the absence of a request for data processing from any welding installation located in the welding area of the product. In other words, welding units that are in the certification mode or mode selection parameters will be serviced by processor 1 only after all the service requests that are installed, which are in the welding mode of the device, are serviced. To increase the flexibility of the group service algorithm, the registers 22 and 23 of the service priority selection unit of the welding units 13 can also be controlled directly by the processor 1 through the interface block 6 and logic circuits OR 18-21 of the block 13. The mode 13 registers 22 and 23. operation of the welding unit, (not shown in the drawing), is carried out through the logic circuits OR 19 and 21 of block 13, and the request for service from the synchronizer of this setup is fed to the inputs of logic circuits AND 25 and 27 of block 13. After determining Neither the address of the welding unit requesting to switch on the welding, processor 1 through the interface 6 with the help of the control unit of the supply lines of the welding units with electric power, water, air and protective gas 7 determines whether the mains voltage, water pressure and air are within the tolerances and shielding gas in supply lines of welding installations. In addition, the processor 1, using the welding equipment condition control unit 5., controls these parameters directly at the welding installation. If the conditions of normal operation are not fulfilled, the processor 1 through a block 6 of the interface sends to the block 8 signals of the strength of the welded structure and equipment malfunction information about possible malfunctions. Under normal conditions, the processor 1, via the block 6.control, generates a welding enable signal to the control command generation unit 10. In case of malfunctions in the welding unit during welding of the product, welding equipment condition monitoring unit 5 outputs an interrupt signal to interrupt device 3, according to which processor 1 reads the code at output of welding equipment state control unit 5 through the interface 6, determines the appearance of malfunctions and blocks further welding by issuing a signal to prohibit welding in the unit GO for the formation of control commands. When welding is turned on, the processor 1 for continuous resistance seam welding and arc welding sets up through block 6

interface to register 30 of the unit 15 for setting the sampling frequency of the sensors, the code of the value of the 4-step weld control step. The rec code is converted using a digital-to-analog converter 31 of block 15 to an analog signal and multiplied by block 32 of block 15 with a signal proportional to the welding speed V at the output of block 12 of sensors transmitted through the correlator 33 of block 15. Block 15 correlates the signal levels on both inputs of the multiplying device 32 of the block 15. The signal from the output of the multiplying device 32 of the block 15 is converted by the B analog signal converter to the frequency signal 34 of the block 15, into pulses, the frequency of which toth proportional to its size. From these pulses, the results of previous measurements in the mode parameter control block 9 are reset to zero, and this block is started in the mode of measuring data from the output of the block 12 of mode parameter sensors. Thus, the polling period of the sensors T will be

t - -

where K is the transfer coefficient of matcher 33 of block 15. That is, the control of the mode parameters for resistance continuous welding and arc welding is carried out, with variable time resolution, but constant time length discreteness. For contact precision and shchashogo shchagovogo welding during the passage of the welding current to the input of the coordinator 33 of the block 15 is supplied strobe of such a level that the frequency of interrogation of mode parameter sensors is 50 Hz, and in the absence of current - the strobe of such a level that the frequency of interrogation of sensors is 10 Hz The pulse from the output of the analog signal converter 34 to the frequency signal of the unit 15 is fed to the input of the synchronizer 11, which, through the unit 13 for selecting the priority of servicing the welding units and the synchronization unit 4 with the power supply network, sends the mode parameter data collection signal to the interrupt unit 3. The processor 1, via the interface block 6, using the mode parameter control block 9 reads the values of the mode parameters at the beginning of the mains voltage period. According to the data obtained, the processor 1 determines the strength of the weld, the required correction value of the mode parameters to prevent defects, and the stability of the set mode parameters. These data are accumulated in the random access memory 2, according to which the processor 1 calculates and provides in block 8 data on the strength of the welded structure and the technical state of the equipment.

To control one of the main indicators of the technical condition of the welding

unit - the secondary circuit impedance is used. Block 16. A signal proportional to the voltage at the input of the secondary circuit of the welding unit, which comes from the output of the sensor 35, the voltage of the block 16 is summed in the adder 36 of the block 16 with the signal at the output of the inverter 37 of the block 16. As the input of the inverter 37 of block 16 from the output of block 12 of mode parameter sensors, a signal is received that is proportional to the voltage on the electrodes of the welding installation; the signal at the output of the adder 36 of block 16 will be proportional to the voltage drop on the secondary conductors new contour of the welding installation. The processor 1 measures this voltage, as well as the welding current, using the block 9 of the control parameters of mode 9, and from these data calculates the impedance of the secondary contour of the welding installation. The value obtained by the processor 1 is compared with the tolerance, and in the event that the specified value is exceeded, information about the need for repair of the welding installation is given in block 8.

Random access memory 2 serves for storing the settings, the results of intermediate calculations and the control program. The connection of other welding units to the proposed device is carried out by additionally introducing into the device blocks 5, 9, 10, 11, 12, 14, 15 and 16.

In the proposed device, the group control algorithm takes into account the operation mode of the welding units. This increases the efficiency of the group control algorithm and allows you to simultaneously control a large number of welding stations. The control of the technical condition of the welding equipment is carried out taking into account the impedance of the secondary circuit of welding installations, which increases the reliability of the control and reduces the likelihood of defects in the welded joints. The device improves the accuracy of monitoring the parameters of the welding mode, as the selection of the optimal frequencies of their interrogation is carried out. This ultimately increases the reliability of quality control of welded joints.

The use of the device for controlling the processes of contact and arc welding in the manufacture of welded structures and aircraft construction, automotive industry and other areas of the plant-building industry allows a significant reduction in the rates used in the. currently costly control methods, improve the reliability of welded structures and the productivity of welding.

Claims (4)

A preliminary feasibility study shows that the device, while simultaneously servicing 50 welding installations, can produce an economic effect of 400 thousand rubles a year. The need for a people's household is 50 or more similar devices. Claim 1. Device for controlling the welding process, comprising a processor connected to a random access memory and, through an interrupt unit, with synchronization units with the power supply network of the welding units and monitoring the status of the welding equipment connected to the welding unit, to the processor also via the interface unit the welding equipment state control unit, the power supply control unit of the welding systems with electricity, water, air and protective gas are connected, the signal unit Accuracy of the welded structure and equipment health, the mode parameter control unit, and the control command generation unit connected to the welding unit and the Synchronizer, the mode parameter control unit through the mode parameter sensor unit connected to the welding unit, in order to improve the quality welded joints by increasing the accuracy of monitoring the parameters of the mode and the technical state of the welding equipment, the unit for selecting the welding service priority has been entered into the device x units, the recorder of the welding unit operation mode, the unit for setting the polling period of the mode parameter sensors and the impedance control unit of the secondary circuit of the welding installation; the output of the latter is connected to the mode parameter control unit; the first and second inputs of the impedance control unit of the secondary circuit of the welding installation are connected respectively the welding unit and with the sensor module of the mode parameters; the first output of the block for selecting the priority of service of the welding units is connected to the synchronization unit with a set The power supply of the welding units, the second output and the first input of the priority selection unit are connected respectively to the input and output of the interface unit, the second input of the priority selection unit to the synchronizer output and the third input to the output of the welding mode recorder, moreover, the first input of the task setting unit of the polling period of mode parameter sensors is connected to the output of the interface unit, the second input is connected to the output of the mode parameter sensor unit, and the task unit output is connected to the input of the control unit trench mode and a second input of the synchronizer. 2. The device according to claim 1, characterized in that the priority selection block of the welding units is made on four OR circuits, two registers, four AND circuits, an OR-NOT circuit and an initiative signal input module, the outputs of the latter being the first and second outputs the specified block, and its inputs are connected to the outputs of the AND circuits, the first inputs of the first and second circuits And are connected to the first register, the inputs of the last are connected to the outputs of the first and second OR circuits, the first inputs of the OR circuits are connected to the first input of the block, and the second inputs of the circuits OR connected with the outputs of the recorders of the mode of operation of the welding units, the outputs of the third and fourth circuits OR are connected to the second register, and its outputs are connected to the first inputs of the third and fourth schemes AND, the second inputs of these circuits are connected through the circuit OR to the outputs of the first and second circuits AND, the third inputs of the third and fourth circuits And and the second inputs of the first and second circuits And connected to the outputs of the synchronizers. 3. The device, p. 1, characterized in that the block for setting the polling period of the mode parameter sensors comprises a matcher and serially connected register, a digital-to-analog converter, a multiplying device and an analog signal-to-frequency signal converter, the converter output being the output of the polling period setting block, the matcher input is second the input of the polling period setting block, the register input is the first input of the same block, and the other input of the multiplying device is connected to the matcher. 4. The device according to claim 1, characterized in that the impedance measurement unit of the secondary circuit of the welding installation comprises a voltage sensor and an adder in series, as well as an inverter, the input of which is the second input of the specified unit, the output of the same unit connected to the output of the adder the second input of the latter is connected to the inverter, the first input of the measuring unit is connected to the input of the voltage sensor. Sources of information taken into account in the examination 1. Copyright certificate. The USSR on application No. 2572003 / 25-27, cl. In 23 K 11/24, 01.25.78 (prototype). one Ill til ll