WO2011129467A1

WO2011129467A1 - Spot-welder automatic monitoring device

Info

Publication number: WO2011129467A1
Application number: PCT/KR2010/002242
Authority: WO
Inventors: 심술진
Original assignee: 주식회사 코닥트
Priority date: 2010-04-12
Filing date: 2010-04-12
Publication date: 2011-10-20

Abstract

The present invention relates to a spot-welder automatic monitoring device comprising a server MCU which can determine abnormal processing occurring during welding work and transmit a corresponding signal to a main MCU and can communicate in real time with an external apparatus that controls the procedure as a whole, and comprising a portable memory interface unit which interfaces with the server MCU and interfaces with portable memory; wherein various items of control data of the server MCU can be stored in portable memory. The present invention is advantageous in that shipment of defective items can be prevented by means of real-time monitoring for the occurrence of welding defects caused by changes in factors such as the welding material and welding conditions, and it allows real-time implementation of processes such as rewelding, stopping the production line or isolating products when an abnormality occurs in welding work by pre-setting information relating to abnormal processing indications, and various items of data such as rewelding conditions or a work-stop command can be stored in portable memory.

Description

Spot welder automatic monitoring device

The present invention relates to an automatic monitoring apparatus for optimum conditions for welding spot welding machines, and in particular, real-time defects caused by changes in raw or subsidiary materials or working conditions that may occur during spot welding operations used in industrial sites. It prevents the release of defective products at the source by monitoring, and if the abnormality of the welding work occurs, the abnormality can be immediately processed, and the automatic spot welding machine that can store all the history of welding in the portable memory including USB Relates to a device.

In general, spot welding is also called spot welding and is mainly used for welding of sheet material. Rivet seam refers to a hole in the plate and joined by rivets, but spot welding has the advantage that can join both plates without drilling a hole.

This method fuses a pressurized part with the heat of resistance of the contact part through electric current, putting a weld material between electrodes, and pressurizing it. This fusion part is called ‘nugget’.

In order to perform such spot welding well, it is necessary to control the pressing force, the energization time, and the current density. If the pressing force is large, the contact resistance decreases, so that the welding process is not good. On the contrary, if the pressing force is small, the spark occurs when passing the current, and the welding process is not good, and the electrode and the welding surface are violated. And the welding surface should be flat and no solvent is used. The welding time is very short because the heating area is smaller than that of butt welding.

In addition, when pressurizing and reaching the welding temperature, if the pressure is high, the weld is concave and the overall strength is weakened.

However, conventionally, when performing spot welding in an industrial site, even if spot welding defects occur due to changes in raw or subsidiary materials or working conditions, there is no device for monitoring the spot defects.

In addition, conventionally, there was no function of automatically adjusting to process conditions for defects that occur repeatedly during spot welding and automatically determining whether or not welding work was performed during spot welding.

In addition, conventionally, since there is no function to store welding conditions for each process for each of the mainly used welding processes, the welding conditions can be easily called and used at the time of work. .

In order to circumvent this, a device for automatically monitoring the welding condition of the spot welder has been developed. However, this also caused inconvenience due to the lack of a function of judging whether to re-weld or not. It was inconvenient because there was no function to stop the whole welding work process when it was continuously delivered, and it was inconvenient because it could not store data about welding conditions in a mobile database, and it was inconvenient to use because there was no function to communicate with the outside. It was.

The present invention has been proposed to solve the above problems, the purpose of which is to monitor the occurrence of defects due to changes in raw materials or working conditions that can occur during spot welding work in the industrial field in real time It prevents shipping, and if an abnormality occurs in the welding work, it is possible to set up information on the abnormality handling instruction in advance and immediately perform abnormal treatment such as re-welding, stopping the production line, or isolating the product. It is an object of the present invention to provide a spot welder automatic sensing device capable of storing various data related to a welding operation including a stop command in a removable memory.

The automatic spot welding machine monitoring apparatus according to the present invention for achieving the above object, in the automatic spot monitoring apparatus for optimum welding conditions of the spot welder, welding conditions including welding current, welding time and welding pressure during spot welding A welding condition measuring unit which measures and emits a corresponding signal, a welding condition display unit which displays welding conditions measured by the welding condition measuring unit, and sets upper and lower limit values of welding conditions including the welding current. High / low limit limit setting unit, a warning light indicator lamp divided into upper limit alarm operation, lower limit alarm operation, and normal operation for the comparison result of the measured welding condition and the previously set upper and lower limit values, and the spot welder automatic monitoring The welding condition measuring unit controls the overall operation of the apparatus and the operation of the welder for spot welding. By measuring the welding conditions including the measured welding current, and comparing the measured welding conditions with the previously set upper and lower limit values to determine normal and abnormal conditions, thereby controlling the operation of the warning lamp display lamp. Stores welding conditions for each process number inputted from the main MC oil (MCU) for transmitting a corresponding signal, a transmission / reception communication unit for interfacing data with the PC (PC), and the upper / lower limit setting unit. A memory for storing each welding condition measured by the welding condition measuring unit 62 for each process number, and storing a reference for the abnormal processing when an abnormality of the welding operation occurs, and is connected to the main MCU, in the main MCU It controls to store the various information received, and search the memory to determine the abnormal processing when an abnormality of welding work occurs A removable memory that transmits a signal to the main MCU and is connected to a server MCU (MCU) capable of real-time communication with an external device including the entire controller of the process and the server MCU, and connected to a USB (USB) which is a removable memory. Including a connection unit, under the control of the server MCU is characterized in that a variety of data is stored in the USB is a removable memory connected to the removable memory connection.

In addition, the spot welder automatic monitoring device according to the present invention further includes a contact resistance measuring unit for measuring the contact resistance to the welding surface by flowing a value less than the welding current value that will flow during the actual welding on the welding surface before the welding execution, The main MCU may determine the magnitude of the main welding current according to the contact resistance value measured by the contact resistance measuring unit to block welding defects that may occur during welding in advance.

In addition, in the automatic spot welder monitoring apparatus according to the present invention, when a welding operation stop command is given to the entire controller of the process, the server MCU includes a signal for each process provided by the main MCU and a signal issued by the server MCU. It characterized in that the communication so that the detailed information on the welding operation is displayed on the display device that can be recognized by the administrator.

According to the automatic spot welding machine monitoring device according to the present invention, by real-time monitoring the occurrence of defects caused by changes in raw materials or working conditions that can occur during spot welding work used in industrial sites to prevent the release of defective products, re-welding Rewelding can be performed when welding is insufficient for welding condition, and if the re-welding command is repeated a certain number of times, the whole work process can be stopped, and various welding conditions or work stop orders are included. The data can be stored in removable memory.

1 is a view showing an example of an external display panel of the automatic spot welding machine monitoring apparatus according to an embodiment of the present invention

2 is an internal configuration diagram of the automatic spot welding machine shown in FIG.

10. Start number display part 12. Start number switch

14. Lamp part for item display 16. Warning light indication lamp

28. Welding current display part 30. Welding current setting switch part

38. Welding time display part 40. Welding time setting switch part

48. Welding pressure display part 50. Welding pressure setting switch part

58, removable memory connector 60. Memory management switch

62, welding condition measurement unit 64. welding condition display unit

66. Upper / Lower limit setting unit 76. Contact resistance measurement unit

68. Main MCU 74. Server MCU

Hereinafter, a spot welder automatic monitoring device according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 to 2 show an automatic spot welding machine monitoring apparatus according to an embodiment of the present invention, Figure 1 is a view showing an example of an external display panel of the automatic spot welding machine monitoring apparatus according to an embodiment of the present invention, Figure 2 shows the internal configuration of the automatic spot welding machine shown in Figure 1, respectively.

As shown in the drawings, the spot welding machine automatic monitoring device 100 according to an embodiment of the present invention, the welding condition measuring unit 62, the welding condition display unit 64, the upper and lower limit limit setting unit 66 And a warning lamp display lamp 16, a start number display section 10, a start number setting switch 12, a contact resistance measuring section 76, a yield counter section 78, and a defective number counter section ( 80, a memory 72, a transmission / reception communication unit 70, a main MC controller (MCU), a server MCU 74, and a mobile memory connection unit 58.

In addition, an example of the outer panel of the spot welding machine automatic monitoring device 100 according to the present invention is shown in Figure 1, the first displayed on the outer panel will be described.

The outer panel includes a start number display section 10, a start number setting switch 12, an item display lamp section 14, a welding current display section 28, a welding current setting switch section 30, The welding time display section 38, the welding time setting switch section 40, the welding pressure display section 48, the welding pressure setting switch section 50, the movable memory connecting section 58, and the memory management section. Switch 60.

The start number display section 10 displays the number for each process. Process number is indicated to save welding condition for each welding process.

The start number setting switch 12 may set a number for each process. For example, each time a touch of the start number setting switch 12 is made, the process number increases by one.

The item display lamp unit 14 includes a warning lamp display lamp 16, a current lamp 18 for displaying a welding current, a time lamp 20 for indicating a welding time, and a pressure lamp 22 for displaying a welding pressure. ), A production lamp 24 indicating a production amount, and a defective lamp 26 indicating a number of defective products.

The welding current display unit 28 displays the welding number measured by the welding condition measuring unit 62 to be described later.

The welding current setting switch unit 30 includes a current setting switch 32 for setting, a current rising switch 34 indicating a rise, and a current falling switch 36 indicating a fall.

The welding time display unit 38 displays the measured welding time.

The welding time setting switch unit 40 includes a time setting switch 42 for setting, a time rising switch 44 indicating rising, and a time falling switch 46 indicating falling.

The welding pressure display unit 48 displays the measured welding pressure.

The welding pressure setting switch unit 50 includes a pressure setting switch 52 for setting, a pressure rising switch 54 indicating rising and a pressure drop switch 56 indicating falling.

The removable memory connector 58 refers to a connector for storing data, etc., regarding the result of the welding operation in a USB, which is a removable memory.

The memory management switch 60 is for copying the result of the welding operation to the removable memory or deleting the recorded result.

Meanwhile, the welding condition measuring unit 62 measures welding conditions including a welding current, a welding time, and a welding pressure at every working moment of the spot welding, and measures the welding conditions measured by the main microcontroller unit 18. Send the measured value for

The upper / lower limit setting unit 66 includes a welding current setting switch unit 30 for determining the upper and lower limit values of the welding current, and a welding time setting switch unit 40 for setting the upper and lower limit limits of the welding time. ) And a welding pressure setting switch section 50 for determining upper and lower limit values of the welding pressure.

The welding current setting switch 30, the welding time setting switch 40, and the welding pressure setting switch 50 have already been described, and the usage thereof is as follows.

For example, when determining the upper and lower limit values of the welding current, the current setting switch 32 is pressed for 3 seconds or longer. Then, the desired upper limit value is set using the current raising switch 34 and the current lowering switch 36. Subsequently, the current setting switch 32 may be touched again, and then the desired lower limit value may be set using the current increase switch 34 and the current drop switch 36.

In addition, the method of determining the upper and lower limit values of the welding time and the method of determining the upper and lower limit values of the welding pressure are the same as the above methods. However, it is the same as the method mentioned above except using the welding time setting switch part 40 and the welding pressure setting switch part 50, respectively.

At this time, the upper / lower limit values of the welding current, the welding time, and the welding pressure input by the upper / lower limit setting unit 66 are stored in the memory 72 described later.

The warning lamp display lamp 16 is divided into upper limit alarm operation, lower limit alarm operation, and normal operation by a result of comparing the welding current value measured by the welding condition measuring unit 62 with the upper and lower limit values previously set. do.

For example, the red lamp ('HI') lights up during the upper limit alarm operation, the yellow lamp ('LO') lights up during the lower limit alarm operation, and the green lamp ('GO') lights up during the normal operation. .

As described above, the item display lamp unit 14 includes a current lamp 18 for displaying a welding current, a time lamp 20 for indicating a welding time, and a welding pressure, in addition to the warning lamp display lamp 16. The pressure lamp 22 to display, the production lamp 24 which shows the yield, and the defective lamp 26 which shows the number of defective items are contained.

For example, each time the current setting switch 32 is pressed, the light is turned on in the above order, the welding current is in the welding current display unit 28, the welding time is in the welding time display unit 38, and the welding pressure is the welding pressure. Displayed on the display unit 48, respectively, the number indicating the production amount and the number of defective products are displayed on the welding current display unit 28.

The contact resistance measuring unit 76 measures a contact resistance to the welding surface by flowing a welding current value smaller than the welding current value to be flowed during the actual welding before welding.

When welding conditions including welding current, welding time, and upper / lower limit values of welding pressure for each welding process number that are mainly used for each process number are input, the welding conditions are stored in the memory 72. For example, after selecting a number to be input in the starting number display unit 10 and setting an upper / lower limit value for welding conditions, pressing the starting number setting switch 12 for a predetermined time causes the starting number. Current welding conditions are stored in the memory 72 at the number displayed on the display unit 10.

The production counter 78 monitors the progress of the spot welding in real time, accumulates and counts the quantity of work, and stores the value in the memory 72.

The defective number counter 80 monitors the progress of the spot welding in real time, accumulates and counts the quantity found to be defective, and stores the value in the memory 72.

The memory 72 stores welding conditions of the spot welding for each process number (starting number), stores measured values of welding conditions measured by the welding condition measuring unit 62, and measures the contact resistance. Storing the contact resistance value of the welding surface measured by the unit 76, storing the work quantity counted by the production counter unit 78, storing the defective quantity counted by the defective water counter unit 80, The upper / lower limit limit value input by the upper / lower limit setting unit 66 is stored, and other necessary data and programs are stored. The memory 72 also stores matters pertaining to criteria relating to abnormal processing (e.g., re-welding instructions, production line stop instructions, product isolation instructions elsewhere, etc.) when an abnormality occurs in the welding operation.

The transmission and reception communication unit 70 serves to interface with the PC to enable data transmission and reception.

The power supply circuit unit 84 supplies power to a required portion of the spot welder automatic monitoring device 100.

The main MCU 68 controls the welder controller 94 to control the operation of the spot welder for spot welding, and the overall operation of the spot welder automatic monitoring device. The main MCU 68 determines normal and abnormal based on a result of comparing the welding conditions including the welding current measured by the welding condition measuring unit 62 with the upper and lower limit values previously set. It controls the operation of 16 and issues a signal corresponding thereto to the server MCU 74 described later.

The server MCU 74 is connected to the main MCU 68, and controls to store a variety of information received from the main MCU 68, when the abnormality of the welding operation, the memory 72 Search and determine the abnormalities (re-welding instructions, production line stop instructions, product isolation instructions elsewhere) and transmit the corresponding signals to the main MCU (68), the welding machine, robot or the whole controller of the process (90) Communication with external equipment such as) is possible.

That is, based on various information delivered to the main MCU 68, the contents stored in the memory 72 are searched in advance. Corresponding information may be communicated, and in the case of instructions for re-welding, it may also be in communication with a welder (not shown), and in the case of instructions for isolation of a product, it may be in communication with a robot (not shown).

The overall controller 90 of the process is typically to control the overall work process of the factory, and is normally stored in a factory or the like outside the scope of the present invention, detailed description thereof will be omitted. In addition, a welding machine, a robot, etc. are well known devices, and thus detailed description thereof will be omitted.

In addition, when the condition regarding the abnormal processing cannot be found in the memory 72, the production line may be stopped.

In addition, the server MCU 74 received the welding condition determination of the main MCU 68 stores the welding condition information, and at the same time automatically searches for the memory 72 in which the abnormal processing instruction created by the user is pre-built. The abnormal processing instruction is requested, and an abnormal processing condition (upper / lower limit value including current), which is information necessary for abnormal processing, is sent to the main MCU 68.

At this time, when the main MCU 68 receives the re-welding request from the server MCU 74, the main MCU 68 measures the upper / lower limit value with the value provided to the server MCU 74 and controls the re-weld only. It works the same as the time point.

In addition, when the re-welding request is repeatedly generated more than a predetermined number of times, it is also possible to set in advance to stop the entire process.

In addition, the server MCU 74 transmits the entire history (information) on the welding operation including the signal for each process and the signal issued by the main MCU 68 to the mobile memory connection unit.

In addition, when the welding operation stop command is issued to the entire controller 90 of the process, the server MCU 74, the welding including a signal for each process provided by the main MCU 68 and the signal issued by itself. Detailed information about the job is communicated so that it can be displayed on a display device that can be recognized by the administrator, and awaits the next instruction of the administrator.

In this case, a communication method that is widely used, such as E-NET, may be used as a method of communicating to a display device that can be recognized by the administrator.

On the other hand, Table 1 below shows an example of the preferred rated specifications of the automatic spot welding machine 100 according to the present invention.

Table 1

Specification	Contents
Power supply voltage	AC220V (50 / 60Hz) combined use (allowable voltage range; 90-110%)
Power Consumption	5VA
Display method	7-segment LED display (red)
Input sensor	Current sensor (Spotron), dedicated pressure sensor
Measuring range	0 ~ 20.2KA (Measurement resolution function: 100A unit)
Measurement accuracy	Within ± 05.% of maximum range
Communication function	Setting by panel part TAD S / W
External structure	Sheet metal case structure
Insulation Resistance	100 ㏁ (at 500 V DC MEGA) between 1st and 2nd
Withstand voltage	1500 V AC for 1 minute between primary and secondary
Noise resistance	± 2000R phase and S phase pulse width 1㎲ or less
Ambient temperature	-10 ~ 60 ℃
Ambient Humidity	35 ~ 85% RH
Storage temperature	-20 ~ 65 ℃

Meanwhile, reference numeral 86 of FIG. 2 denotes a power switch.

Spot welding machine automatic monitoring device 100 according to the present invention having the above configuration has the following main functions.

1. Measurement and monitoring of welding current

The welding current is measured at every working moment of the spot welding and compared with a preset upper and lower limit value to operate a warning light indicator lamp 16 mounted for alarm so that an operator can discriminate according to the result.

2. Measurement and monitoring of welding time

The welding time is measured at every working moment of the spot welding and compared with a preset upper and lower limit value to operate a warning light indicator lamp 16 mounted for warning so that an operator can discriminate according to the result.

3. Measurement and monitoring of welding pressure

The welding pressure is measured at every working moment of the spot welding and compared with preset upper and lower limit values to operate a warning light indicator lamp 16 mounted for warning so that an operator can discriminate according to the result.

4. Automatic control by contact resistance

It is a function to cut the welding defect that may occur in the main welding by measuring the contact resistance on the welding surface as a result by flowing a value smaller than the welding current that will flow during actual welding (preliminary welding current value) before the welding is executed.

This function should apply a small current within the margin of error so that fusion does not occur on the welding surface due to preliminary welding current.

In the present invention, a current of 1/10 of the main welding current is a preliminary welding current value.

This function has a direct correlation between the contact resistance of the welding surface and the welding current. Therefore, the contact resistance is measured in advance to determine whether the main welding current is to be reduced or flowed further, and the welding device is controlled to prevent defects.

For example, when the main welding current set value is 16000 A, the preliminary welding current set value is 1600 Af. The resistance between the two welding conductors at the moment of preliminary welding current flow is measured, and compared with the welding condition (contact resistance reference value), which has been pre-documented, and transmitted to the welding device.

5. Counting function of cumulative output

The counting function of the cumulative output counts the cumulative output so that you can check the quantity worked in real time while the operation is in progress. The cumulative production counting operation is performed in the production counter unit 78, and the counted cumulative production number is displayed on the welding current display unit 28. In this case, the current setting switch 32 should be touched a few times so as to be turned on at the 'production' of the item display lamp unit 14.

It has already been described that the cumulative counter value is stored in the memory 72 in case the work is stopped due to other reasons while the work is in progress, and the work part found to be defective during monitoring is excluded from the cumulative counter.

6. Cumulative defect counting function

The cumulative defect counting function counts the quantity found to be defective by monitoring in real time while the work is in progress. Accumulating and counting the quantity of production proved to be defective is performed in the number of defectives counter unit 80, where the number of counted accumulated quantities is displayed on the welding current display unit 28. In this case, the current setting switch 32 should be touched several times so as to be turned on in the 'bad' of the item display lamp unit 14.

It has already been described that the cumulative counter value is stored in the memory 72 in case the work is interrupted due to other reasons while the work is in progress. have.

7. Welding work abnormal processing function

As described above, the server MCU 74 is connected to the main MCU 68. Therefore, the welding condition measurement result including the welding current delivered from the main MCU 68 and the condition related to the abnormality processing instruction stored in the memory 72 are searched for, and appropriate abnormality processing is performed. This is described in detail above.

In addition, when the welding operation stop command is given to the entire controller 90 of the process, the server MCU 74, the welding including a signal for each process provided by the main MCU 68 and the signal issued by itself. Detailed information about the job is communicated so that it can be displayed on a display device that can be recognized by the administrator, and awaits the next instruction of the administrator.

8. Ability to save welding job history in removable memory

As described above, the server MCU 74 transmits the entire history (information) about the welding operation including the signal for each process and the signal issued by the main MCU 68 to the mobile memory connection unit. . Therefore, it is possible to store the entire history (information) about the welding operation, such as a removable memory USB.

In addition, the automatic spot welding machine 100 according to the present invention can transmit and receive various data by using the PC by the transmission and reception communication unit 70.

The spot welding machine automatic monitoring device according to the present embodiment is not limited to the above-described form, and may be variously modified within a range not departing from the technical center of the present invention. This will be readily apparent to those skilled in the art.

Claims

In the optimum condition automatic monitoring device for welding spot welding machine,

A welding condition measuring unit which measures welding conditions including a welding current, a welding time, and a welding pressure during spot welding, and emits a signal corresponding thereto;

A welding condition display unit displaying welding conditions measured by the welding condition measuring unit;

An upper / lower limit setting unit for setting upper and lower limit values of welding conditions including the welding current;

A warning light indicator lamp which is divided into an upper limit alarm operation, a lower limit alarm operation, and a normal operation with respect to a result of comparing the measured welding condition with a previously set upper and lower limit values;

It controls the overall operation of the automatic spot welding machine and the operation of the welder for spot welding, measuring the welding conditions including the welding current measured in the welding condition measuring unit, and the upper and lower limits first set with the measured welding conditions A main MC (MCU) for controlling the operation of the beacon light indicator by determining normal and abnormal based on a result of comparing a limit value, and emitting a corresponding signal;

Transmitting and receiving communication unit for interfacing with the PC (PC) to enable data transmission and reception;

Store welding conditions for each process number input from the upper / lower limit setting unit, store each welding condition measured by the welding condition measuring unit 62 for each process number, and if abnormalities occur in the welding operation A memory in which criteria for processing are stored;

It is connected to the main MCU, controls to store a variety of information received from the main MCU, the memory is searched to determine the abnormality processing when an abnormality of the welding operation occurs and transmits a signal rising thereon to the main MCU And, server MCU (MCU) capable of real-time communication with external equipment including the entire controller of the process; And

Includes; is connected to the server MCU, a removable memory connected to the USB (USB) removable memory; including,

Spot welding machine automatic monitoring device, characterized in that a variety of data is stored in the USB as a removable memory connected to the mobile memory connection by the control of the server MCU.
According to claim 1, The spot welder automatic monitoring device,

Contact resistance measuring unit for measuring the contact resistance to the welding surface by flowing a value less than the welding current to be flown during the actual welding to the welding surface before the welding execution;

The main MCU determines the magnitude of the main welding current according to the value of the contact resistance measured by the contact resistance measuring unit to automatically prevent welding failures that may occur in welding during the spot welder.
The method of claim 1,

When a welding operation stop command is given to all the controllers of the process, the server MCU may recognize the detailed information on the welding operation including a signal for each process and a signal issued by the administrator from the main MCU. Spot welder automatic monitoring device, characterized in that the communication to be displayed on the indicator.