CN113042870A - Intelligent management monitoring system and method for fixed spot welding machine production - Google Patents
Intelligent management monitoring system and method for fixed spot welding machine production Download PDFInfo
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- CN113042870A CN113042870A CN202110376869.6A CN202110376869A CN113042870A CN 113042870 A CN113042870 A CN 113042870A CN 202110376869 A CN202110376869 A CN 202110376869A CN 113042870 A CN113042870 A CN 113042870A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
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Abstract
The invention relates to an intelligent management and monitoring system and method for production of a fixed spot welding machine, wherein the system comprises a computer control system, a PLC control system, a fixed spot welding machine system, a network switch, an Ethernet communication line, a CCLINK communication line, a fixed spot welding machine control box, a PLC signal acquisition control module and a working state indicator lamp, the computer control system acquires welding data of the fixed spot welding machine control box during working to exchange data with the PLC control system, and displays and stores production related information, and the PLC control system realizes control and acquisition of the number of times of production welding in the production process of the fixed spot welding machine control box and control of the running state of the fixed spot welding machine system through the PLC signal acquisition control module. The invention realizes the monitoring and management of the welding quality of the fixed spot welding machine, the alarm prompt of production counting, boxing counting and coping counting, traces and inquires the production record of the product, avoids the occurrence of welding missing, and improves the production efficiency and the product quality.
Description
Technical Field
The invention belongs to the technical field of fixed spot welder production quality management, and particularly relates to an intelligent management and monitoring system and method for fixed spot welder production, which can be used for centrally managing and monitoring a plurality of fixed spot welders.
Background
Generally, a fixed spot welding machine works by adopting a welding principle of double-sided double-point overcurrent resistance welding, when the fixed spot welding machine works, two electrodes press a workpiece to enable two layers of metals to form a certain contact resistance under the pressure of the two electrodes, when welding current flows from one electrode to the other electrode, instant hot fusion is formed at the two contact resistance points, and the welding current instantly flows from the other electrode to the electrodes along the two workpieces to form a loop.
The fixed spot welding machine has high processing production efficiency, low production cost, convenient operation and mature and wide application process. However, welding data in the production process of the fixed-point welding machine cannot be displayed visually, and the welding process is affected by a plurality of external interference factors, so that the welding quality has certain deviation. Thus, there is no way in the actual production process to ensure that all production is acceptable. Meanwhile, fixed spot welders are often used to weld nuts and bolts, and there is no way to count the number of nuts and bolts that are too small. Furthermore, one or more nuts and bolts may be welded to a workpiece, with the risk of missing welds. If the workpieces which are missed to be welded flow into the next working procedure or a customer site, serious events such as rework maintenance cost or scrapped claims can be caused.
At present, most enterprises adopt a marking pen to mark and check on a workpiece after welding to avoid welding missing, but manual marking and checking is uncontrollable, and welding missing is caused. Meanwhile, the manual marking and spot inspection mode increases the workload of workers and reduces the production efficiency.
The existing part of fixed point welding machines have the function of a counter, but the counter only records the welding times, does not specially record the number of parts and the number of nuts or bolts aiming at the number of the nuts or bolts welded on a certain product, and does not compare and analyze the number of the parts and the number of the nuts or bolts after the production task is finished, so that the welding missing accident is easy to occur in the actual production. Meanwhile, quality accidents caused by insufficient welding strength besides missing welding, which affect the welding quality. For resistance welding, electrode grinding is a key factor influencing welding strength, and if the electrode is not ground in time according to process standards, resistance is increased and current is reduced during welding, so that the welding strength is insufficient, and the problem of welding failure is caused.
Disclosure of Invention
The invention aims to provide an intelligent management and monitoring system for production of a fixed spot welding machine and an intelligent management and monitoring method for production of the fixed spot welding machine, and aims to solve the problems that an existing fixed spot welding machine cannot prompt an operator to grind and pack according to different products and different process requirements, cannot check the equivalent relation between the production quantity and the use quantity of nuts/bolts according to different products, then prompts the operator whether welding falls occur, and monitors and manages the welding quality state of each time.
The invention is realized by the following technical scheme:
an intelligent management monitoring system for fixed spot welder production mainly comprises a computer control system 1, a PLC control system 2, a plurality of fixed spot welders, a PLC signal acquisition control module 8 and a plurality of working state indicator lamps 9 arranged on the fixed spot welders;
each fixed spot welding machine consists of a fixed spot welding machine system 3 and a fixed spot welding machine control box 7; the fixed spot welder control box 7 is respectively connected with the PLC signal acquisition control module 8, the working state indicator lamp 9 and the fixed spot welder system 3; the PLC signal acquisition control module 8 is respectively in control connection with the spot welder control box 7 and the working state indicator lamp 9;
each fixed spot welding machine system 3 is connected with the PLC control system 2 and the computer control system 1 through an Ethernet communication line 5 to form an Ethernet signal information exchange network; the PLC control system 2 is connected with each PLC signal acquisition control module 8 through a CCLINK communication line 6 to form a CCLINK information exchange network; the computer control system 1, the PLC control system 2 and the fixed electric welding machine control box 7 are connected together through an Ethernet communication line 5 and a network switch 4 to form a local area network;
the computer control system 1 is used for storing the production task of each fixed point welding machine system 3 and transmitting the production task to the PLC control system 2 through data exchange; welding data in the production process of the fixed spot welding machine system 3 can be uploaded to the computer control system 1 and the PLC control system 2 through the fixed spot welding machine control box 7 and are used for centralized management and monitoring of the production state and the product quality of spot welding equipment by managers; the PLC control system 2 can also perform production control on the fixed spot welding machine system 3 according to the production information of the fixed spot welding machine control box 7 acquired by the PLC signal acquisition control module 8; the computer control system 1 can judge whether the welding current collected by the fixed spot welder control box 7 is qualified or not, transmits unqualified welding information to the PLC control system 2, and controls equipment to stop working and give an alarm for prompting by the PLC control system 2.
Further, the fixed spot welding machine system 3 and the PLC signal acquisition control module 8 are respectively in threaded connection with the fixed electric welding machine control box 7.
Further, the working state indicator lamp 9 is arranged at an opening on the side surface of the fixed point welding machine control box 7.
An intelligent management monitoring method for fixed spot welder production comprises the following steps:
A. manually filling production tasks such as the production plan number, the product boxing number, the electrode repairing times setting and the like of each fixed spot welding machine system 3 into the programmed computer control system 1;
B. after the programmed computer control system 1 writes the production tasks in a filling manner, the data transmission function is started, and the production tasks of each fixed spot welding machine system 3 are transmitted to the PLC control system 2 through the pre-established Ethernet communication line 5;
C. when receiving a production task sent by the computer control system 1, the PLC control system 2 sends production information to a PLC signal acquisition control module 8 through a pre-established CCLINK communication line 6, and then carries out production control on each fixed spot welding machine system 3 through the PLC signal acquisition control module 8;
D. when each fixed spot welder system 3 performs each welding operation, the computer control system 1 acquires welding data such as welding current, welding time and the like during each welding operation through the established Ethernet communication line 5, and then stores and displays the welding data in the computer control system 1, so that after the welding data are acquired through the computer control system 1, specific welding data information can be observed manually and directly, the state of welding quality can be monitored and historically inquired through welding information, the computer control system 1 can judge whether the acquired welding current is qualified or not, welding unqualified information is transmitted to the PLC control system 2, and the PLC control system 2 controls equipment to stop working and give an alarm for prompting;
E. meanwhile, when each fixed spot welder system 3 performs each welding operation, the PLC control system 2 acquires and counts a welding completion signal of the fixed spot welder control box 7 by the PLC signal acquisition control module 8 through the established CCLINK communication line 6, when the welding count of each fixed spot welder system 3 reaches a repair electrode setting value in the PLC control system 2, the PLC control system 2 lights an A repair electrode indicator lamp in a working state indicator lamp 9 on the corresponding fixed spot welder and stops the equipment to work through the PLC signal acquisition control module 8, and after the electrode is repaired, the equipment can continue to work after a D reset button is manually pressed;
F. when the welding count of each fixed spot welding machine system 3 reaches a boxing set value in the PLC control system 2, the PLC control system 2 lights a B boxing indicator lamp in a working state indicator lamp 9 on the corresponding fixed spot welding machine and stops the equipment to work through a PLC signal acquisition control module 8, and the equipment can continue to work after an electrode is repaired by manually pressing a D reset button;
G. when the welding count of each fixed spot welder system 3 reaches the production quantity set value in the PLC control system 2, the PLC control system 2 lights a C production completion indicator lamp in a working state indicator lamp 9 on the corresponding fixed spot welder system 3 through a PLC signal acquisition control module 8 to prompt the completion of a production task, and then waits for the next production plan to circulate;
H. the method for identifying the welding missing risks of the system comprises the steps that if a workpiece needs to be welded for 2 times, 20 workpieces are packed into one box, when the B packing indicator lamp in the working state indicator lamp 9 is turned on after the 21 st workpiece is finished, the produced products are manually packed to find that more products are produced, so that the workers can find that the products which are welded in the box actually have welding missing in the workpiece and weld for 2 times, the workers are required to perform welding missing detection on the box which is just produced, the welding missing can be timely found and processed by a missing detection worker, and the welding missing workpiece is prevented from flowing into the next process or being delivered to a customer site; if the B boxing indicating lamp is lightened after the 20 th piece is finished, the box is normally produced without welding missing;
I. after the last box C production completion indicating lamp and the B boxing indicating lamp are lighted together, the fact that welding missing does not occur normally in production is indicated, otherwise, when the C production completion indicating lamp is lighted, the fact that welding missing workpieces exist in the last box is indicated if the B boxing indicating lamp is not lighted.
Furthermore, the number of the fixed spot welding machine systems 3, the fixed spot welding machine control boxes 7 and the working state indicator lamps 9 is multiple, and each fixed spot welding machine control box 7 is provided with 1 PLC signal acquisition control module 8, 1 working state indicator lamp 9 and 1 fixed spot welding machine system 3.
Further, the computer control system 1 reads the welding data in each welding operation process through the self-contained ethernet communication interface of the fixed spot welding machine control box 7, and stores and displays the welding data in the display of the computer control system 1.
Furthermore, welding data in the production process of the fixed spot welding machine system 3 can be uploaded to the computer control system 1 and the PLC control system 2 through the fixed spot welding machine control box 7, and managers can perform centralized management and monitoring on the production state and the product quality of spot welding equipment through the computer control system 1 and the PLC control system 2.
Further, the PLC control system 2 controls the operation of the spot welding machine fixing system 3 through a program programmed in the PLC control system 2 according to the production information of the spot welding machine fixing control box 7 collected by the PLC signal collection control module 8.
Furthermore, the computer control system 1 sets an upper limit value and a lower limit value of the process parameters such as welding current, compares the process parameters such as welding current collected in the fixed spot welding machine control box 7 with the set upper limit value and lower limit value, if the process parameters are qualified and normally work in a specified range, and if the process parameters are not in the specified range, the computer control system 1 considers that the process parameters are unqualified.
Compared with the prior art, the invention has the beneficial effects that:
1. the intelligent management monitoring system for fixed spot welding machine production realizes the monitoring and real-time display of welding data in the fixed spot welding machine production process, and can monitor and manage the welding quality each time;
2. when the missing inspection occurs, the alarm is given in time, the risk of missing welding is avoided, the production record tracing and query of the product can be realized while the production efficiency is improved, the quality state of the product is qualified, the material waste and the waste of rework operation are avoided, the production cost is reduced, and the product quality is improved;
3. the alarm prompt of production counting, boxing counting and grinding counting is realized, the difference alarm prompt function is realized by comparing the process requirements of different products, the waste of ineffective resources due to manual counting is avoided, and the labor intensity is reduced; when the welding times reach the grinding times of the process requirement, the work is automatically stopped, the grinding time is prompted to the operator, the operator can carry out the next production after the grinding is carried out and the operator resets, and the defect that the traditional equipment needs workers to check the production quantity to grind and has deviation is avoided.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a schematic structural view of a conventional fixed spot welding machine;
FIG. 2 is a schematic structural diagram of an intelligent management monitoring system for fixed spot welding machine production according to the present invention;
FIG. 3 is a schematic diagram of the electrical information control principle;
FIG. 4 is a schematic view of the construction of the tack spot welder system of the present invention;
FIG. 5 is a schematic diagram of signal acquisition of a control box and a PLC signal acquisition control module of a fixed-point welding machine;
FIG. 6 is a schematic diagram of a computer control system;
fig. 7 is a schematic diagram of mechanical connection of a fixed spot welder system, a PLC signal acquisition control module, a working state indicator light, and a fixed electric welder control box.
In the figure, 1, a computer control system 2, a PLC control system 3, a fixed spot welding machine system 4, a network switch 5, an Ethernet communication line 6, a CCLINK communication line 7, a fixed spot welding machine control box 8, a PLC signal acquisition control module 9 and a working state indicator lamp.
Detailed Description
The invention is further illustrated by the following examples:
the present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures. Meanwhile, in the description of the present invention, the terms "first", "second", and the like are used only for distinguishing the description, and are not to be construed as indicating or implying relative importance.
As shown in fig. 1-6, the intelligent management and monitoring system for fixed spot welding machine production comprises a computer control system 1, a PLC control system 2, a plurality of fixed spot welding machine systems 3, a network switch 4, an ethernet communication line 5, a CCLINK communication line 6, a plurality of fixed spot welding machine control boxes 7, a PLC signal acquisition control module 8 and a plurality of working state indicator lamps 9.
As shown in fig. 7, each fixed spot welder is composed of a fixed spot welder control box 7 and a fixed spot welder system 3, the fixed spot welder control box 7 is connected with the fixed spot welder system 3 through A M8 screws, wherein the fixed spot welder control box 7 is an electrical control part of each fixed spot welder, the fixed spot welder system 3 is a mechanical structure part of each fixed spot welder, and the fixed spot welder control box 7 and the fixed spot welder system 3 are together a complete fixed spot welder. The PLC signal acquisition control module 8 is fixed on the spot welder control box 7 through B M5 screws. The side of the fixed spot welder control box 7 is provided with a hole, and then the working state indicator lamp 9 is installed.
As shown in fig. 2, each fixed spot welding machine system 3 is connected to the PLC control system 2 and the computer control system 1 via an ethernet communication line 5, respectively, to form an ethernet signal information exchange network. The PLC control system 2 is connected with each PLC signal acquisition control module 8 through a CCLINK communication line 6 to form a CCLINK information exchange network.
As shown in fig. 5, the PLC signal acquisition control module 8 is connected to the spot welder control box 7 and the operating status indicator lamp 9 by control wires, so that the PLC signal acquisition control module 8 can control the spot welder control box 7 and the operating status indicator lamp 9.
The computer control system 1 is used for storing the production task of each fixed spot welding machine system 3 and transmitting the production task to the PLC control system 2 through data exchange. The computer control system 1 also reads the welding data in each welding operation process through the self-contained Ethernet communication interface of the fixed spot welding machine control box 7, and stores and displays the welding data in the display of the computer control system 1.
The fixed spot welding machine system 3 is a mechanical motion part of welding operation, information of an electrical control system and welding data in the production process can be uploaded to the computer control system 1 and the PLC control system 2 through the fixed spot welding machine control box 7, and managers can perform centralized management and monitoring on the production state and the product quality of spot welding equipment through the computer control system 1 and the PLC control system 2. Meanwhile, the PLC control system 2 controls the work of the fixed spot welding machine system 3 through a program programmed in the PLC control system 2 according to the production information of the fixed spot welding machine control box 7 acquired by the PLC signal acquisition control module 8.
The computer control system 1 is composed of a computer and special development software, and the software can display and edit quantity information such as production tasks. The computer control system 1 software program will set up the upper limit value and the lower limit value of the welding current and other technological parameters, then, will fix the welding current and other technological parameters collected in the spot welder control box 7 and compare with upper limit value and lower limit value that is set up. If the computer control system 1 is qualified and works normally within the specified range, if the computer control system 1 is not within the specified range, the computer control system 1 is considered unqualified; then, the computer control system 1 transmits the unqualified information to the PLC control system 2, and the PLC control system 2 controls the equipment to stop working and give an alarm for prompting.
According to the actual situation on site, the computer control system 1 and the PLC control system 2 are firstly installed near a plurality of fixed spot welding machine systems 3, and then the computer control system 1, the PLC control system 2 and the fixed spot welding machine control box 7 are connected together by an Ethernet communication line 5 and a network switch 4 to form a local area network. And then the PLC control system 2 and the fixed electric welding machine control box 7 are connected through a CCLINK communication line 6 to establish an information exchange network of a control end.
As shown in fig. 2, the intelligent management monitoring method for fixed spot welding machine production of the invention comprises the following steps:
1. and manually filling the production tasks of the production plan number, the product packing number, the electrode repairing times setting and the like of each fixed spot welding machine system 3 into the programmed computer control system 1.
2. After the programmed computer control system 1 writes the production task in a filling manner, the data transmission function is started, and the production task of each fixed spot welder system 3 is transmitted to the PLC control system 2 through the pre-established Ethernet communication line 5.
3. When receiving the production task sent by the computer control system 1, the PLC control system 2 sends the production information to the PLC signal acquisition control module 8 through the pre-established CCLINK communication line 6, and then performs production control on each fixed spot welding machine system 3 through the PLC signal acquisition control module 8.
4. When each fixed spot welder system 3 carries out welding work each time, the computer control system 1 can collect welding data such as welding current, welding time and the like during each welding work through the established Ethernet communication line 5, then the welding data are stored and displayed in the computer control system 1, specific welding data information can be observed manually and directly after the welding data are collected through the computer control system 1, the state of welding quality can be monitored and historically inquired through welding information, the computer control system 1 can judge whether the collected welding current is qualified or not, welding unqualified information is transmitted to the PLC control system 2, and the PLC control system 2 controls equipment to stop working and give an alarm for prompting.
5. Meanwhile, when each welding operation is carried out on each fixed spot welder system 3, the PLC control system 2 can collect and count the welding completion signal of the fixed spot welder control box 7 through the established CCLINK communication line 6, when the welding count of each fixed spot welder system 3 reaches the repair electrode setting value in the PLC control system 2, the PLC control system 2 can light the A repair electrode indicator lamp in the working state indicator lamp 9 on the corresponding fixed spot welder system 3 and stop the equipment working through the PLC signal collection control module 8, and the manual work can continue working after the D reset button is pressed after the electrode is repaired.
6. When the welding count of every fixed spot welder system 3 reaches the vanning set value in the PLC control system 2, PLC control system 2 can light the B vanning pilot lamp and stop equipment work in the operating condition pilot lamp 9 on the corresponding fixed spot welder system 3 through PLC signal acquisition control module 8, can continue work after the electrode is repaiied the manual work and press D reset button rear.
7. When the welding count of each fixed spot welder system 3 reaches the production quantity set value in the PLC control system 2, the PLC control system 2 lights the C production completion indicator lamp in the working state indicator lamp 9 on the corresponding fixed spot welder system 3 through the PLC signal acquisition control module 8, prompts the completion of the production task, and then waits for the next production plan to cycle so.
8. The method for identifying the welding missing risks of the system is that if a workpiece needs to be welded for 2 times, 20 workpieces are packed into one box, after the B packing indicator lamp in the working state indicator lamp 9 is turned on after the 21 st workpiece is finished, the produced products are manually packed to find that more products are produced, so that the workers can find that the products which are welded in the actual box are welded in a missing mode, the welding missing is welded for 2 times, the workers are required to perform welding missing detection on the box which is just produced, the welding missing can be found and processed in time through the missing detection workers, and the condition that the welding missing workpieces flow into the next process or are delivered to a customer site is avoided. If the B box indicator lamp is lighted after the 20 th workpiece is finished, the box is normally produced without welding missing.
9. After the last box C production completion indicating lamp and the B boxing indicating lamp are lighted together, the fact that welding missing does not occur normally in production is indicated, otherwise, when the C production completion indicating lamp is lighted, the fact that welding missing workpieces exist in the last box is indicated if the B boxing indicating lamp is not lighted.
When the spot-fixing spot-welding machine system 3 is used for welding once, the pin 12 of the system mainboard wiring port a in the fixed spot-welding machine control box 7 is welded with an output port, a signal is output, the output signal which is welded can be collected by the PLC signal collection control module 8 after the wiring in the figure, then the working state of the equipment is calculated by a program in the PLC control system 2, if the welding count reaches the set number of grinding, boxing and production, the PLC control system 2 controls the starting and stopping of the equipment by the pin 10 and the pin 12 of the wiring control system mainboard wiring port a of the PLC signal collection control module 8 in the figure, and meanwhile, the corresponding A repair electrode indicator lamp, B boxing indicator lamp and C in the working state indicator lamp 9 are lightened to prompt workers of the current working state of the equipment.
It is to be noted that the foregoing is only illustrative of the preferred embodiments of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.
Claims (9)
1. An intelligent management monitoring system and method for fixed spot welder production is characterized in that: the spot welding machine mainly comprises a computer control system 1, a PLC control system 2, a plurality of fixed spot welding machines, a PLC signal acquisition control module 8 and a plurality of working state indicator lamps 9 arranged on the fixed spot welding machines;
each fixed spot welding machine consists of a fixed spot welding machine system 3 and a fixed spot welding machine control box 7; the fixed spot welder control box 7 is respectively connected with the PLC signal acquisition control module 8, the working state indicator lamp 9 and the fixed spot welder system 3; the PLC signal acquisition control module 8 is respectively in control connection with the spot welder control box 7 and the working state indicator lamp 9;
each fixed spot welding machine system 3 is connected with the PLC control system 2 and the computer control system 1 through an Ethernet communication line 5 to form an Ethernet signal information exchange network; the PLC control system 2 is connected with each PLC signal acquisition control module 8 through a CCLINK communication line 6 to form a CCLINK information exchange network; the computer control system 1, the PLC control system 2 and the fixed electric welding machine control box 7 are connected together through an Ethernet communication line 5 and a network switch 4 to form a local area network;
the computer control system 1 is used for storing the production task of each fixed point welding machine system 3 and transmitting the production task to the PLC control system 2 through data exchange; welding data in the production process of the fixed spot welding machine system 3 can be uploaded to the computer control system 1 and the PLC control system 2 through the fixed spot welding machine control box 7 and are used for centralized management and monitoring of the production state and the product quality of spot welding equipment by managers; the PLC control system 2 can also perform production control on the fixed spot welding machine system 3 according to the production information of the fixed spot welding machine control box 7 acquired by the PLC signal acquisition control module 8; the computer control system 1 can judge whether the welding current collected by the fixed spot welder control box 7 is qualified or not, transmits unqualified welding information to the PLC control system 2, and controls equipment to stop working and give an alarm for prompting by the PLC control system 2.
2. The intelligent management and monitoring system and method for fixed spot welding machine production according to claim 1 are characterized in that: the fixed spot welding machine system 3 and the PLC signal acquisition control module 8 are respectively in threaded connection with a fixed electric welding machine control box 7.
3. The intelligent management and monitoring system and method for fixed spot welding machine production according to claim 1 are characterized in that: the working state indicator lamp 9 is arranged at the opening on the side surface of the fixed point welding machine control box 7.
4. The fixed point welding machine production intelligent management monitoring method is characterized by comprising the following steps:
A. manually setting the production plan number, the product boxing number and the electrode repairing times of each fixed spot welding machine system 3, and filling the production plan number, the product boxing number and the electrode repairing times into the computer control system 1;
B. after filling and writing the production task, the computer control system 1 starts a data transmission function to transmit the production task of each fixed spot welder system 3 to the PLC control system 2 through the pre-established Ethernet communication line 5;
C. the PLC control system 2 receives the production task sent by the computer control system 1, sends production information to the PLC signal acquisition control module 8 through the pre-established CCLINK communication line 6, and then carries out production control on each fixed spot welder system 3 through the PLC signal acquisition control module 8;
D. when each fixed spot welder system 3 performs each welding work, the computer control system 1 acquires welding data such as welding current, welding time and the like during each welding work through the established Ethernet communication line 5, stores and displays the welding data into the computer control system 1, the computer control system 1 can judge whether the acquired welding current is qualified or not, transmits unqualified welding information to the PLC control system 2, and the PLC control system 2 controls equipment to stop working and give an alarm for prompting;
E. when each fixed spot welder system 3 performs each welding operation, the PLC control system 2 acquires and counts a welding completion signal of a fixed spot welder control box 7 by a PLC signal acquisition control module 8 through an established CCLINK communication line 6, when the welding count of each fixed spot welder system 3 reaches a repair electrode setting value in the PLC control system 2, the PLC control system 2 lights an A repair electrode indicator lamp in a working state indicator lamp 9 on the corresponding fixed spot welder system 3 through the PLC signal acquisition control module 8 and stops the equipment work, and when the electrode is repaired, the equipment can continue to work after a D reset button is manually pressed;
F. when the welding count of each fixed spot welder system 3 reaches a boxing set value in the PLC control system 2, the PLC control system 2 lights a B boxing indicator lamp in a working state indicator lamp 9 on the corresponding fixed spot welder system 3 through the PLC signal acquisition control module 8 and stops the equipment from working, and the equipment can continue to work after an electrode is repaired by manually pressing a D reset button;
G. when the welding count of each fixed spot welder system 3 reaches the production quantity set value in the PLC control system 2, the PLC control system 2 lights a C production completion indicator lamp in a working state indicator lamp 9 on the corresponding fixed spot welder system 3 through a PLC signal acquisition control module 8 to prompt the completion of a production task, and then waits for the next production plan to circulate;
H. and (3) identifying the welding missing risk of the system: if one workpiece needs to be welded for 2 times, 20 workpieces are packed into one box, after the B packing indicator lamp in the working state indicator lamp 9 is lightened after the 21 st workpiece is finished, the produced products are manually packed to find that one more workpiece is produced, the manual worker can find that the actually produced workpiece in the box has a welding missing product, the welding missing is performed for 2 times, at the moment, the worker is required to perform welding missing detection on the just produced box for one hundred times, and the welding missing can be timely found and processed by a hundred-time detection worker; if the B boxing indicating lamp is lightened after the 20 th piece is finished, the box is normally produced without welding missing;
I. after the indicator lamp is turned on together with the B boxing indicator lamp after the last box C is produced, the fact that welding missing does not occur normally in production is indicated, otherwise, when the indicator lamp is turned on after the C is produced, and the fact that welding missing workpieces exist in the last box is indicated when the B boxing indicator lamp is not turned on.
5. The intelligent management and monitoring method for production of the fixed spot welding machine according to claim 4, characterized in that: the spot welding machine comprises a plurality of fixed spot welding machine systems 3, a plurality of fixed spot welding machine control boxes 7 and a plurality of working state indicator lamps 9, wherein each fixed spot welding machine control box 7 is provided with 1 PLC signal acquisition control module 8, 1 working state indicator lamp 9 and 1 fixed spot welding machine system 3.
6. The intelligent management and monitoring method for production of the fixed spot welding machine according to claim 4, characterized in that: the computer control system 1 reads the welding data in each welding operation process through the self-contained Ethernet communication interface of the fixed spot welding machine control box 7, and stores and displays the welding data in the display of the computer control system 1.
7. The intelligent management and monitoring method for production of the fixed spot welding machine according to claim 4, characterized in that: welding data in the production process of the fixed spot welding machine system 3 can be uploaded to the computer control system 1 and the PLC control system 2 through the fixed spot welding machine control box 7, and managers can perform centralized management and monitoring on the production state and the product quality of spot welding equipment through the computer control system 1 and the PLC control system 2.
8. The intelligent management and monitoring method for production of the fixed spot welding machine according to claim 4, characterized in that: the PLC control system 2 controls the work of the fixed spot welding machine system 3 through a program programmed in the PLC control system 2 according to the production information of the fixed spot welding machine control box 7 acquired by the PLC signal acquisition control module 8.
9. The intelligent management and monitoring method for production of the fixed spot welding machine according to claim 4, characterized in that: the computer control system 1 is provided with an upper limit value and a lower limit value of technological parameters such as welding current, the technological parameters such as welding current collected in the fixed spot welding machine control box 7 are compared with the set upper limit value and lower limit value, if the technological parameters are qualified and normal work in a specified range, and if the technological parameters are not in the specified range, the computer control system 1 considers that the technological parameters are not qualified.
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| CN113601086A (en) * | 2021-08-12 | 2021-11-05 | 奇瑞商用车（安徽）有限公司 | Manual welding anti-welding system and control method thereof |
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