CN113909628B - Intelligent welding production line system and welding method - Google Patents
Intelligent welding production line system and welding method Download PDFInfo
- Publication number
- CN113909628B CN113909628B CN202111314449.1A CN202111314449A CN113909628B CN 113909628 B CN113909628 B CN 113909628B CN 202111314449 A CN202111314449 A CN 202111314449A CN 113909628 B CN113909628 B CN 113909628B
- Authority
- CN
- China
- Prior art keywords
- welding
- workpiece
- management unit
- central control
- data
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
Images
Classifications
-
- 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
- B23K9/00—Arc welding or cutting
-
- 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- 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
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Plasma & Fusion (AREA)
- Optics & Photonics (AREA)
- General Factory Administration (AREA)
- Management, Administration, Business Operations System, And Electronic Commerce (AREA)
Abstract
The invention provides an intelligent welding production line system and a welding method, wherein the system comprises: the process design unit is used for uploading welding process parameters to the central control management unit; the welding program unit is used for uploading a welding operation process to the central control management unit; the quality management unit is used for receiving the workpiece welding quality data sent by the central control management unit; the welding operation unit is used for executing workpiece welding actions based on the instruction of the central control management unit; the order management unit and the central control management unit are connected with the order management unit; the order management unit is used for uploading an order plan to the central control management unit and receiving work reporting information sent by the central control management unit; and the central control management unit is used for controlling the operation of the intelligent welding production line system. The intelligent welding production line system and the welding method provided by the embodiment of the invention realize automatic processing of the whole welding process, improve the welding efficiency and save human resources.
Description
Technical Field
The invention relates to the technical field of welding, in particular to an intelligent welding production line system and a welding method.
Background
Welding is one of the most important processes in rail vehicle production, the influence of welding on product quality is critical, but a welding program is used as a special process, quality control is complex, and a plurality of flows are involved in the welding process, so that the unmanned operation of a welding production line cannot be realized due to the fact that manual participation is still relied on at present.
The welding production line under manual intervention has high labor cost and low automation efficiency, the quality of welding products is uneven due to the inconsistency of operation managers, and meanwhile, the body damage of the operation managers working on the welding production line for a long time also becomes a problem which needs to be solved urgently at present.
Disclosure of Invention
The invention provides an intelligent welding production line system and a welding method, which are used for solving the technical problems in the prior art.
The invention provides an intelligent welding production line system, which comprises: the welding system comprises a process design unit, a welding program unit, a quality management unit, a welding operation unit, an order management unit and a central control management unit connected with the units; the process design unit is used for uploading welding process parameters to the central control management unit; the welding program unit is used for uploading a welding operation process to the central control management unit; the quality management unit is used for receiving the workpiece welding quality data sent by the central control management unit; the welding operation unit is used for executing workpiece welding actions based on the instruction of the central control management unit; the order management unit is used for uploading an order plan to the central control management unit and receiving work reporting information sent by the central control management unit; and the central control management unit is used for controlling the operation of the intelligent welding production line system.
According to the intelligent welding production line system provided by the invention, the system further comprises an equipment management unit, and the equipment management unit is used for receiving the equipment operation data sent by the central control management unit and generating an equipment maintenance plan based on the equipment operation data.
According to the intelligent welding production line system provided by the invention, the welding operation unit comprises an identification module, a logistics module, a manipulator module, a welding module, a monitoring module and a data uploading module; the identification module is used for acquiring workpiece information; the logistics module is used for executing workpiece transportation actions based on the logistics path sent by the central control management unit; the manipulator module is used for clamping a workpiece; the welding module is used for performing welding operation on the workpiece; the monitoring module is used for acquiring workpiece welding quality data and equipment operation data in real time; the data uploading module is used for uploading the workpiece welding quality data and the equipment operation data to the central control management unit.
According to the intelligent welding production line system provided by the invention, the monitoring module comprises an equipment monitoring submodule and a workpiece welding quality monitoring submodule; the equipment monitoring submodule comprises an electrical parameter signal collector, a sound signal collector, a fault data memory and an analysis platform, wherein the electrical parameter signal collector is used for collecting current and voltage output in the running process of equipment, the sound signal collector is used for sound signals of movement of each main shaft in the running process of the equipment, the fault data memory is used for recording the electrical parameter signals and the sound signals under different fault conditions, and the analysis platform is used for judging the current running condition of the equipment based on the electrical parameter signals and the sound signals collected in real time; the workpiece welding quality monitoring submodule comprises a laser tracker, a welding parameter monitor, an abnormal alarm and an adaptive regulator, wherein the laser tracker is used for tracking and recording a workpiece which is welded currently, the welding parameter monitor is used for collecting welding current, welding voltage and protective gas flow in the workpiece welding process, the abnormal alarm is used for warning that welding parameters are abnormal, and the adaptive regulator is used for controlling the state of a manipulator.
According to the intelligent welding production line system provided by the invention, the self-adaptive regulator comprises a defect analysis subsystem, a defect database and a feedback control subsystem; the defect analysis subsystem obtains workpiece welding quality data by comparing workpiece welding parameters with defect data in the defect database, and the feedback control subsystem sends a control instruction to the manipulator based on the workpiece welding quality data.
According to the intelligent welding production line system provided by the invention, the defect analysis system obtains the welding quality data of the workpiece by comparing the welding parameters of the workpiece with the defect data in the defect database, and the method specifically comprises the following steps: and establishing a logical relation between the multiple welding parameters and the welding quality of the workpiece, and obtaining the welding quality of the workpiece based on the logical relation and the obtained welding parameters of the workpiece.
According to the intelligent welding production line system provided by the invention, the defect data comprises: appearance of the welded joint, X-ray defect detection pictures, metallographic pictures, welding parameter mutation waveforms and defect cause analysis.
The invention also provides a welding method, which comprises the following steps: the parameter modulation flow, the central control management unit receives the welding process parameters sent by the process design unit, the order plan sent by the order management unit and the welding operation flow sent by the welding program unit;
in the workpiece transferring process, the identification module reads the workpiece information on the workpiece buffer table and sends the workpiece information to the central control management unit, and the central control management unit controls the logistics module to transfer the workpiece to the manipulator based on the workpiece information;
the central control management unit calls welding process parameters, a welding operation flow and an order plan based on the workpiece information and starts a welding program based on the welding process parameters, the welding operation flow and the order plan;
and in the welding monitoring process, a monitoring module monitors the change conditions of welding current, welding voltage and protective gas flow in the welding execution process in real time, generates workpiece welding quality data and uploads the workpiece welding quality data to a quality management unit.
According to a welding method provided by the present invention, the welding method further includes: the monitoring module acquires equipment operation data in real time and uploads the equipment operation data to the equipment management unit so that the equipment management unit can generate an equipment maintenance plan.
According to a welding method provided by the present invention, the welding method further includes: and automatically polishing the welded semi-finished workpiece to obtain a finished workpiece.
According to the intelligent welding production line system and the welding method, the central control management unit controls the process design unit, the welding program unit, the quality management unit, the welding operation unit and the order management unit, the whole-process automatic processing of the welding production line is realized, the efficiency of the welding process is improved, and the dependence of the welding production line on the manual control process is thoroughly eliminated.
Drawings
In order to more clearly illustrate the technical solutions of the present invention or the prior art, the drawings needed for the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and those skilled in the art can also obtain other drawings according to the drawings without creative efforts.
FIG. 1 is a schematic diagram of an intelligent welding line system according to the present invention;
FIG. 2 is one of the flow diagrams of the welding method provided by the present invention;
FIG. 3 is a second schematic flow chart of the welding method provided by the present invention;
FIG. 4 is a graph of welding current monitoring provided by the present invention;
FIG. 5 is a graph of weld voltage monitoring provided by the present invention;
FIG. 6 is a graph of weld shield gas flow monitoring provided by the present invention;
FIG. 7 is a schematic structural diagram of a circumferential weld welding quality assessment system provided by the present invention;
FIG. 8 is a schematic diagram of the operation of a girth weld quality assessment system provided by the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is obvious that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without inventive step based on the embodiments of the present invention, are within the scope of protection of the present invention.
Fig. 1 is a schematic structural diagram of an intelligent welding production line system provided by the present invention, and as shown in fig. 1, the system includes: the welding system comprises a process design unit, a welding program unit, a quality management unit, a welding operation unit, an order management unit and a central control management unit connected with the units;
the process design unit is used for uploading welding process parameters to the central control management unit;
the welding program unit is used for uploading a welding operation process to the central control management unit;
the quality management unit is used for receiving the workpiece welding quality data sent by the central control management unit;
the welding operation unit is used for executing workpiece welding actions based on the instruction of the central control management unit;
the order management unit is used for uploading an order plan to the central control management unit and receiving worker reporting information sent by the central control management unit;
and the central control management unit is used for controlling the operation of the intelligent welding production line system.
It should be noted that the welding process parameters include: the welding current, the welding voltage and the flow of the welding shielding gas, and the three variables can directly determine the final welding condition, so the specific set values of the three variables are uploaded as welding process parameters; the welding operation flow is an operation sequence in the welding process, for example, a welding sequence which has a large influence on welding needs to be standardized by the welding program unit; the workpiece welding quality data indicates the completion condition of workpiece welding and is divided into a plurality of evaluation grades such as excellent, good and medium-poor; the order plan in the order management unit is the type of the welded workpieces needing to be finished and the quantity corresponding to the type of the welded workpieces, and the work reporting information belongs to feedback information and informs the order management unit of the completion condition of the order plan so as to carry out subsequent workload statistics according to the work reporting information; the central control management unit is a data storage station and a data processing center, and can send instructions to other units, and the central control management unit is equivalent to the brain of a human body.
According to the intelligent welding production line system, the central control management unit controls the process design unit, the welding program unit, the quality management unit, the welding operation unit and the order management unit, the whole-process automatic processing of the welding production line is realized, the efficiency of the welding process is improved, and the dependence of the welding production line on the manual control process is thoroughly eliminated.
According to the intelligent welding production line system provided by the invention, in the invention, the system further comprises an equipment management unit, wherein the equipment management unit is used for receiving the equipment operation data sent by the central control management unit and generating an equipment maintenance plan based on the equipment operation data.
The welding operation unit in the intelligent welding production line system directly executes the welding action on the workpiece, and in the process, the cooperation of a plurality of devices, such as a manipulator, a workpiece transport vehicle, a workpiece reading device and the like, is required, namely, the workpiece welding process is accompanied with the cooperative operation of the plurality of devices, the device state data and the health score are provided through the electrical parameter of each joint of the manipulator device, the sound frequency spectrum information of a lead screw is acquired, the device failure is early warned by combining a failure database and analyzing big data, the device failure is prompted to be predicted and repaired when the threshold value is exceeded, the logic of the device state monitoring system is basically consistent with that of welding, the device data is uploaded to a device management unit, a device maintenance plan is generated, the timed maintenance and the maintenance of the device are realized based on the plan, and the stable and reliable operation of the welding production line operation process is ensured.
According to the intelligent welding production line system, the equipment maintenance plan is generated through the equipment management unit, and the equipment is regularly maintained on the basis of the plan, so that the stable and reliable operation of the welding production line is ensured.
According to the intelligent welding production line system provided by the invention, the welding operation unit comprises an identification module, a logistics module, a manipulator module, a welding module, a monitoring module and a data uploading module; the identification module is used for acquiring workpiece information; the logistics module is used for executing workpiece transportation actions based on the logistics path sent by the central control management unit; the manipulator module is used for clamping a workpiece; the welding module is used for performing welding operation on the workpiece; the monitoring module is used for acquiring workpiece welding quality data and equipment operation data in real time; the data uploading module is used for uploading workpiece welding quality data and equipment operation data to the central control management unit.
It should be noted that the identification module is used for acquiring the class information of the workpiece to be welded, because the welding processes and welding flows required by workpieces of different classes are very different, the identification module provides a basis for identifying the class of the workpiece for calling the subsequent process parameters and the welding flows; specifically, the identification mode may be RFID radio frequency identification, or may be identification by scanning a two-dimensional code preset on the workpiece.
The logistics module is mainly a logistics transportation system composed of AGV (Automated Guided Vehicle), and the transportation paths of all the AGV are controlled by the central control management unit, so that the carrying efficiency of workpieces is greatly improved.
The monitoring module is mainly divided into an equipment monitoring part and a workpiece welding quality monitoring part which are respectively monitored, equipment operation data and workpiece welding quality data are respectively obtained, the equipment operation data and the workpiece welding quality data are not influenced mutually in the data acquisition process, and when the monitoring data are obtained, the data uploading module uploads the workpiece welding quality data and the equipment operation data to the central control management unit in real time so as to facilitate the subsequent data analysis process.
According to the intelligent welding production line system, the modules including the identification module, the logistics module, the manipulator module, the welding module, the monitoring module and the data uploading module are matched with one another, so that full-process automation of workpiece transportation, welding operation, whole-process welding monitoring and monitoring data uploading is realized, the automation operation level of a welding production line is effectively improved, personnel use is reduced in response, and the reliability of equipment operation is improved.
According to the intelligent welding production line system provided by the invention, in the invention, the monitoring module comprises an equipment monitoring submodule and a workpiece welding quality monitoring submodule; the equipment monitoring submodule comprises an electrical parameter signal collector, a sound signal collector, a fault data memory and an analysis platform, wherein the electrical parameter signal collector is used for collecting current and voltage output in the running process of equipment, the sound signal collector is used for sound signals of movement of each main shaft in the running process of the equipment, the fault data memory is used for recording the electrical parameter signals and the sound signals under different fault conditions, and the analysis platform is used for judging the current running condition of the equipment based on the electrical parameter signals and the sound signals collected in real time; the workpiece welding quality monitoring submodule comprises a laser tracker, a welding parameter monitor, an abnormal alarm and an adaptive regulator, wherein the laser tracker is used for tracking and recording a workpiece which is welded at present, the welding parameter monitor is used for collecting welding current, welding voltage and protective gas flow in the workpiece welding process, the abnormal alarm is used for alarming that welding parameters are abnormal, and the adaptive regulator is used for controlling the state of a manipulator.
It should be noted that the fault data storage is mainly used for accumulating corresponding electrical parameter signal values and sound signal conditions under different fault conditions, a logical relationship between the fault type and the signal is established based on the electrical parameter signal values and the sound signal values, and the analysis platform determines the fault type in the operation process of the equipment in an algorithm mode based on the logical relationship. The laser tracker is used for tracking and recording a workpiece being welded, the welding parameter monitor is used for collecting specific parameters of the workpiece in a welding process, and mainly comprises welding current, welding voltage, protective gas flow and the like, fig. 4 is a welding current monitoring curve provided by the invention, fig. 5 is a welding voltage monitoring curve provided by the invention, fig. 6 is a welding protective gas flow monitoring curve provided by the invention, the three curves respectively show the change conditions of the welding current, the welding voltage and the protective gas flow in the welding process, when the value of the welding parameter exceeds a preset interval, the abnormal alarm is triggered to give an alarm, the abnormal alarm is composed of a warning lamp and a buzzer, and the adaptive regulator can control the manipulator to stop the welding operation process so as to ensure the safety of a welding production line and the welding quality of the workpiece.
According to the intelligent welding production line system, the data acquisition and data analysis processes of the equipment operation condition and the workpiece welding quality condition in the workpiece welding process are respectively realized through the equipment monitoring submodule and the workpiece welding quality submodule, so that a decision basis is provided for the automatic adjustment of a welding production line, and the intelligent operation of the welding production line system is favorably realized.
According to the intelligent welding production line system provided by the invention, the self-adaptive regulator comprises a defect analysis subsystem, a defect database and a feedback control subsystem; the defect analysis subsystem obtains workpiece welding quality data by comparing workpiece welding parameters with defect data in the defect database, and the feedback control subsystem sends a control instruction to the manipulator based on the workpiece welding quality data; the defect analysis system obtains workpiece welding quality data by comparing workpiece welding parameters with defect data in the defect database, and specifically comprises: establishing a logical relation between multiple welding parameters and workpiece welding quality, and obtaining the workpiece welding quality based on the logical relation and the obtained workpiece welding parameters; the defect data includes: appearance of the welded joint, X-ray defect detection pictures, metallographic pictures, welding parameter mutation waveforms and defect cause analysis.
It should be noted that, the defect analysis subsystem: establishing a corresponding relation between the parameters and the defects through a mathematical analysis method, judging the types of the defects by a system when the parameters exceed a set threshold value, and calling corresponding pictures in a database; a defect database: a basic defect database of the framework girth weld automatic welding joint is established, the defects caused by abrupt change of welding parameters are counted to form a defect database, and the corresponding contents of the database meet the following technical requirements: a) Having a corresponding welding parameter break waveform; b) The method has the corresponding appearance of the welding joint, X-ray defect detection and metallographic pictures; c) Having a corresponding defect cause analysis; a feedback control subsystem: the feedback subsystem is connected with the welding system through a bus, and controls the welding machine to stop welding when the parameter exceeds a threshold value. For example, in the welding process, if the conditions of welding penetration, welding leakage and the like occur, the fluctuation of the welding current and voltage is large, the sudden change condition occurs on the parameter monitoring curve, and the relationship between the parameters and the welding quality can be correspondingly established.
According to the intelligent welding production line system, the welding defect data is collected to form the defect database, the logical relation between the multiple welding parameters and the welding quality of the workpiece is established, the defect analysis subsystem judges the welding quality in the welding process of the workpiece based on the logical relation, and sends the judgment result to the feedback control subsystem, so that the closed-loop control process of monitoring data acquisition, data analysis and data feedback is realized, and therefore, the intelligent welding production line system is beneficial to realizing the high-efficiency and high-quality operation of the welding production line and ensuring the welding quality of the workpiece.
Fig. 2 is a schematic flow diagram of a welding method provided by the present invention, as shown in fig. 2, the method includes:
s210, a parameter modulation process, a central control management unit receiving welding process parameters sent by a process design unit, an order plan sent by an order management unit and a welding operation process sent by a welding program unit;
s220, in the workpiece transferring process, the identification module reads workpiece information on a workpiece buffer table and sends the workpiece information to the central control management unit, and the central control management unit controls the logistics module to transfer the workpiece to the manipulator based on the workpiece information;
s230, a welding execution process, wherein the central control management unit calls welding process parameters, a welding operation process and an order plan based on the workpiece information and starts a welding program based on the welding process parameters, the welding operation process and the order plan;
and S240, a welding monitoring process, wherein the monitoring module monitors the change conditions of welding current, welding voltage and protective gas flow in the welding execution process in real time, generates workpiece welding quality data and uploads the workpiece welding quality data to the quality management unit.
It should be noted that, when different workpieces are welded, the specifically required welding process and welding operation flow are different, for example, workpieces suitable for high-speed rails and workpieces suitable for passenger cars have obvious differences in welding requirements, so before welding the workpieces, the welding process parameters and the welding operation flow need to be sent to the central control management unit, which belongs to a preparation flow before welding.
Each workpiece to be welded is provided with a two-dimensional code or an RFID mark, the identification module reads information of the workpiece to be welded by scanning the two-dimensional code or the RFID mark on the workpiece and sends the information of the workpiece to the central control management unit, and the central control management unit generates a control instruction by taking the information of the workpiece as a basis and sends the control instruction to the AGV and the manipulator, so that the two realize a process of cooperative transportation.
And the central control management unit calls the welding process parameters, the welding operation flow and the order plan matched with the workpiece to be welded according to the received workpiece information, and starts the welding program after the calling program is finished.
In the process of welding a workpiece, the monitoring module monitors the change conditions of welding current, welding voltage and protective gas flow in real time, the specific numerical values of the parameters are used as the basis for judging the welding quality of the workpiece, the evaluation condition of the welding quality of the workpiece is generated, and the evaluation condition is uploaded to the quality management unit.
The welding method provided by the invention realizes presetting of the process parameters and the welding process of the workpiece to be welded through the parameter modulation process, and realizes identification of the information of the workpiece to be welded based on the two-dimensional code or the RFID on the workpiece, thereby providing a basis for the subsequent instruction sending process of the central control management unit, realizing automatic calling of the welding process parameters and the welding process based on the information of the workpiece, realizing automatic operation of a welding production line, and having no need of human participation; meanwhile, the monitoring module realizes real-time monitoring on the welding process and ensures stable and reliable operation of the welding production line.
According to the welding method provided by the invention, the welding method further comprises the following steps: the monitoring module acquires equipment operation data in real time and uploads the equipment operation data to the equipment management unit so that the equipment management unit can generate an equipment maintenance plan.
It should be noted that, in the welding monitoring process, in addition to monitoring the welding quality of the workpiece, monitoring the operation condition of the equipment is also performed, the monitoring module acquires the operation data of the equipment in real time and uploads the data to the equipment management unit, so as to generate an equipment maintenance plan, and based on the plan, the maintenance and repair node of the equipment can be determined, so that the repair time of the equipment is earlier than the time when the equipment has problems.
According to the welding method provided by the invention, the process of generating the equipment maintenance plan based on the equipment operation data is realized through the monitoring module, and the equipment is maintained and repaired regularly based on the maintenance plan, so that the stable and reliable operation of a welding production line system is ensured.
According to the welding method provided by the invention, the welding method further comprises the following steps: and automatically polishing the welded semi-finished workpiece to obtain a finished workpiece.
It should be noted that, after a series of welding processes on a workpiece are completed, the automatic polishing module performs polishing action on the workpiece, and finally a finished workpiece after polishing is obtained, so as to ensure the flatness of the surface of the workpiece.
According to the welding method provided by the invention, the automatic grinding process of the workpiece is realized through the grinding module, the flatness of the surface of the welded workpiece is ensured, and the production consistency and the attractiveness of the workpiece are ensured.
Fig. 3 is a second schematic flow chart of the welding method provided by the present invention, and as shown in fig. 3, the welding method includes:
step1, upstream process design, wherein a technician finishes process design based on a minimum operation unit at TC, generates an order plan in an ERP system, finishes automatic welding programming in an off-line programming system, calibrates the order plan, and then downloads the order plan to a production line central control system, wherein the work reporting information is feedback of order completion conditions and is used for counting the work hour completion conditions.
Step2, after the assembly of the cross beam is completed by the assembly station, an RFID chip is installed and placed on the material storage table, in order to achieve universality of an interface of the material storage table, unilateral positioning is adopted (before RFID material identification is not adopted, the cross beam is placed on the material storage table, the position needs to be accurate, and the interface of the material storage table needs to be adjusted manually during mixed line production), an RFID reading device identifies material information, and the information is transmitted to an AGV and a welding manipulator.
And Step3, calling a logistics program by the AGV according to the material information, automatically adjusting the positioning of the telescopic arm and transferring the cross beam of the material storage table to the welding manipulator.
And Step4, automatically adjusting a clamp interface by the welding manipulator according to the RFID information, completing clamping, automatically calling a welding program by the system, carrying out secondary photographing check on the beam by adopting a visual identification technology for error prevention, avoiding the error of the RFID information and the misuse of the program, and starting program welding after confirmation.
And Step5, scanning and confirming the position of the welding seam by a laser scanning device at the front end of the welding gun, adjusting the angle of the welding gun in real time, monitoring welding current and voltage signals in real time by a welding monitoring system, judging the quality condition by the welding monitoring system, and early warning or stopping.
And Step6, uploading the quality data, and doubly transmitting the welding quality score and the quality information to a QMS (quality management system) by the welding monitoring system.
And Step7, monitoring welding equipment, developing a manipulator equipment monitoring system to avoid welding quality problems caused by equipment problems, electrically participating in each joint of the manipulator equipment, collecting sound spectrum information of a lead screw, combining a fault database, providing equipment state data and health scores through big data analysis, early warning equipment faults, prompting prediction and repair when the equipment state data exceeds a threshold value, basically conforming the logic of the equipment state monitoring system to welding, transmitting the equipment data to an EAM system in a double-transmission mode, and generating an equipment maintenance plan.
According to the welding method, the process parameters and the welding process of the workpiece to be welded are preset through the parameter modulation process, and the information of the workpiece to be welded is identified based on the RFID on the workpiece, so that a basis is provided for the subsequent instruction sending process of the central control management unit, the automatic calling of the welding process parameters and the welding process based on the workpiece information is realized, the automatic operation of a welding production line is realized, and no human intervention is needed; meanwhile, the monitoring module realizes real-time monitoring on the welding process and ensures stable and reliable operation of the welding production line.
Fig. 7 is a schematic structural diagram of a circumferential weld welding quality evaluation system provided by the present invention, and as shown in fig. 7, the system is composed of a hardware part and a software part, and specifically composed as follows:
hardware system:
(1) The parameter acquisition system mainly comprises current, voltage and gas flow sensors.
(2) And the sound and light alarm system consists of a warning lamp and a buzzer, and gives an alarm and stops working when the welding parameters exceed a set threshold value.
(3) The system adopts general commercial equipment, and comprises an LED display, an internal processor, a system memory and the like.
Software system
(1) The defect analysis system establishes a corresponding relation between the parameters and the defects through a mathematical analysis method, judges the types of the defects when the parameters exceed a set threshold value, and calls corresponding pictures in a database.
(2) The defect database is established, a basic defect database of the framework girth weld automatic welding joint is established, defects caused by abrupt change of welding parameters are counted to form a defect database, and the corresponding contents of the database meet the following technical requirements: having a corresponding welding parameter break waveform; the method has the advantages that the appearance of the corresponding welding joint, X-ray defect detection and metallographic pictures are provided; with a corresponding defect cause analysis.
(3) And the feedback system is connected with the welding system through a bus, and controls the welding machine to stop welding when the parameter exceeds a threshold value.
According to the intelligent welding production line system, the hardware system is formed by the parameter acquisition system, the sound-light alarm system and the host display system, the software system is formed by the defect analysis system, the defect database and the feedback control system, and the real-time monitoring and data uploading of the welding quality of the workpiece are realized by utilizing the coordination and cooperation of the hardware system and the software system, so that the welding quality of the workpiece is effectively ensured, and the probability of defective products is greatly reduced.
Fig. 8 is a schematic operation diagram of the girth weld quality evaluation system provided by the present invention, and as shown in fig. 8, the operation flow of the quality evaluation system is as follows:
(1) establishing a logical relation between welding parameters and defects, detecting the defects of the welding joints by adopting X-ray flaw detection through the current, the voltage, the gas flow, the gap, the welding gun angle, the misalignment, the welding deviation and the welding gun height change, and establishing the parameter change, the defect type, the type and the form under different parameter changes through observing the metallographic structure of the welding joint structure.
(2) Establishing a logical relation between multi-parameter changes and defects, on the basis of welding process procedures, researching the influence of single factors and interaction of welding parameters on the defects by adopting an orthogonal experiment, detecting the defects of the welding joints by adopting X-ray flaw detection, and establishing the logical relation between the multi-parameter changes and the defects by observing metallographic structures of the welding joint structures.
(3) And establishing a basic defect database of the girth welding joint, establishing the defect types, types and forms of different red early warning parameter waveform changes aiming at the parameter waveform that the welding parameter variation exceeds the red early warning in the welding process, and establishing the basic defect database of the girth welding joint.
(4) And (3) establishing an early warning interval, namely setting a yellow early warning interval waveform and a red early warning interval waveform of the circumferential weld welding quality on-line monitoring system according to the defect grade judgment standard.
(5) And (3) defect analysis, wherein a plurality of sensors monitor gas flow, voltage and current in the welding process of the welding seam, and when main welding parameters in the welding process fluctuate, a mathematical method is adopted to find out corresponding defect types corresponding to a defect database, so that the real-time monitoring of the automatic welding process is realized, and the traceability of data and the prediction of welding defects are realized.
(6) And (4) specifically positioning the position with abrupt change of welding parameters (welding current and welding voltage) according to system display, and finding out the position of the defect for repairing.
According to the intelligent welding production line system, the strict correspondence between the welding parameters and the welding defects is realized by establishing the logical relationship between the welding parameters and the welding defects, and meanwhile, the defect database is used as the judgment basis of the welding defects, so that the accurate judgment of the welding quality of the workpiece is realized, the reliability basis is provided for the instruction sending in the welding process of the workpiece, and the stable and reliable operation of the welding process of the workpiece is realized.
The above-described embodiments of the apparatus are merely illustrative, and the units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of the present embodiment. One of ordinary skill in the art can understand and implement it without inventive effort.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (9)
1. The utility model provides an intelligence welding production line system which characterized in that includes: the welding system comprises a process design unit, a welding program unit, a quality management unit, a welding operation unit, an order management unit and a central control management unit connected with the units; the welding operation unit comprises a monitoring module;
the process design unit is used for uploading welding process parameters to the central control management unit;
the welding program unit is used for uploading a welding operation flow to the central control management unit;
the quality management unit is used for receiving the workpiece welding quality data sent by the central control management unit;
the welding operation unit is used for executing workpiece welding actions based on the instruction of the central control management unit;
the order management unit is used for uploading an order plan to the central control management unit and receiving work reporting information sent by the central control management unit;
the central control management unit is used for controlling the operation of the intelligent welding production line system;
the monitoring module is used for acquiring workpiece welding quality data and equipment operation data in real time;
the monitoring module comprises an equipment monitoring submodule and a workpiece welding quality monitoring submodule;
the equipment monitoring submodule comprises an electrical parameter signal collector, a sound signal collector, a fault data memory and an analysis platform, wherein the electrical parameter signal collector is used for collecting current and voltage output in the running process of equipment, the sound signal collector is used for sound signals of movement of each main shaft in the running process of the equipment, the fault data memory is used for recording the electrical parameter signals and the sound signals under different fault conditions, and the analysis platform is used for judging the current running condition of the equipment based on the electrical parameter signals and the sound signals collected in real time;
the workpiece welding quality monitoring submodule comprises a laser tracker, a welding parameter monitor, an abnormal alarm and an adaptive regulator, wherein the laser tracker is used for tracking and recording a workpiece which is welded currently, the welding parameter monitor is used for collecting welding current, welding voltage and protective gas flow in the workpiece welding process, the abnormal alarm is used for warning that welding parameters are abnormal, and the adaptive regulator is used for controlling the state of a manipulator.
2. The intelligent welding production line system of claim 1, further comprising an equipment management unit configured to receive the equipment operation data sent from the central control management unit and generate an equipment maintenance plan based on the equipment operation data.
3. The intelligent welding production line system of claim 1, wherein the welding operation unit comprises an identification module, a logistics module, a manipulator module, a welding module, and a data upload module;
the identification module is used for acquiring workpiece information;
the logistics module is used for executing workpiece transportation actions based on the logistics path sent by the central control management unit;
the manipulator module is used for clamping a workpiece;
the welding module is used for performing welding operation on the workpiece;
the data uploading module is used for uploading workpiece welding quality data and equipment operation data to the central control management unit.
4. The intelligent welding production line system of claim 1, wherein the adaptive regulator comprises a defect analysis subsystem, a defect database, and a feedback control subsystem;
the defect analysis subsystem obtains workpiece welding quality data by comparing workpiece welding parameters with defect data in the defect database, and the feedback control subsystem sends a control instruction to the manipulator based on the workpiece welding quality data.
5. The intelligent welding production line system of claim 4, wherein the defect analysis subsystem obtains workpiece welding quality data by comparing workpiece welding parameters with defect data in the defect database, and specifically comprises:
and establishing a logical relation between the multiple welding parameters and the welding quality of the workpiece, and obtaining the welding quality of the workpiece based on the logical relation and the obtained welding parameters of the workpiece.
6. The intelligent welding production line system of claim 4, wherein the defect data comprises at least one of: appearance of the welded joint, X-ray defect detection pictures, metallographic pictures, welding parameter mutation waveforms and defect cause analysis.
7. A welding method using the intelligent welding production line system as claimed in any one of claims 1 to 6,
a parameter modulation process, in which the central control management unit receives welding process parameters sent by the process design unit, an order plan sent by the order management unit and a welding operation process sent by the welding program unit;
in the workpiece transferring process, the identification module reads the workpiece information on the workpiece buffer table and sends the workpiece information to the central control management unit, and the central control management unit controls the logistics module to transfer the workpiece to the manipulator based on the workpiece information;
the central control management unit calls welding process parameters, a welding operation flow and an order plan based on the workpiece information and starts a welding program based on the welding process parameters, the welding operation flow and the order plan;
and in the welding monitoring process, a monitoring module monitors the change conditions of welding current, welding voltage and protective gas flow in the welding execution process in real time, generates workpiece welding quality data and uploads the data to a quality management unit.
8. The welding method of claim 7, further comprising: the monitoring module acquires equipment operation data in real time and uploads the equipment operation data to the equipment management unit so that the equipment management unit can generate an equipment maintenance plan.
9. The welding method of claim 7, further comprising: and automatically polishing the welded semi-finished workpiece to obtain a finished workpiece.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111314449.1A CN113909628B (en) | 2021-11-08 | 2021-11-08 | Intelligent welding production line system and welding method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111314449.1A CN113909628B (en) | 2021-11-08 | 2021-11-08 | Intelligent welding production line system and welding method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN113909628A CN113909628A (en) | 2022-01-11 |
| CN113909628B true CN113909628B (en) | 2023-01-20 |
Family
ID=79245627
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202111314449.1A Active CN113909628B (en) | 2021-11-08 | 2021-11-08 | Intelligent welding production line system and welding method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN113909628B (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114932341B (en) * | 2022-04-18 | 2023-07-28 | 广州东焊智能装备有限公司 | Intelligent control system for welding automobile body |
| CN114951938A (en) * | 2022-06-17 | 2022-08-30 | 苏州安智无线电能传输研究院有限公司 | Automatic operation system based on intermediate frequency inversion direct current resistance welding |
| CN115139003A (en) * | 2022-08-18 | 2022-10-04 | 中建科工集团绿色科技有限公司 | Method for assembling steel structure top frame of box type house |
| CN115373360B (en) * | 2022-10-20 | 2023-03-03 | 山东芯合机器人科技有限公司 | Industrial robot based machining process quality monitoring system |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102270879A (en) * | 2010-06-02 | 2011-12-07 | 李景禄 | Equipment audio monitoring system of unattended substation |
| CN106563898A (en) * | 2016-11-11 | 2017-04-19 | 南京理工大学 | Management system for digital welding workshop |
| CN107363561A (en) * | 2017-07-14 | 2017-11-21 | 中车青岛四方机车车辆股份有限公司 | A kind of automatic welding production line integrated system |
| CN109093228A (en) * | 2018-09-25 | 2018-12-28 | 无锡三虹重工机械设备有限公司 | A kind of welding parameter intelligent monitor system |
| CN110193686A (en) * | 2019-06-06 | 2019-09-03 | 南宁嘉昌机电设备有限责任公司 | A kind of information-based welding management control system and control method |
| CN211589134U (en) * | 2019-08-29 | 2020-09-29 | 中车青岛四方机车车辆股份有限公司 | Motor train unit framework manufacturing system |
-
2021
- 2021-11-08 CN CN202111314449.1A patent/CN113909628B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102270879A (en) * | 2010-06-02 | 2011-12-07 | 李景禄 | Equipment audio monitoring system of unattended substation |
| CN106563898A (en) * | 2016-11-11 | 2017-04-19 | 南京理工大学 | Management system for digital welding workshop |
| CN107363561A (en) * | 2017-07-14 | 2017-11-21 | 中车青岛四方机车车辆股份有限公司 | A kind of automatic welding production line integrated system |
| CN109093228A (en) * | 2018-09-25 | 2018-12-28 | 无锡三虹重工机械设备有限公司 | A kind of welding parameter intelligent monitor system |
| CN110193686A (en) * | 2019-06-06 | 2019-09-03 | 南宁嘉昌机电设备有限责任公司 | A kind of information-based welding management control system and control method |
| CN211589134U (en) * | 2019-08-29 | 2020-09-29 | 中车青岛四方机车车辆股份有限公司 | Motor train unit framework manufacturing system |
Non-Patent Citations (1)
| Title |
|---|
| 智能监造***在转向架组装线上的应用与研究;梁立鹏等;《现代制造技术与装备》;20200215(第02期);第91-93页 * |
Also Published As
| Publication number | Publication date |
|---|---|
| CN113909628A (en) | 2022-01-11 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN113909628B (en) | Intelligent welding production line system and welding method | |
| CN110605489B (en) | System for accurately controlling welding parameters of complex structure and welding method | |
| CN107562034A (en) | Fault handling method and processing system on line | |
| CN116824731A (en) | Intelligent inspection method and equipment for thermal power plant | |
| CN115091491B (en) | Power distribution room maintenance patrol robot and control method thereof | |
| CN114851195A (en) | Control method of visual welding process system | |
| CN106271260B (en) | Intelligent control method in a kind of Robot Spot Welding | |
| CN116872206A (en) | Robot fault detection method and system based on industrial Internet | |
| CN114290073A (en) | Intelligent management system of steel rail welding production line and steel rail welding production line | |
| CN111070694B (en) | Pipeline welding quality monitoring method and system based on big data | |
| CN107918800A (en) | The maintenance system and maintenance method of harbour machinery | |
| CN116757645A (en) | Intelligent management system for glass processing production based on data analysis | |
| CN111596620A (en) | Assembly line quality management system | |
| KR101863047B1 (en) | Apparatus for discriminating quality of welding real time typed in kiosk | |
| CN114091700A (en) | Operation and maintenance method and device for power equipment, operation and maintenance management equipment and operation and maintenance robot | |
| CN109623190B (en) | Shaver welding control system and method | |
| CN113996953B (en) | State data comprehensive acquisition and analysis system of laser welder | |
| CN112445680A (en) | Remote monitoring and overhauling system and method for server of data center machine room | |
| CN111552248A (en) | Method for intelligent control system equipment OEE remote operation and maintenance | |
| CN115373360B (en) | Industrial robot based machining process quality monitoring system | |
| CN118335633A (en) | Automatic packaging method and system for chip process | |
| CN116618785B (en) | Circuit board welding abnormality recognition processing system based on image recognition | |
| CN216938915U (en) | Projection welding equipment with recognition function | |
| CN115366958B (en) | Self-diagnosis method, system and data management system | |
| CN219358379U (en) | Welding production line process monitoring system |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |