WO2022259290A1 - 溶接データ処理装置、及び、溶接データ処理方法 - Google Patents
溶接データ処理装置、及び、溶接データ処理方法 Download PDFInfo
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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
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- B23K9/02—Seam welding; Backing means; Inserts
- B23K9/028—Seam welding; Backing means; Inserts for curved planar seams
- B23K9/0282—Seam welding; Backing means; Inserts for curved planar seams for welding tube sections
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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
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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
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- B23K15/0053—Seam welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0093—Welding characterised by the properties of the materials to be welded
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
- B23K26/242—Fillet welding, i.e. involving a weld of substantially triangular cross section joining two 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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- B23K26/21—Bonding by welding
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- B23K26/282—Seam welding of curved planar seams of tube sections
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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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
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Definitions
- the present invention relates to a welding data processing device and a welding data processing method.
- welding machines monitor the welding state during welding operation and record it as a welding execution record.
- a welding state such as current, voltage, and energization time is detected by a welding state detection device, and the detected welding state is recorded on a recording medium as welding information (welding execution record).
- welding execution record A welder is disclosed.
- a radiographic inspection step is performed to determine the presence or absence of weld defects at the weld location.
- the welding execution record acquired as welding information by the welding machine disclosed in Patent Document 1 is associated with defect determination data indicating the result of determining the presence or absence of welding defects in the radiographic inspection process. Both data were not managed in an integrated manner. Therefore, knowledge derived by performing various processes such as analysis, prediction, machine learning, etc., using both welding execution records and defect determination data for each welding location has not been effectively utilized.
- the present invention has been made in view of the above problems, and a welding data processing device that enables effective utilization of knowledge derived from welding execution records and results of determining the presence or absence of welding defects, and , to provide a welding data processing method.
- a welding data processing device includes: a welding process registration unit that registers, in a welding process database, welding conditions and welding execution records of welding processes performed according to the welding conditions for each welding location; Defect determination data indicating the presence/absence of a weld defect at the weld location is registered in an inspection process database for each weld location, based on the image data of the weld location acquired in the radiographic inspection process. an inspection process registration unit; and an information processing unit that performs predetermined processing based on information registered in the welding process database and the inspection process database.
- the information processing unit performs predetermined processing based on the welding execution record registered in the welding process database and the defect determination data registered in the inspection process database. is performed, knowledge derived from the welding execution record and the defect determination data can be effectively utilized.
- FIG. 1 is an overall view showing an example of a welding integrated management system 1;
- FIG. 1 is a spool view showing an example of a weld location 11 provided at a welding site 10;
- FIG. 2 is a configuration diagram showing an example of a welder 6;
- FIG. 2 is a configuration diagram showing an example of an inspection machine 7;
- FIG. 2 is a block diagram showing an example of a welding data processing device 2;
- FIG. 3 is a data configuration diagram showing an example of a welding process database 211;
- FIG. 3 is a data configuration diagram showing an example of an inspection process database 212;
- FIG. 2 is a hardware configuration diagram showing an example of a computer 900 that constitutes each device of the integrated welding management system 1.
- FIG. 1 is a spool view showing an example of a weld location 11 provided at a welding site 10;
- FIG. 2 is a configuration diagram showing an example of a welder 6;
- FIG. 2 is a configuration diagram showing an example
- 4 is a flowchart showing an example of registration processing, qualification determination processing, and deviation determination processing in a welding process
- 10 is a flowchart (continued from FIG. 9) showing an example of registration processing, qualification determination processing, and deviation determination processing in the welding process
- 6 is a flow chart showing an example of registration processing and qualification determination processing in an imaging process.
- 4 is a flowchart showing an example of registration processing and qualification determination processing in an image determination step;
- 4 is a flowchart showing an example of defect analysis processing;
- 4 is a diagram showing an example of an analysis condition input screen 42;
- FIG. FIG. 10 is a diagram showing an example of an analysis result display screen 43 in defect analysis processing;
- FIG. 11 is a flowchart showing an example of eligibility analysis processing;
- FIG. 1 is an overall view showing an example of the welding integrated management system 1.
- FIG. 2 is a spool diagram showing an example of a weld location 11 provided at a welding site 10.
- the welding integrated management system 1 is a system that comprehensively manages welding processes and radiographic inspection processes performed at welding points 11 provided at various locations in a welding site 10 .
- the welding integrated management system 1 includes, as its main components, a welding data processing device 2, a construction progress management device 3, a manager terminal device 4, a welder terminal device 5A, a welding manager terminal device 5B, and an imaging operator terminal device. 5C, judge terminal device 5D, and inspection manager terminal device 5E.
- the welding integrated management system 1 includes a welder 6, a welder monitoring device 60, a temperature measurement device 61, and a distribution board 62 as devices used in the welding process, and in the radiographic inspection process.
- An inspection machine 7 is provided as equipment to be used.
- FIG. 1 for simplification of the drawing, the number of each device constituting the welding integrated management system 1 is illustrated one by one, but the number and arrangement of each device are not limited to the example in FIG. .
- Each of the above-described devices that make up the integrated welding management system 1 is connected to a wired or wireless network 8 and configured to be able to mutually transmit and receive various data.
- the form of the network 8 is not limited to the example in FIG. 1, and may be changed as appropriate.
- a plurality of mutually independent sub-networks such as the sub-network formed by the welding data processing device 2 and the sub-network formed by the construction progress management device 3, are connected to the integrated network formed by the administrator terminal device 4. By doing so, the network 8 may be constructed as a whole.
- the welding site 10 is, for example, a site for constructing (building) plant facilities such as natural gas plants, oil refining plants, chemical processing plants, power plants, steel plants, etc., and ships such as tankers, cargo ships, and passenger ships.
- a welder 50A, a welding manager 50B, an imaging operator 50C, a judge 50D, and an inspection manager 50E who belong to a plurality of subcontractors (contractors) who undertake the welding process and the radiographic inspection process.
- workers 50A to 50E carry out various works associated with the welding process and the radiographic inspection process under process control by the site manager 40 of the main contractor. Therefore, the integrated welding management system 1 is used, for example, by a main contractor to manage welding processes and radiographic inspection processes performed by a plurality of subcontractors (contractors).
- the welding site 10 is divided into a plurality of welding areas and managed.
- the welding site 10 is managed by dividing the building into a plurality of welding areas according to division criteria such as floor, section, purpose of use, and the like.
- the welding site 10 includes not only the case where the above construction is newly constructed, but also the case where it is repaired. Further, the welding site 10 is not limited to the above examples of constructions as long as the welding sites 11 are provided at various locations.
- the welding point 11 is represented in a spool drawing that is created as part of the design drawing of the plant, ship, etc. that will be the welding site 10 .
- the welding point 11 is, at the welding site 10, a point where arbitrary fluid-flowing pipes are welded together, a pipe and a pipe joint member (for example, a flange, an elbow, a tee, etc.) are welded together, or a pipe joint member is welded to another joint member. This is the place where the is welded.
- the welding location 11 is not limited to the above example as long as it is a location where members are welded together.
- the welding process is a work process performed by the welder 50A using the welding machine 6 according to the welding conditions determined for each welding point 11.
- arc welding is mainly used for the welding process, but any welding method such as gas welding, laser welding, electron beam welding, and resistance pressure welding may be used.
- Welding conditions in the welding process include, for example, the diameter, thickness, material (base material), joint shape, welding material, preheating, post-welding heat treatment, shielding gas, electrical characteristics (welding current, welding voltage, etc.) of the welded portion 11. , welding method (welding speed, welding direction, welding angle, arc time), etc. are determined.
- Welding conditions are determined for each welding point 11 by, for example, a welding process execution instruction, etc., and part of the information of the welding conditions is represented in a spool diagram (see FIG. 2). Then, as welding execution records in the welding process performed according to the welding conditions, for example, welding machine operation data recording the operation state of the welding machine 6 and preheating data recording the preheating state of the welding location 11 are acquired. be done.
- the imaging operator 50C uses the inspection machine 7 to irradiate the welded portion 11 where the welding process has been performed with radiation (X-rays, ⁇ rays, etc.), and the radiation transmitted through the welded portion 11 is measured. It consists of an imaging step of imaging strength as image data, and an image judgment step of judging whether or not there is a weld defect at the weld location 11 based on the image data by the judge 50D using the judge terminal device 5D. Welding defects are classified into defect types such as blowholes, pits, cracks, undercuts, overlaps, etc. If the size, depth or shape exceeds the allowable range, it is "defective" (failed). Otherwise, it is determined as "no defect” (accepted). In the image determination step, defect determination data indicating the result of determining whether or not there is a defect in the weld based on the image data of the welded portion 11 is acquired.
- defect determination data indicating the result of determining whether or not there is a defect in
- the welding data processing device 2 is composed of, for example, a general-purpose or dedicated computer (see FIG. 8 described later).
- the welding data processing device 2 manages various data acquired in the welding process and the radiographic inspection process. Details of the welding data processing device 2 will be described later.
- the construction progress management device 3 is composed of, for example, a general-purpose or dedicated computer (see FIG. 8 described later).
- the construction progress management device 3 includes design data including blueprints, spool drawings, construction instructions, etc. of the building to be the welding site 10, and the work schedule and progress of the entire construction process including the welding process and the radiographic inspection process.
- the design data and progress management data are displayed on the display screens of the manager terminal device 4 and worker terminal devices 5A to 5E.
- a notification based on the progress management data is sent to the site manager 40 and the workers 50A to 50E via the manager terminal device 4 and the worker terminal devices 5A to 5E.
- the construction progress management device 3 is connected to beacon receivers 30 installed at various locations on the welding site 10 .
- the beacon receiving device 30 acquires the card information included in the beacon signal and also acquires the position of the beacon card 31 that is the source of the beacon signal.
- the beacon cards 31 are possessed by the workers 50A to 50E, respectively, and the beacon receiving device 30 receives the card information of the beacon cards 31 possessed by the workers 50A to 50E (for example, each identification information specifying the workers 50A to 50E). (ID)) and the current position at regular intervals, the construction progress management device 3 obtains the position history data of each of the workers 50A to 50E.
- the beacon cards 31 are attached to the welding machine 6 and the inspection machine 7 respectively, and the beacon receiving device 30 receives the card information of the beacon cards 31 attached to the welding machine 6 and the inspection machine 7 (for example, the welding machine 6 and the inspection machine 7).
- the construction progress management device 3 acquires the position history data of the welding machine 6 and the inspection machine 7 by periodically acquiring each identification information (ID) that identifies the machine 7 and the current position.
- the administrator terminal device 4 is composed of a general-purpose or dedicated computer (see FIG. 8, which will be described later), etc., and is used by the site administrator 40.
- the administrator terminal device 4 includes a card reader 41 that reads card information on the beacon card 31 .
- the administrator terminal device 4 receives various input operations through the input screen, and displays various information through the display screen of applications, browsers, and the like.
- Welder terminal device 5A, welding manager terminal device 5B, imaging operator terminal device 5C, judge terminal device 5D and inspection manager terminal device 5E are general-purpose or It is composed of a dedicated computer (see FIG. 8, which will be described later) or the like, and is used by workers 50A to 50E, respectively.
- the worker terminal devices 5A to 5E are provided with a card reader 51 for reading card information of the beacon card 31.
- FIG. 1 the worker terminal devices 5A to 5E accept various input operations via input screens, and display various information via display screens such as applications and browsers.
- the welder terminal device 5A, the welding manager terminal device 5B, the imaging worker terminal device 5C, and the inspection manager terminal device 5E are used by the welder 50A, the welding manager 50B, the imaging worker 50C, and the inspection manager 50E. Since it is used when moving to 11 and working, it is preferably configured with a portable computer.
- the judge terminal device 5D receives and displays the image data acquired in the imaging process of the radiographic inspection process, for example, via the network 8 (including the Internet), so that the judge 50D can determine the welding point Since it is used when working at a place different from 11, it may be configured with either a portable computer or a stationary computer.
- FIG. 3 is a configuration diagram showing an example of the welding machine 6.
- the welding machine 6 includes a welding torch 63 held by the welder 50A, a power supply circuit 64 that receives power supply from the distribution board 62 and outputs a predetermined welding current to the welding torch 63, and various input operations ( For example, an operation control panel 65 for receiving setting operations for setting electrical characteristics of welding conditions, etc., and for controlling each part of the welding machine 6 .
- the welding torch 63 includes an electric discharge electrode 630, a nozzle 631 for supplying shielding gas from the gas tank 66, and a switch 632 for on/off operation.
- the welder 50A causes the welder terminal device 5A to display a spool drawing and a work instruction sheet for the welding point 11 to be worked, confirms the welding conditions of the welding point 11, and controls the welding point on the operation control panel 65. 11 welding conditions are set. Then, when the welder 50A brings the welding torch 63 close to the welding point 11 and turns on the switch 632, an arc is generated between the welding torch 63 to which a predetermined welding voltage is applied from the power supply circuit 64 and the welding point 11. is generated, and welding of the welding point 11 is performed.
- the welder monitoring device 60 is connected to the power supply circuit 64 and generates the welder operation data 12 recording the operation state of the welder 6 in accordance with the welding execution.
- the welding machine operation data 12 includes detailed data representing the operation state of the welding machine 6, such as time-series data of welding current, welding voltage, welding speed, welding direction and welding angle, their average values, and maximum values. , minimum value, arc time, etc. are recorded.
- the temperature measuring device 61 is composed of, for example, a non-contact thermometer, and generates preheating data 13 recording the preheating state of the welded portion 11 before welding is performed.
- preheating data 13 as detailed data representing the preheating state of the welding point 11, for example, time-series data of the surface temperature of the pipe, average preheating temperature, minimum temperature, maximum temperature, and preheating time are recorded.
- the distribution board 62 includes a switch 620 to which a power line for supplying power to the welding machine 6 is connected.
- the distribution board 62 receives the switch control command from the welding data processing device 2 to switch the switch 620 from the energized state to the cut-off state.
- FIG. 4 is a configuration diagram showing an example of the inspection machine 7.
- the inspection machine 7 includes a radiation irradiation unit 70 that irradiates radiation toward the welding location 11 , a detector 71 that is arranged facing the radiation irradiation unit 70 , and a guide that is detachably attached to the outer circumference of the welding location 11 . 72, a drive unit 73 that moves the radiation irradiation unit 70 and the detector 71 in the circumferential direction along the guide 72, and an operation control panel 74 that receives various input operations and controls each unit of the inspection machine 7.
- the detector 71 is composed of, for example, a flat panel detector (FPD) or the like.
- FPD flat panel detector
- the above configuration of the inspection machine 7 is an example, and for example, the inspection machine 7 including a detector 71 configured by computed radiography (CR) may be used.
- CR computed radiography
- the operation control panel 74 causes the drive unit 73 to operate the radiation irradiation unit 70 and the detection
- the radiation irradiation section 70 and the detector 71 are operated.
- the radiation irradiation unit 70 irradiates the welding point 11 with radiation
- the detector 71 detects the intensity distribution of the radiation transmitted through the welding point 11 .
- Generate image data 14 that records the entire orientation.
- FIG. 5 is a block diagram showing an example of the welding data processing device 2.
- the welding data processing device 2 includes a control unit 20 configured by a processor or the like, a storage unit 21 configured by a HDD (Hard Disk Drive), an SSD (Solid State Drive), a memory or the like, and a communication interface with the network 8.
- a communication unit 22, an input unit 23 configured by a keyboard, a mouse, etc., and a display unit 24 configured by a display, etc. are provided. Note that the input unit 23 and the display unit 24 may be omitted.
- the storage unit 21 stores a welding data processing program 210, a welding process database 211, and an inspection process database 212.
- FIG. 6 is a data configuration diagram showing an example of the welding process database 211.
- the welding process database 211 includes a welding location table 211A, a welder table 211B, a welder table 211C, and a welding manager table 211D.
- the welding location table 211A registers welding conditions, required qualifications, and welding execution records for each welding location 11 specified by the welding site ID, welding area ID, drawing number, and welding location number.
- Welding conditions include diameter, wall thickness, material (base metal), joint shape, welding material, preheating, post-weld heat treatment, shielding gas, welding current, welding voltage, welding speed, welding direction, welding angle, and , has an arc time.
- the welding execution record has, as its fields, the execution start date and time, the execution end date and time, the welder ID, the welder ID, the welder qualification determination data, the preheat data 13, the welder operation data 12, the preheat deviation determination data, and It has welding deviation judgment data.
- the manufacturer name, model name, and specifications are registered in the welder table 211B for each welder 6 specified by the welder ID.
- the affiliation ID, name, qualification, and welding manager ID are registered for each welder 50A specified by the welder ID.
- the welding manager table 211D the affiliation ID, name, and qualification are registered for each welding manager 50B identified by the welding manager ID.
- FIG. 7 is a data configuration diagram showing an example of the inspection process database 212.
- the inspection process database 212 is composed of a welding location table 212A, an inspection machine table 212B, an imaging operator table 212C, a judge table 212D, and an inspection manager table 212E.
- the welding location table 212A includes, for each welding location 11 specified by a welding site ID, a welding area ID, a drawing number, and a welding location number, required qualifications of an imaging operator, required qualifications of a judge, inspection implementation records, defect prediction data, And defect inference data is registered.
- the inspection execution record includes, as its fields, imaging date and time, imaging operator ID, inspection machine ID, imaging operator qualification determination data, image data 14, image judgment date and time, execution judge ID, judge qualification judgment data, and , has defect determination data.
- the image data 14 includes one or more images for one welding spot 11.
- the defect determination data further includes the presence or absence of a welding defect (“defective” or “no defect”) and, if “defective” is present, detailed defect status indicating the detailed status of the defect.
- the defect detailed status has, as its fields, for example, a defect position indicating a position on the image data 14, a defect type, a size, and a depth. Note that when a plurality of defects are imaged for one image data 14, the defect determination data includes detailed defect status for each defect.
- the manufacturer name, model name, and specifications are registered in the inspection machine table 212B for each inspection machine 7 specified by the inspection machine ID.
- the imaging operator table 212C registers the affiliation ID, name, qualification, and inspection manager ID for each imaging operator 50C specified by the imaging operator ID.
- the assessor table 212D registers the affiliation ID, name, qualification, and inspection manager ID for each assessor 50D specified by the assessor ID.
- the inspection manager table 212E the affiliation ID, name, and qualifications are registered for each inspection manager 50E specified by the inspection manager ID.
- the data configurations of the welding process database 211 and the inspection process database 212 are not limited to the above examples and may be changed as appropriate. may be added.
- the welding process database 211 and the inspection process database 212 may be stored in an external database management device instead of the storage unit 21 of the welding data processing device 2. In that case, the welding data processing device 2 accesses the database management device via the communication unit 22 .
- the control unit 20 By executing the welding data processing program 210 stored in the storage unit 21, the control unit 20, as shown in FIG. It functions as a unit 203 , an inspection process support unit 204 and an output processing unit 205 .
- the welding process registration unit 200 registers, in the welding process database 211, the welding conditions and the welding execution record of the welding process performed according to the welding conditions for each welding point 11.
- the inspection process registration unit 201 determines whether or not there is a welding defect at each welding point 11 based on the image data 14 of the welding point 11 acquired in the radiographic inspection process.
- An inspection execution record including at least defect determination data indicating the results obtained is registered in the inspection process database 212 .
- the information processing section 202 performs predetermined processing based on the information registered in the welding process database 211 and the inspection process database 212.
- the information processing section 202 includes a qualification determination section 202A, a deviation determination section 202B, a defect analysis section 202C, a disqualification analysis section 202D, a deviation analysis section 202E, a deviation determination criteria setting section 202F, and a welding assistant as sections that perform predetermined processes. It includes a unit 202G, a defect prediction unit 202H, a machine learning unit 202I, and a defect inference unit 202J. The details of each section 202A to 202J of the information processing section 202 will be described later.
- the welding process support unit 203 cooperates with the information processing unit 202 and performs various processes to support the implementation of the welding process.
- the inspection process support unit 204 cooperates with the information processing unit 202 and performs various processes for supporting the implementation of the inspection process.
- the output processing unit 205 generates display data for displaying the result of processing by the information processing unit 202, for example, on the display screen of an application or browser that operates on the administrator terminal device 4 and the worker terminal devices 5A to 5E, The generated display data is transmitted (output) to the manager terminal device 4 and the worker terminal devices 5A to 5E.
- the output processing unit 205 may generate print data for printing out the processing result of the information processing unit 202 using a printer or the like, or may store the print data in the storage unit 21 .
- each portion provided in the control unit 20 are distributed to a plurality of devices, thereby providing a plurality of functions. It may be implemented in a device.
- FIG. 8 is a hardware configuration diagram showing an example of a computer 900 that constitutes each device of the integrated welding management system 1. As shown in FIG.
- Each of the welding data processing device 2, the construction progress management device 3, the manager terminal device 4, the worker terminal devices 5A to 5E, the operation control panel 65 of the welding machine 6, and the operation control panel 74 of the inspection machine 7 is a general-purpose Alternatively, it is configured by a dedicated computer 900 .
- the computer 900 includes, as its main components, a bus 910, a processor 912, a memory 914, an input device 916, an output device 917, a display device 918, a storage device 920, a communication I/F (interface).
- the processor 912 is composed of one or more arithmetic processing units (CPU (Central Processing Unit), MPU (Micro-processing unit), DSP (digital signal processor), GPU (Graphics Processing Unit), etc.), and the entire computer 900 It operates as a control unit that supervises the
- the memory 914 stores various data and programs 930, and is composed of, for example, a volatile memory (DRAM, SRAM, etc.) functioning as a main memory, a non-volatile memory (ROM), a flash memory, and the like.
- the input device 916 is composed of, for example, a keyboard, mouse, numeric keypad, electronic pen, etc., and functions as an input unit.
- the output device 917 is configured by, for example, a sound (voice) output device, a vibration device, or the like, and functions as an output unit.
- a display device 918 is configured by, for example, a liquid crystal display, an organic EL display, electronic paper, a projector, or the like, and functions as an output unit.
- the input device 916 and the display device 918 may be configured integrally like a touch panel display.
- the storage device 920 is composed of, for example, an HDD, SSD, etc., and functions as a storage unit. The storage device 920 stores various data necessary for executing the operating system and programs 930 .
- the communication I/F unit 922 is connected to a network 940 (which may be the same as the network 8 in FIG. 1) such as the Internet or an intranet by wire or wirelessly, and exchanges data with other computers according to a predetermined communication standard. functions as a communication unit that transmits and receives.
- the external device I/F unit 924 is connected to the external device 950 such as a camera, printer, scanner, reader/writer, etc. by wire or wirelessly, and serves as a communication unit that transmits and receives data to and from the external device 950 according to a predetermined communication standard. Function.
- the I/O device I/F unit 926 is connected to I/O devices 960 such as various sensors and actuators, and exchanges with the I/O devices 960, for example, detection signals from sensors and control signals to actuators. functions as a communication unit that transmits and receives various signals and data.
- the media input/output unit 928 is composed of a drive device such as a DVD (Digital Versatile Disc) drive, a CD (Compact Disc) drive, etc., and transfers data to media (non-temporary storage media) 970 such as DVDs and CDs. read and write.
- the processor 912 calls the program 930 stored in the storage device 920 to the memory 914 and executes it, and controls each part of the computer 900 via the bus 910 .
- the program 930 may be stored in the memory 914 instead of the storage device 920 .
- the program 930 may be recorded on the media 970 in an installable file format or executable file format and provided to the computer 900 via the media input/output unit 928 .
- Program 930 may be provided to computer 900 by downloading via network 940 via communication I/F section 922 .
- the computer 900 may implement various functions realized by the processor 912 executing the program 930 by hardware such as FPGA (field-programmable gate array), ASIC (application specific integrated circuit), or the like. good.
- the computer 900 is, for example, a stationary computer or a portable computer, and is an arbitrary form of electronic equipment.
- the computer 900 may be a client-type computer, a server-type computer, or a cloud-type computer.
- each part of the welding data processing device 2 (each step of the welding data processing method executed by the welding data processing method) and a series of operations by the welding integrated management system 1 will be described below with reference to FIGS. 9 to 25. .
- the site manager 40 operates the manager terminal device 4 to provide the welding data processing device 2 with design data managed by the construction progress management device 3 .
- the welding process registration unit 200 stores a plurality of records corresponding to each of the plurality of welding points 11 provided at the welding site 10 in the welding process database 211. Add to table 211A.
- the welding process registration unit 200 accepts, for example, the welding site ID determined based on the name of the building from the manager terminal device 4 operated by the site manager 40, and , register a common welding site ID.
- Welding process registration unit 200 receives welding area IDs assigned to a plurality of welding areas obtained by dividing welding site 10 according to a predetermined division criterion, so that each welding point 11 includes each welding point 11. Register the welding area ID that specifies the welding area to be used.
- the welding process registration unit 200 captures the drawing number and the welding point number assigned to each welding point 11 from, for example, the spool drawing of the design data, and the welding conditions determined for each welding point 11 from the spool drawing of the design data.
- the drawing number, welding point number, and welding conditions are registered for each welding point 11 by importing from the construction instruction sheet. Then, the welding process registration unit 200 identifies the required qualifications required of the welder 50A based on the welding conditions of each welding spot 11, and thus determines the required qualifications required of the welder 50A for each welding spot 11. to register.
- the welding process registration unit 200 receives information about the welding machine 6 used at the welding site 10 from the administrator terminal device 4, and assigns a welding machine ID that identifies the welding machine 6 to each welding machine 6. , the manufacturer name, model name, and specifications of each welder 6 are registered in the welder table 211B.
- the welding process registration unit 200 receives information about the welder 50A working at the welding site 10 from the administrator terminal device 4, and assigns a welder ID that identifies the welder 50A to each welder 50A.
- a welder ID that identifies the welder 50A to each welder 50A.
- an affiliation ID, name, and qualification that identifies the affiliation (subcontractor or team) to which the welder 50A belongs
- a welding manager that identifies the welding manager 50B that manages the welder 50A
- the ID is registered in the welder table 211C.
- Welding process registration unit 200 receives information about welding manager 50B who manages welder 50A working at welding site 10 from manager terminal device 4, thereby obtaining a welding manager ID that identifies welding manager 50B.
- an affiliation ID, name, and qualification to identify the affiliation to which the welding manager 50B belongs are registered in the welding manager table 211D for each welding manager 50B.
- the inspection process registration unit 201 Similar to the welding process registration unit 200, the inspection process registration unit 201, based on the design data provided from the construction progress management device 3, sets a plurality of welding locations 11 corresponding to each of the plurality of welding locations 11 provided at the welding site 10. The record is added to the weld location table 212A of the inspection process database 212. That is, the inspection process registration unit 201 registers a welding site ID, a welding area ID, a drawing number, and a welding point number for each welding point 11 . Then, the inspection process registration unit 201 specifies the required qualifications required of the imaging operator 50C and the judge 50D based on the welding conditions of each welding point 11, and thus, for each welding point 11, the imaging operator 50C and the required qualifications of the judge 50D required of the judge 50D.
- the inspection process registration unit 201 receives information about the inspection machines 7 used at the welding site 10 from the administrator terminal device 4, and assigns inspection machine IDs for specifying the inspection machines 7 to each inspection machine 7. , the manufacturer name, model name, and specifications of each inspection machine 7 are registered in the inspection machine table 212B.
- the inspection process registration unit 201 receives information about the imaging worker 50C working at the welding site 10 from the administrator terminal device 4, and assigns an imaging worker ID that identifies the imaging worker 50C to each imaging worker. 50C, and for each imaging operator 50C, an affiliation ID, name, and qualification that identifies the affiliation (subcontractor or team) to which the imaging operator 50C belongs, and an inspection manager that manages the imaging operator 50C.
- the inspection manager ID specifying 50E is registered in the imaging operator table 212C.
- the inspection process registration unit 201 receives information about the judge 50D working at the welding site 10 from the manager terminal device 4, and assigns each judge ID identifying the judge 50D to each judge 50D.
- the inspection process registration unit 201 identifies the inspection manager 50E by receiving information on the inspection manager 50E that manages the imaging operator 50C and the judge 50D working at the welding site 10 from the manager terminal device 4. Allocate an inspection manager ID to each inspection manager 50E, and register, for each inspection manager 50E, an affiliation ID specifying the organization to which the inspection manager 50E belongs, a name, and qualifications held in the inspection manager table 212E. do.
- the welding process database 211 and the inspection process database 212 are registered in advance with information necessary for the welding process and the inspection process.
- the welding execution record and the inspection execution record are in an unregistered state.
- the welding process registration unit 200 performs a registration process of registering the welding practice record in the welding process database 211 as the welding process is carried out. Further, in conjunction with the registration process, the qualification determination section 202A performs qualification determination processing for the qualification possessed by the welder 50A, and the deviation determination section 202B performs deviation determination processing.
- FIGS. 9 and 10 are flowcharts showing an example of registration processing, qualification determination processing, and deviation determination processing in the welding process.
- FIGS. 9 and 10 describe the operation after the welder 50A scheduled to perform the welding process moves to the work target welding location 11 and installs the welder 6 to be used at the work target welding location 11.
- step S101 the welder 50A inputs a welding site ID, a welding area ID, a drawing number, and a welding point number into the welder terminal device 5A as welding point identification information for specifying the welding point 11 to be worked on. , perform a welding process start operation for starting the welding process. At that time, the welder 50A holds his/her beacon card 31 over the card reader 51 .
- the welder's terminal device 5A receives the welding process start operation to acquire welding point identification information.
- the welder terminal device 5A acquires the welder ID that identifies the welder 50A by reading the card information from the beacon card 31 of the welder 50A using the card reading unit 51 .
- the welder terminal device 5A acquires the welder ID that specifies the welder 6 by reading the card information from the beacon card 31 attached to the welder 6 to be used by the card reader 51 .
- the welder terminal device 5A may acquire the welder ID from the construction progress management device 3 .
- step S103 the welder terminal device 5A transmits to the welding data processing device 2 a welding process start notification including the welding location identification information, the welder ID, and the welder ID.
- step S110 when the welding data processing device 2 receives a welding process start notification from the welder terminal device 5A, the welding process registration unit 200 refers to the welding process database 211, and welds in the welding point table 211A.
- a record hereinafter referred to as "welding process target record" corresponding to the welding point identification information included in the process start notification is specified.
- the welding process registration unit 200 registers the reception date and time of the welding process start notification as the implementation start date and time of the welding process target record.
- the welding process registration unit 200 registers the welder ID included in the welding process start notification as the welder ID included in the welding process target record, and registers the welder ID included in the welding process start notification in the welding process target record. Register with the welding machine ID.
- the qualification determination unit 202A refers to the welding process database 211, and the welder 50A who performs the welding process at the welding point 11 to be worked performs the welding process according to the welding conditions at the welding point 11. Judge whether or not you have the qualification to carry out the training. Specifically, the qualification determination unit 202A acquires the qualification registered for the welder ID included in the welding process start notification in the welder table 211C, and registers it in the welding process target record of the welding location table 211A. Get the requested qualification. Then, the qualification determination unit 202A compares the qualifications possessed by the welder 50A and the required qualifications of the weld location 11 to determine whether the above qualifications are appropriate.
- step S121 the welding process registration unit 200 , the welder qualification determination data indicating that the qualification is "eligible" is registered in the welding process target record, and the process proceeds to step S130.
- step S120 the welding process registration unit 200 moves to step S122. Registers welder qualification determination data indicating that the suitability of the qualification is "unqualified" in the welding process target record. Then, in step S123, the welding process support unit 203 executes qualification ineligibility processing when the welder 50A is ineligible. Specifically, the welding process support unit 203 notifies the welder 50A that the qualifications held by the welder 50A are “inappropriate”, for example, the welder terminal device 5A of the welder 50A and the welding process that manages the welder 50A.
- the welding process support unit 203 transmits to the distribution board 62 a switch control command for controlling the switch 620 connected to the welder 6 to be used to be in the cut-off state.
- the welder 50A and the welding manager 50B receive the notification and reconfirm their qualifications, and since the switch 620 is blocked and the use of the welder 6 is prohibited, the welding process is prohibited by an unqualified person. can be suppressed.
- step S130 the welding process support unit 203 transmits the welding conditions registered in the welding process target record of the welding location table 211A to the welder terminal device 5A.
- step S131 when the welder terminal device 5A receives the welding conditions from the welding data processing device 2, it displays a preheating support screen based on the welding conditions.
- step S132 the welder 50A preheats the weld location 11 using a welding preheating device (not shown) in accordance with the display contents (preheating of welding conditions, etc.) displayed on the preheating support screen, while the temperature measuring device 61 is used to measure the temperature of the weld location 11 .
- step S133 the temperature measurement device 61 transmits the preheating data 13 in which the measured temperature is recorded as the preheating state of the welding location 11 to the welding data processing device 2.
- step S140 when the welding data processing device 2 receives the preheating data 13 from the temperature measuring device 61, the welding process registration unit 200 registers the preheating data 13 in the welding process target record.
- the deviation determination unit 202B refers to the welding process database 211, and the welding conditions (preheating conditions) registered in the welding process target record of the welding location table 211A according to the preheating data 13 received from the temperature measurement device 61. ), it is determined whether or not there is a deviation exceeding the preheating deviation criteria. For example, when a preheating temperature and a preheating time are specified as the preheating of the welding conditions, the deviation determination unit 202B, for example, sets the preheating temperature and the preheating time indicated by the preheating data 13 to the preheating temperature and the preheating time of the welding conditions. and if the difference exceeds the preheating deviation determination criterion (predetermined threshold value), it is determined that the preheating data 13 deviates.
- preheating deviation determination criterion predetermined threshold value
- step S142 the welding process registration unit 200 determines whether the deviation is "no deviation". is registered in the welding process target record, and the process proceeds to step S150.
- step S141 determines whether or not there is deviation in step S143. Register the preheating deviation judgment data in the welding process target record. Then, in step S144, the welding process support unit 203 executes preheating deviation processing when the preheating data 13 deviates. Specifically, the welding process support unit 203 sends a notification that the presence or absence of deviation is "deviation present", for example, to the welder terminal device 5A of the welder 50A and the welding manager 50B who manages the welder 50A. to the welding manager terminal device 5B.
- the welding process support unit 203 transmits to the distribution board 62 a switch control command for controlling the switch 620 connected to the welder 6 to be used to be in the cut-off state.
- the welder 50A and the welding manager 50B receive the notification and perform preheating again, and the switch 620 is shut off to prohibit the use of the welder 6, so that the welding quality can be improved.
- the preheating deviation determination data may include not only the presence or absence of deviation, but also the amount of deviation of the preheating data 13 from the welding conditions as detailed data.
- the amount of deviation includes, for example, the amount of preheating temperature deviation (difference value, ratio, etc.) with respect to the preheating temperature of the welding conditions.
- step S150 the welding process support unit 203 transmits the welding conditions registered in the welding process target record of the welding location table 211A to the welder terminal device 5A.
- step S151 when the welder terminal device 5A receives the welding conditions from the welding data processing device 2, it displays the welding support screen based on the welding conditions.
- step S152 the welder 50A operates the operation control panel 65 of the welder 6 according to the display contents (electrical characteristics of welding conditions, welding method, etc.) displayed on the welding support screen. Then, when the welder 50A brings the welding torch 63 close to the welding spot 11 and turns on the switch 632, the welding of the welding spot 11 is performed.
- step S ⁇ b>153 welder monitoring device 60 records the operation state of welder 6 and transmits welder operation data 12 recording the operation state to welding data processing device 2 .
- step S160 when the welding data processing device 2 receives the welding machine operation data 12 from the welding machine monitoring device 60, the welding process registration unit 200 registers the welding machine operation data 12 in the welding process target record. do. At this time, the welding process registration unit 200 registers the date and time when the operation state of the welding machine 6 ended in the welding machine operation data 12 as the execution end date and time of the welding process target record.
- the deviation determination unit 202B refers to the welding process database 211 and determines whether the welding machine operation data 12 received from the welding machine monitoring device 60 is registered in the welding process target record of the welding location table 211A. A determination is made as to whether or not there is deviation from the conditions (at least one of welding current, welding voltage, welding speed, welding direction, and welding angle) exceeding the welding deviation determination criteria.
- the deviation determination unit 202B for example, combines the welding current, welding voltage, welding speed, welding direction, and welding angle indicated by the welding machine operation data 12 with the welding current, welding voltage, welding speed, welding direction, and welding angle under the welding conditions. When at least one of the differences exceeds the welding deviation determination criterion (predetermined threshold value), it is determined that the welder operation data 12 has deviated.
- step S161 the welding process registration unit 200 determines whether the deviation is "no deviation" in step S162. Welding deviation determination data to the effect that there is one is registered in the welding process target record, and the series of processes is terminated.
- welding process registration unit 200 determines whether or not there is deviation in step S163. Welding deviation determination data to the effect that there is a welding deviation is registered in the welding process target record. Then, in step S164, the welding process support unit 203 executes welding deviation processing when the welder operation data 12 is deviated. Specifically, the welding process support unit 203 sends a notification that the presence or absence of deviation is "deviation present", for example, to the welder terminal device 5A of the welder 50A and the welding manager 50B who manages the welder 50A. to the welding manager terminal device 5B. Upon receiving the notification, the welder 50A and the welding manager 50B determine, for example, the necessity of welding repair or re-welding, the priority of radiographic inspection, etc., so as to accelerate decision-making and improve welding quality. can be planned.
- the welding deviation determination data may include not only the presence or absence of deviation, but also the amount of deviation of the welding machine operation data 12 from the welding conditions as detailed data.
- the deviation amount includes, for example, the welding voltage deviation amount (difference value, ratio, etc.) when the welding voltage of the welding condition is used as a reference, and the welding current deviation amount (difference value, ratio, etc.) when the welding current of the welding condition is used as a reference.
- the amount of welding speed deviation (difference value, ratio, etc.) when the welding speed of the welding conditions is the standard the amount of welding direction deviation (difference value, ratio, etc.) when the welding direction of the welding conditions is the standard, or , the welding angle deviation amount (difference value, ratio, etc.) when the welding angle of the welding condition is used as a reference.
- welding machine operation data is stored in the welding process database 211 (specifically, each welding process target record corresponding to each welding point 11).
- Welding records including 12 and preheating data 13 are registered and accumulated at any time.
- the inspection process registration unit 201 performs a registration process of registering an inspection execution record in the inspection process database 212 along with the execution of the imaging process included in the radiographic inspection process. Also, in conjunction with the registration process, the qualification determination unit 202A performs qualification determination processing for the qualification possessed by the imaging operator 50C.
- FIG. 11 is a flowchart showing an example of registration processing and qualification determination processing in the imaging process included in the radiographic inspection process.
- FIG. 11 describes the operation after the imaging operator 50C who performs the imaging process moves to the welding point 11 to be worked and installs the inspection machine 7 to be used at the welding point 11 to be worked.
- step S201 the imaging operator 50C sends the welding site ID, welding area ID, drawing number, and welding location number to the imaging operator terminal device 5C as welding location identification information for specifying the welding location 11 to be worked on. Then, an imaging process start operation is performed to start the imaging process. At that time, the imaging operator 50C holds his/her own beacon card 31 over the card reader 51 .
- the imaging operator terminal device 5C acquires the welding point identification information by receiving the imaging process start operation.
- the imaging operator terminal device 5C acquires an imaging operator ID that identifies the imaging operator 50C by reading the card information from the beacon card 31 of the imaging operator 50C using the card reader 51 .
- the imaging operator terminal device 5C acquires an inspection machine ID that identifies the inspection machine 7 by reading the card information from the beacon card 31 attached to the inspection machine 7 to be used by the card reader 51 .
- the imaging operator terminal device 5C may acquire the inspection machine ID from the construction progress management device 3. FIG.
- step S203 the imaging operator terminal device 5C transmits to the welding data processing device 2 an imaging process start notification including the welding location identification information, the imaging operator ID, and the inspection machine ID.
- step S210 when the welding data processing device 2 receives the imaging process start notification from the imaging operator terminal device 5C, the inspection process registration unit 201 refers to the inspection process database 212, and in the welding location table 212A, A record (hereinafter referred to as "imaging process target record") corresponding to the welding point identification information included in the imaging process start notification is specified. Then, in step S211, the inspection process registration unit 201 registers the reception date and time of the imaging process start notification as the imaging date and time of the imaging process target record.
- the inspection process registration unit 201 registers the imaging operator ID included in the imaging process start notification as the imaging operator ID included in the imaging process start notification in the imaging process target record, and registers the inspection machine ID included in the imaging process start notification as the imaging process target record. Register in the inspection machine ID of the record.
- the qualification determination unit 202A refers to the inspection process database 212, and the imaging worker 50C who performs the imaging process at the welding point 11 to be worked performs the imaging process at the welding point 11. It determines whether or not the qualification is qualified. Specifically, the qualification determination unit 202A acquires the qualification registered for the imaging operator ID included in the imaging process start notification in the imaging operator table 212C, and acquires the imaging process target record in the welding location table 212A. Acquire the imaging operator requirement qualification registered in . Then, the qualification determination unit 202A compares the qualification possessed by the imaging operator 50C with the required qualification of the imaging operator for the welded portion 11 to determine whether the above qualification is appropriate.
- step S211 the inspection process
- the registration unit 201 registers, in the imaging process target record, imaging operator qualification determination data indicating that the appropriateness of the qualification is "eligible”, and proceeds to step S230.
- step S222 inspection is performed.
- the process registration unit 201 registers, in the imaging process target record, imaging operator qualification determination data indicating that the appropriateness of the qualification is "unqualified”.
- the inspection process support unit 204 executes qualification ineligibility processing when the imaging operator 50C has ineligibility.
- the inspection process support unit 204 sends a notification that the qualification is “unqualified”, for example, to the imaging operator terminal device 5C of the imaging operator 50C and the inspection process that manages the imaging operator 50C. It is transmitted to the inspection manager terminal device 5E of the manager 50E.
- the imaging operator 50C and the inspection manager 50E receive the notification and reconfirm their qualifications, so that the imaging process can be suppressed by unqualified persons.
- the inspection process support unit 204 refers to the welding process database 211, and records corresponding to the welding point identification information included in the imaging process start notification in the welding point table 211A (hereinafter referred to as "welding process reference"). record”), and obtains the welding conditions registered in the welding process reference record. Then, the inspection process support unit 204 transmits the welding conditions to the imaging operator terminal device 5C.
- step S231 when the imaging operator terminal device 5C receives the welding conditions from the welding data processing device 2, it displays an imaging process support screen based on the welding conditions.
- step S232 the imaging operator 50C controls the operation of the inspection machine 7 by referring to the display contents (welding conditions such as diameter, wall thickness, material, joint shape, welding material, etc.) displayed on the imaging process support screen.
- the panel 74 is operated to set operation parameters of the radiation irradiation section 70 , the detector 71 and the driving section 73 .
- the inspection machine 7 images the entire circumferential direction of the welding point 11 and generates the image data 14 in step S233.
- the inspection machine 7 transmits the image data 14 to the welding data processing device 2 .
- step S240 when the welding data processing device 2 receives the image data 14 from the inspection machine 7, the inspection process registration unit 201 registers the image data 14 in the imaging process target record, and executes a series of processes. finish.
- the image data 14 is stored in the inspection process database 212 (specifically, each imaging process target record corresponding to each welding point 11) by performing the imaging process at each welding point 11. Inspection execution records including inspection records are registered and accumulated at any time.
- the inspection process registration unit 201 performs a registration process of registering an inspection execution record in the inspection process database 212 along with the execution of the image judgment process included in the radiographic inspection process. . Also, in conjunction with the registration process, the qualification determination unit 202A performs qualification determination processing for the qualification possessed by the judge 50D.
- FIG. 12 is a flowchart showing an example of registration processing and qualification determination processing in the image determination process included in the radiographic inspection process. With reference to FIG. 12, the operation when the judge 50D who carries out the image judgment process works at a place different from the welding point 11 will be described.
- step S301 the judge 50D inputs a welding site ID, a welding area ID, a drawing number, and a welding point number into the judge terminal device 5D as welding point identification information for specifying the welding point 11 to be worked on. , perform an image determination process start operation for starting the determination process. At that time, the judge 50D holds his/her own beacon card 31 over the card reader 51 .
- step S302 the judge terminal device 5D acquires the welding point identification information by accepting the image judgment process start operation.
- the judge terminal device 5D acquires the judge ID that identifies the judge 50D by reading card information from the beacon card 31 of the judge 50D by the card reading unit 51 .
- step S303 the judge terminal device 5D transmits to the welding data processing device 2 an image judgment process start notification including the welding point identification information and the judge ID.
- step S310 when the welding data processing device 2 receives the image judgment process start notification from the judge terminal device 5D, the inspection process registration unit 201 refers to the inspection process database 212, and in the welding point table 212A A record (hereinafter referred to as an “image determination process target record”) corresponding to the welding point identification information included in the image determination process start notification is specified. Then, in step S311, the inspection process registration unit 201 registers the reception date and time of the image judgment process start notification as the image judgment date and time of the image judgment process target record, and also registers the judge ID included in the image judgment process start notification. Register with the implementation judge ID of the judgment process target record.
- the qualification determination unit 202A refers to the inspection process database 212, and the judge 50D, who performs the image determination process at the welding point 11 to be worked on, performs the image determination process at the welding point 11. determine whether or not the person has the qualification to do so.
- the qualification judging section 202A acquires the qualification registered for the judge ID included in the image judgment process start notification in the judge table 212D, and acquires the image judgment process target record in the welding part table 212A. Acquire the qualification required to be a judge registered in the Then, the qualification determination unit 202A compares the qualification possessed by the judge 50D with the required qualification of the judge 50D to determine the appropriateness of the qualification.
- step S320 the qualification determination unit 202A determines that the qualification of the judge 50D is qualified for the required qualification of the judge 50D of the weld location 11 (step S320: qualified)
- step S321 the inspection process registration unit 201 registers the judge qualification judgment data indicating that the suitability of the qualification is "eligible" in the image judgment process target record, and proceeds to step S330.
- step S320 when the qualification determination unit 202A determines that the qualification of the judge 50D is not eligible for the required qualification of the judge 50D of the weld location 11 (step S320: unqualified), inspection process registration is performed in step S322.
- the section 201 registers, in the record for the image judgment step, the judge qualification judgment data indicating that the suitability of the qualification is "unqualified”.
- step S323 the inspection process support unit 204 executes qualification disqualification processing when the qualification of the judge 50D is disqualified. Specifically, the inspection process support unit 204 sends a notification indicating that the qualification is “unsuitable”, for example, through the terminal device 5D of the judge 50D and the inspection manager 50E who manages the judge 50D. to the inspection administrator terminal device 5E.
- the judge 50D and the inspection manager 50E receive the notification and reconfirm the possessed qualifications, so that it is possible to suppress the execution of the image judgment process by an unqualified person.
- the inspection process support unit 204 acquires the image data 14 registered in the image determination process target record of the welding location table 212A. Also, the inspection process support unit 204 refers to the welding process database 211, and selects a record (hereinafter referred to as a "welding process reference record") corresponding to the welding part identification information included in the image determination process start notification in the welding part table 211A. Welding conditions and welding execution records registered in the identified welding process reference record are obtained. The inspection process support unit 204 then transmits the determination target data including the acquired image data 14, welding conditions, and welding execution record to the judge terminal device 5D.
- a welding process reference record a record corresponding to the welding part identification information included in the image determination process start notification in the welding part table 211A. Welding conditions and welding execution records registered in the identified welding process reference record are obtained.
- the inspection process support unit 204 transmits the determination target data including the acquired image data 14, welding conditions, and welding execution record to the judge terminal device 5D.
- step S331 when the judge terminal device 5D receives the judgment target data from the welding data processing device 2, it displays an image judgment process support screen based on the judgment target data.
- step S332 the judge 50D visually confirms the image data 14 displayed on the image judgment process support screen, and judges whether or not there is a welding defect at the weld location 11.
- FIG. At that time, the judge 50D can refer to the contents of the welding conditions and the welding execution record displayed on the image judgment process support screen.
- step S333 when the judge 50D performs a defect judgment result input operation for inputting the result of judging the presence or absence of welding defects on the image judgment process support screen, in step S334, the judge terminal device 5D generates defect determination data based on the defect determination result input operation, and transmits the defect determination data to the welding data processing device 2 .
- step S340 when the welding data processing device 2 receives the defect determination data from the judge terminal device 5D, the inspection process registration unit 201 registers the defect determination data in the image determination process target record, end the processing of
- the image determination process is performed at each welding point 11, so that defect determination data is stored in the inspection process database 212 (specifically, each image determination process target record corresponding to each welding point 11). Inspection execution records including are registered and accumulated at any time.
- the defect analysis unit 202C performs defect analysis processing for analyzing defect occurrence tendency based on the information of each record registered in the welding process database 211 and the inspection process database 212 .
- the defect analysis unit 202C analyzes the defect occurrence tendency based on at least one of the welding conditions and the welding execution record as the information of each record, and the defect determination data. At that time, the defect analysis unit 202C receives a predetermined analysis condition and performs statistical processing according to the analysis condition to analyze the defect occurrence tendency.
- the defect occurrence tendency indicates the tendency when welding defects occur at the weld location 11. For example, statistics such as average value, median value, maximum value, minimum value, variance, standard deviation, ratio, frequency, etc. Expressed as an index value.
- the defect occurrence tendency is obtained by statistical methods such as simple tabulation, cross tabulation, frequency distribution, Pareto analysis, matrix analysis, regression analysis, factor analysis, and the like.
- analysis target range and the analysis axis are specified.
- the analysis target range specifies the range of records to be analyzed by the defect analysis unit 202C among the records registered in the welding process database 211 and the inspection process database 212.
- the analysis target range is, for example, location, period, workers 50A to 50E, working hours, affiliation, welding conditions, welding execution record, presence or absence of welding defects, detailed defect status, welding machine 6 or inspection machine 7, Alternatively, it is designated by a combination of these.
- the analysis target range is specified, for example, by one or more field variables of each of the tables 211A to 221D of the welding process database 211 and each of the tables 212A to 222E of the inspection process database 212. FIG. Note that the specification of the analysis target range may be omitted.
- the defect analysis unit 202C determines the specified welding site 10 and welding area. Extract matching records for analysis.
- a period for example, past one week, one month, one year, etc.
- the defect analysis unit 202C extracts records matching the specified period as analysis targets.
- the defect analysis unit 202C A record that matches at least one of the manager ID, welding manager ID, and affiliation ID is extracted as an analysis target.
- the defect analysis unit 202C extracts records that match the specified period as analysis targets. do.
- the defect analysis unit 202C selects a record that matches the specified field variable. Extract for analysis. At least one of the fields (preheating data 13, welding machine operation data 12, preheating deviation determination data, and welding deviation determination data) included in the welding execution record of the welding location table 211A and the field is specified, the defect analysis unit 202C extracts records matching the specified field variables as analysis targets. At that time, the analysis target range may be specified by any one of the detailed data included in the preheating data 13, the welding machine operation data 12, the preheating deviation determination data, and the welding deviation determination data.
- the analysis axis designates a field used when the defect analysis unit 202C analyzes multiple records included in the analysis target range using a predetermined statistical method.
- Analysis axes include, for example, location, period, workers 50A to 50E, working time, affiliation, welding conditions, welding execution record, presence or absence of welding defects, detailed defect status, welding machine 6, or inspection machine 7, or , specified by a combination of these.
- the analysis axis is specified, for example, by one or more fields of the tables 211A to 221D of the welding process database 211 and the tables 212A to 222E of the inspection process database 212.
- the defect analysis unit 202C determines the specified welding site 10 and the welding area.
- the defect occurrence tendency is analyzed using at least one as an analysis axis.
- a period for example, one day, one week, one month
- the defect analysis unit 202C analyzes the defect occurrence tendency using the specified period as an analysis axis.
- the defect analysis unit 202C analyzes the specified welder 50A, The defect occurrence tendency is analyzed using at least one of the welding manager 50B and the department to which he belongs as an analysis axis. If a work time based on the implementation start date and time and the implementation end date and time (for example, actual work time, standby time before work, work time zone, etc.) is specified as an analysis axis, the defect analysis unit 202C calculates the specified work time as an analysis axis to analyze the defect occurrence tendency.
- the defect analysis unit 202C analyzes the defect occurrence tendency with the specified at least one field as an analysis axis.
- the defect The analysis unit 202C analyzes the defect occurrence tendency using the specified at least one field as an analysis axis.
- the analysis axis may be specified by any of the detailed data included in the preheating data 13, the welding machine operation data 12, the preheating deviation determination data, and the welding deviation determination data.
- the defect occurrence tendency is periodically analyzed, and the analysis frequency of periodically notifying the analysis result, for example, the defect occurrence tendency is analyzed as in the case where the defect occurrence rate is higher than a predetermined value.
- Notification conditions for notifying analysis results may be specified.
- FIG. 13 is a flowchart showing an example of defect analysis processing.
- the defect analysis unit 202C receives analysis conditions in the defect analysis process from the manager terminal device 4 and analyzes the defect occurrence tendency according to the analysis conditions.
- step S401 the administrator terminal device 4 displays the analysis condition input screen 42 upon receiving an operation requesting defect analysis processing from the site administrator 40.
- step S402 when the on-site manager 40 performs an analysis condition input operation for inputting analysis conditions on the analysis condition input screen 42, in step S403, the manager terminal device 4 inputs the analysis conditions. It receives it and transmits it to the welding data processing device 2 .
- FIG. 14 is a diagram showing an example of the analysis condition input screen 42.
- the analysis condition input screen 42 includes input fields 420 to 423 for designating analysis conditions when the defect analysis section 202C analyzes the defect occurrence tendency.
- the defect analysis unit 202C analyzes the defect determination tendency according to the analysis conditions. Specifically, the defect analysis unit 202C extracts records that match the analysis target range specified as the analysis condition from the welding location table 211A of the welding process database 211 and the welding location table 212A of the inspection process database 212. When the analysis conditions are specified as shown in FIG. Records corresponding to the condition of diameter "3 inches or more" are extracted.
- the defect analysis unit 202C statistically processes the extracted records according to the statistical method, statistical index value, and analysis axis specified as analysis conditions, thereby deriving analysis results of defect determination tendencies.
- the analysis conditions are specified as shown in FIG. 14, the three analysis axes of the period "monthly unit", the worker “welder unit”, and the defect detailed situation "defect type", A 'cross-tabulation' for the 'proportions' is performed.
- step S411 the output processing unit 205 transmits the analysis result of the defect determination tendency to the administrator terminal device 4.
- step S420 when the manager terminal device 4 receives the analysis result of defect determination tendency from the welding data processing device 2 as a response to the analysis conditions, the analysis result display screen 43 based on the analysis result is displayed.
- FIG. 15 is a diagram showing an example of the analysis result display screen 43 in defect analysis processing.
- the analysis result display screen 43 has a display area 430 for displaying the defect occurrence tendency, which is the analysis result of the defect analysis unit 202C, in a predetermined table format or graph format.
- the analysis result display screen 43 shown in FIG. 15 is a screen displayed when the analysis conditions are specified as shown in FIG. Therefore, in the display area 430, the analysis results obtained by "cross-tabulation" are displayed in the form of a pie chart on the three analysis axes of "welder unit", "month unit", and "defect type". ing.
- the pie chart shows the defect occurrence ratio for each "defect type", and the size of the defect indicates the frequency.
- the analysis result display screen 43 may be configured such that the table format and the graph format can be changed. Further, the analysis result display screen 43 may have a button for displaying the analysis condition input screen 42, and when the analysis conditions are changed, the analysis results based on the changed analysis conditions may be displayed.
- the defect judgment tendency for them are derived and displayed.
- the deviation amount included in the preheating deviation determination data preheating temperature deviation amount
- the deviation amount included in the welding deviation determination data welding voltage deviation amount, welding current deviation amount, welding speed deviation amount, welding direction deviation amount or welding angle deviation amount
- the defect occurrence tendency is analyzed by the defect analysis unit 202C based on the information registered in the welding process database 211 and the inspection process database 212.
- the on-site manager 40 (workers 50A to 50E may also be used) refers to the analysis results of the defect occurrence tendency to investigate the situation and cause of the occurrence of welding defects and discover them at an early stage, and the workers 50A to 50E This can be reflected in the education and guidance for the workers and the assignment of the workers 50A to 50E to the welding points 11, so that the welding quality and productivity can be improved.
- a disqualification analysis process is performed to analyze eligibility trends. If the qualifications possessed by the workers 50A to 50E are not qualified for the required qualifications for the welding location 11, the unqualified workers 50A to 50E can The work by 50E is suppressed. Therefore, the qualification disqualification analysis processing by the qualification disqualification analysis unit 202D analyzes the situation when the workers 50A to 50E are unqualified and have mistakenly performed the work. It is assumed.
- the ineligibility analysis unit 202D analyzes the occurrence tendency of ineligibility based on at least one of welding conditions and welding execution records as information of each record, and welder qualification determination data. At that time, similarly to the defect analysis section 202C, the ineligibility analysis section 202D receives predetermined analysis conditions and performs statistical processing according to the analysis conditions to analyze the occurrence tendency of ineligibility.
- the disqualification tendency indicates the tendency when disqualification occurs when comparing the welder 50A's qualification and the required qualification of the welding location 11, and similar to the defect generation tendency, various statistics It is expressed as an index value and obtained by various statistical methods. As with the analysis conditions for defect occurrence trends, statistical methods, statistical index values, analysis target ranges, and analysis axes are specified for analysis conditions for disqualification occurrence trends.
- the qualification disqualification analysis unit 202D determines the qualifications possessed by the imaging operator 50C and the required qualifications of the welding location 11. It is also possible to analyze an eligibility ineligibility occurrence trend that indicates the tendency when ineligibility occurs when comparing with. In addition, the qualification disqualification analysis unit 202D determines the possessed qualification of the judge 50D and the required qualification of the weld location 11 based on at least one of the welding conditions, the welding execution record, and the inspection execution record, and the qualification judgment data of the judge 50D. It is also possible to analyze an eligibility ineligibility occurrence trend that indicates the tendency when ineligibility occurs when compared.
- FIG. 16 is a flowchart showing an example of eligibility analysis processing.
- FIG. 16 shows the operation when the disqualification analysis unit 202D receives the analysis conditions in the disqualification analysis process from the administrator terminal device 4 and analyzes the trend of occurrence of disqualification according to the analysis conditions. Since the basic operation is the same as the defect analysis processing shown in FIG. 13, detailed description will be omitted.
- FIG. 17 is a diagram showing an example of the analysis result display screen 44 in the eligibility analysis process.
- the analysis result display screen 44 has a display area 440 for displaying the trend of occurrence of ineligibility, which is the analysis result of the ineligibility analysis unit 202D, in a predetermined table format or graph format.
- a display area 440 shown in FIG. 17 the analysis result of "cross-tabulation" of judge qualification determination data is displayed in the form of a bar graph on the two analysis axes of "welding site unit" and "affiliation unit". It is
- the ineligibility analysis unit 202D analyzes the occurrence tendency of ineligibility based on the information registered in the welding process database 211 and the inspection process database 212.
- On-site manager 40 (workers 50A to 50E may also be used) refers to the analysis results of disqualified occurrence trends, and, for example, welder 50A who has mistakenly performed the welding process while being unqualified, A welding manager 50B who manages the welder 50A and the department to which the welder 50A belongs can be grasped, and education and guidance can be provided, so that welding quality and productivity can be improved.
- the deviation analysis unit 202E analyzes the deviation occurrence tendency regarding the deviation of the welding execution record with respect to the welding conditions based on the information of each record registered in the welding process database 211 and the inspection process database 212. Perform deviation analysis processing.
- the deviation analysis unit 202E analyzes deviation occurrence tendencies based on at least one of the welding conditions and welding execution records, and at least one of the preheating deviation determination data and the welding deviation determination data, as the information of each record. At that time, the deviation analysis unit 202E receives a predetermined analysis condition and performs statistical processing according to the analysis condition to analyze the deviation occurrence tendency in the same manner as the defect analysis unit 202C.
- the deviation occurrence tendency indicates the tendency when deviation occurs when comparing the welding execution record (welding machine operation data 12 or preheating data 13) and the welding conditions of the welding location 11. Similarly, it is represented by various statistical index values and obtained by various statistical methods.
- the analysis conditions for the deviation occurrence tendency specify the statistical method, the statistical index value, the analysis target range, and the analysis axis.
- the deviation determination criteria setting unit 202F sets the deviation determination criteria used when the deviation determination unit 202B determines whether or not there is a deviation, based on the welding conditions, the welding execution record, and the defect determination data.
- the deviation determination criteria setting unit 202F performs welding corresponding to the weld location 11 registered as “no defect” in the defect determination data in the weld location table 212A of the inspection process database 212.
- the conditions (welding current and welding voltage) and the welding machine operation data 12 are acquired from the welding location table 211A of the welding process database 211, and the difference between the welding current and welding voltage of the acquired welding conditions and the welding machine operation data 12 (for example , maximum value and confidence interval) to set the weld deviation criteria.
- the deviation determination criterion setting unit 202F performs welding corresponding to the weld location 11 registered as “no defect” in the defect determination data in the weld location table 212A of the inspection process database 212.
- Conditions (preheating) and preheating data 13 are acquired from the welding location table 211A of the welding process database 211, and based on the difference (for example, maximum value or confidence interval) between the preheating of the acquired welding conditions and the preheating data 13, Set the preheat deviation criteria.
- FIG. 18 is a flowchart showing an example of deviation analysis processing.
- FIG. 18 shows the operation when the deviation analysis unit 202E receives the analysis conditions in the deviation analysis process from the manager terminal device 4 and analyzes the deviation occurrence tendency according to the analysis conditions. Since the basic operation is the same as the defect analysis processing shown in FIG. 13, detailed description will be omitted.
- FIG. 19 is a diagram showing an example of the analysis result display screen 45 in deviation analysis processing.
- the analysis result display screen 45 has a display area 450 that displays the deviation occurrence tendency, which is the analysis result of the deviation analysis unit 202E, in a predetermined table format or graph format.
- the analysis result of "cross tabulation" of the preheating deviation determination data and the welding deviation determination data is performed on the two analysis axes of "welding manager unit” and "welder unit". , shown in bar graph form.
- the deviation analysis unit 202E analyzes the deviation occurrence tendency based on the information registered in the welding process database 211 and the inspection process database 212.
- the on-site manager 40 (workers 50A to 50E may also be used) refers to the deviation occurrence tendency analysis result, and, for example, the welder who performed the welding process in a state where the deviation occurred with respect to the welding conditions of the welding location 11. 50A, a welding manager 50B who manages the welder 50A, and the department to which the welder 50A belongs can be grasped, and education and guidance can be provided, so that welding quality and productivity can be improved.
- Welding assist function before welding process execution using defect occurrence tendency Welding assist processing for generating assist information including characteristics of the welding execution record that is predicted to cause welding defects at the welding location 11 based on the defect occurrence tendency obtained by analyzing the registered information.
- the welding point 11 to be assisted may be the welding point 11 corresponding to the record in which the welding conditions are registered in the welding point table 211A of the welding process database 211 . Therefore, the welding assist processing is performed at an arbitrary timing before the welding process is performed at the welding location to be assisted.
- FIG. 20 is a flowchart showing an example of welding assist processing.
- FIG. 20 describes the operation when the welding assist unit 202G transmits assist information by the welding assist process in step S130 of FIG. 9 or S150 of FIG. 10 and displays the assist information in step S131 or S151.
- step S701 the welding assist unit 202G accepts the welding location 11 specified by the welding process target record as the welding location 11 to be assisted, thereby registering it in the welding process target record of the welding location table 211A. Get welding conditions.
- the welding assist section 202G generates analysis conditions for defect analysis processing by the defect analysis section 202C based on the welding conditions at the welding location 11 to be assisted.
- the analysis conditions for example, as the statistical method and statistical index value, the minimum value when a welding defect occurs by simple aggregation is specified, and as the analysis target range, the welding conditions at the welding point 11 to be assisted are specified.
- the same or a predetermined similarity range is specified for the preheating deviation determination data, or the deviation amount included in the welding deviation determination data is specified as the analysis axis.
- the defect analysis section 202C analyzes the defect occurrence tendency according to the analysis conditions generated by the welding assist section 202G, and derives the analysis results.
- the defect analysis unit 202C selects from the welding location table 211A of the welding process database 211 and the welding location table 212A of the inspection process database 212, the welding conditions at the welding location 11 to be assisted, which are the same as or predetermined welding conditions. Extract the records included in the similar range.
- the defect analysis unit 202C refers to the deviation amount in the welding execution record of the record indicating that the defect determination data indicates "defective" among the extracted records, and calculates the minimum value of the deviation amount (defect occurrence tendency analysis result). derive
- the welding assist section 202G generates assist information based on the analysis result of the defect occurrence tendency derived by the defect analysis section 202C.
- step S710 the output processing unit 205 transmits the welding conditions and assist information from the welding assist unit 202G to the welder terminal device 5A of the welder 50A.
- step S711 the welder terminal device 5A, upon receiving the welding conditions and the assist information from the welding data processing device 2, displays the preheating support screen or the welding support screen based on the welding conditions and the assist information. indicate.
- the welder 50A confirms the assist information (for example, the minimum deviation amount) displayed on the preheating support screen or the welding support screen, thereby grasping in advance how much deviation will cause a welding defect. can do.
- Welding assist portion 202G includes the defect occurrence rate when welder 50A, who is scheduled to perform the welding process, performed the welding process in the past under the same welding conditions as welding conditions at welding location 11 to be assisted. Assist information may be generated.
- the welder 50A grasps his/her own defect rate in advance, and when the defect rate is high, the welder 50A is encouraged to carefully perform the welding process, thereby improving the welding quality.
- the welding execution record in which a welding defect is predicted to occur at the welding location 11 to be assisted is obtained.
- Assist information including features is generated.
- the welder 50A can perform the welding process with reference to the assist information provided before the welding process is performed, thereby improving welding quality and productivity.
- the welding point 11 to be predicted may be the welding point 11 corresponding to the record in which the welding condition and the welding execution record are registered in the welding point table 211A of the welding process database 211 . Therefore, the defect prediction process is performed at an arbitrary timing after the welding process is performed at the welding location 11 to be predicted.
- FIG. 21 is a flowchart showing an example of defect prediction processing.
- FIG. 21 describes the operation when the defect prediction unit 202H performs defect prediction processing following step S162 or S164 in FIG.
- step S801 the defect prediction unit 202H accepts the welding point 11 specified by the welding process target record as the welding point 11 to be predicted, thereby registering it in the welding process target record of the welding point table 211A. Acquire welding conditions and welding execution records.
- the defect prediction unit 202H generates analysis conditions for defect analysis processing by the defect analysis unit 202C based on the welding conditions and the welding execution record at the welding location 11 to be predicted.
- the analysis conditions here, for example, as the statistical method and statistical index value, the defect occurrence rate of welding by simple aggregation is specified, and as the analysis target range, the welding conditions and welding execution records at the welding point 11 to be predicted The same or a predetermined range of similarity is designated by using , and the designation of the analysis axis is omitted.
- the defect analysis unit 202C analyzes defect occurrence trends according to the analysis conditions generated by the defect prediction unit 202H, and derives the analysis results.
- the defect analysis unit 202C selects the welding conditions and the welding performance record at the welding location 11 to be predicted from the welding location table 211A of the welding process database 211 and the welding location table 212A of the inspection process database 212. Records that are the same or included in a predetermined similarity range are extracted.
- the defect analysis unit 202C uses the total number of the extracted records as the denominator and the total number of the extracted records whose defect determination data indicates "defective" as the numerator, that is, the welding defect occurrence ratio. (analysis result of defect occurrence tendency) is derived.
- the defect prediction unit 202H predicts the presence or absence of welding defects based on the defect occurrence tendency analysis results derived by the defect analysis unit 202C.
- the defect prediction unit 202H predicts that there is a defect when the welding defect occurrence ratio is equal to or greater than a predetermined reference value, and predicts that there is a defect when it is less than the predetermined reference value. Predict no.
- the defect prediction unit 202H may use the welding defect occurrence ratio as the result of predicting the presence or absence of welding defects.
- the defect prediction unit 202H refers to the welding process database 211 and identifies a record corresponding to the welding point 11 to be predicted in the welding point table 212A. Then, the defect prediction unit 202H registers, in the identified record, defect prediction data indicating the prediction result of the presence or absence of the welding defect.
- step S820 the output processing unit 205 outputs the defect prediction data from the defect prediction unit 202H to the welder terminal device 5A of the welder 50A and the welding manager terminal of the welding manager 50B who manages the welder 50A. device 5B.
- steps S821 and S822 when the welder terminal device 5A and the welding manager terminal device 5B receive the defect prediction data from the welding data processing device 2, they display a prediction result display screen based on the defect prediction data.
- the defect prediction unit 202H predicts whether or not there is a welding defect at the welding location 11 to be predicted.
- the welder 50A and the welding manager 50B receive the display of the prediction result display screen based on the prediction result, for example, the necessity of welding repair or re-welding, Since the priority of radiographic inspection is determined, it is possible to speed up decision-making and improve welding quality.
- FIG. 22 is a schematic diagram showing an example of machine learning processing and defect inference processing.
- the machine learning unit 202I inputs a plurality of sets of learning data to the learning model 25, and performs machine learning processing to cause the learning model 25 to machine-learn the correlation between the input data and the teacher data.
- the learning data is registered in the welding point table 212A with the welding conditions and welding execution records registered in the welding point table 211A for the common welding point 11 as input data. It is configured by associating the defect determination data obtained from the training as teacher data.
- the learning model 25 is composed of, for example, a neural network (including deep learning).
- the input layer of the learning model 25 receives welding conditions and welding records (or partial data), and the output layer of the learning model 25 outputs defect inference data for the welding conditions and welding records.
- the learning model 25 may output the inference result (binary classification) of determining the presence or absence of a welding defect as defect inference data, or may output the inference result of determining the welding defect type together with the presence or absence of a welding defect ( multi-level classification) may be output as defect inference data.
- the learning model 25 is preferably composed of a recursive neural network.
- the machine learning technique is not limited to machine learning using a neural network, and other machine learning techniques may be employed. Other machine learning techniques include, for example, tree types such as decision trees, ensemble learning, clustering, multivariate analysis, and support vector machines.
- the machine learning unit 202I inputs the input data constituting the learning data to the input layer of the learning model 25. Then, using an error function that compares the defect inference data output from the output layer of the learning model 25 and the teacher data that constitutes the learning data, between each layer so that the evaluation value of the error function becomes small. Adjust the associated weight parameter.
- the machine learning unit 202I repeats the above operation using a plurality of sets of learning data, and stores the weight parameter when a predetermined learning end condition is satisfied as the learned learning model 25 in the storage unit 21, for example.
- the defect inference unit 202J inputs the welding conditions and the welding execution record at the welding point 11a to be inferred as input data to the learning model 25 (with the weight parameter adjusted), thereby determining the presence or absence of a welding defect at the welding point 11a. is inferred, and defect inference processing is performed to generate advice information including the inference result.
- the welding point 11a to be inferred may be the welding point 11 corresponding to the record in which the welding condition and the welding execution record are registered in the welding point table 211A of the welding process database 211. FIG. Therefore, the defect inference process is performed at an arbitrary timing after the welding process is performed at the welding point 11a to be inferred.
- FIG. 23 is a flowchart showing an example of defect inference processing.
- FIG. 23 describes the operation when the defect inference unit 202J performs defect inference processing following step S162 or S164 in FIG.
- step S901 the defect inference unit 202J accepts the welding location 11 specified by the welding process target record as the inference target welding location 11a, thereby registering it in the welding process target record of the welding location table 211A. Acquire welding conditions and welding execution records.
- step S902 the defect inference unit 202J inputs the welding conditions and the welding execution record at the welding point 11a to be inferred into the input layer of the learning model 25, and infers defects from the output layer of the learning model 25. output the data.
- the defect inference unit 202J refers to the welding process database 211 and identifies a record corresponding to the welding point 11 identified by the welding process target record in the welding point table 212A. Then, the defect inference unit 202J registers the defect inference data output from the learning model 25 in the specified record.
- step S920 the output processing unit 205 transfers the defect inference data output from the learning model 25 to the welder terminal device 5A of the welder 50A and the welding management of the welding manager 50B who manages the welder 50A. to the party terminal device 5B.
- steps S921 and S922 when the welder terminal device 5A and the welding manager 50B receive the defect inference data from the welding data processing device 2, an inference result display screen based on the defect inference data is displayed.
- the defect inference unit 202J infers whether or not there is a welding defect at the welding point 11a to be inferred.
- the welder 50A and the welding manager 50B receive the display of the inference result display screen based on the inference result, for example, the necessity of welding repair or re-welding, Since the priority of radiographic inspection is determined, it is possible to speed up decision-making and improve welding quality.
- the information processing section 202 is provided with the respective sections 202A to 202J, but may be provided with only some of the sections 202A to 202J.
- the execution order of each step may be changed as appropriate, or some steps may be omitted.
- the image data 14 has been described as being generated by the inspection machine 7 .
- the image data 14 may be generated by scanning, for example, a film on which the transmitted radiation of the welded portion is imaged with an image reading device such as a scanner.
- the input data of the learning model 25 in the machine learning unit 202I and the defect inference unit 202J is described as being the welding conditions and the welding execution record at the welding point 11, but the input data of the learning model is It may be image data 14 at the welding location 11 .
- the information processing unit 202 further includes a machine learning unit and a defect inference unit separately from the machine learning unit 202I and the defect inference unit 202J.
- the defect inferring unit converts the image data 14 of the welding point 11a to be inferred into the input data may be input to a learned learning model to output the defect inference data at the welded portion 11a.
- analysis result display screen 50A... welder, 50B... welding manager, 50C... imaging operator, 50D... judge, 50E Inspection manager 51 Card reader 60 Welder monitoring device 61 Temperature measuring device 62 Distribution board 63 Welding torch 64 Power supply circuit 65 Operation control panel 66 Gas tank , 70... Radiation irradiation unit 71... Detector 72... Guide 73... Drive unit 74... Operation control panel 200... Welding process registration unit 201... Inspection process registration unit 202... Information processing unit 202A... Qualification Judgment part 202B... Deviation judgment part 202C... Defect analysis part 202D... Disqualification analysis part 202E... Deviation analysis part 202F... Deviation judgment criteria setting part 202G...
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Abstract
Description
溶接箇所毎に、溶接条件と、前記溶接条件に従って実施された溶接工程における溶接実施記録とを溶接工程データベースに登録する溶接工程登録部と、
前記溶接箇所毎に、放射線透過検査工程にて取得された前記溶接箇所の画像データに基づいて前記溶接箇所における溶接の欠陥の有無が判定された結果を示す欠陥判定データを検査工程データベースに登録する検査工程登録部と、
前記溶接工程データベース及び前記検査工程データベースに登録された情報に基づいて、所定の処理を行う情報処理部とを備える。
図3は、溶接機6の一例を示す構成図である。溶接機6は、溶接士50Aにより把持される溶接トーチ63と、分電盤62から電力の供給を受けて、溶接トーチ63に所定の溶接電流を出力する電源回路64と、各種の入力操作(例えば、溶接条件の電気特性を設定する設定操作等)を受け付けるとともに溶接機6の各部を制御する操作制御盤65とを備える。溶接トーチ63は、放電用の電極630と、ガスタンク66からのシールドガスを供給するノズル631と、オンオフ操作用のスイッチ632とを備える。
図4は、検査機7の一例を示す構成図である。検査機7は、溶接箇所11に向けて放射線を照射する放射線照射部70と、放射線照射部70に対向して配置される検出器71と、溶接箇所11の外周に着脱可能に取り付けられたガイド72と、ガイド72に沿って放射線照射部70及び検出器71を周方向に移動させる駆動部73と、各種の入力操作を受け付けるとともに、検査機7の各部を制御する操作制御盤74とを備える。検出器71は、例えば、フラットパネルディテクタ(FPD)等で構成される。なお、検査機7の上記構成は一例であり、例えば、コンピューテッドラジオグラフィ(CR)で構成される検出器71を備える検査機7を用いてもよい。
図5は、溶接データ処理装置2の一例を示すブロック図である。溶接データ処理装置2は、プロセッサ等により構成される制御部20と、HDD(Hard Disk Drive)、SSD(Solid State Drive)、メモリ等により構成される記憶部21と、ネットワーク8との通信インターフェースである通信部22と、キーボード、マウス等により構成される入力部23と、ディスプレイ等により構成される表示部24とを備える。なお、入力部23及び表示部24は省略されてもよい。
溶接工程登録部200及び検査工程登録部201は、溶接工程及び検査工程が実施される前に、溶接工程データベース211及び検査工程データベース212に各種の情報(溶接実施記録及び検査実施記録を除く)を事前に登録する事前登録処理を行う。
溶接工程登録部200は、溶接工程の実施に伴って、溶接実施記録を溶接工程データベース211に登録する登録処理を行う。また、その登録処理と連動して、資格判定部202Aは、溶接士50Aの保有資格に対する資格判定処理を行うとともに、逸脱判定部202Bは、逸脱判定処理を行う。
検査工程登録部201は、放射線透過検査工程に含まれる撮像工程の実施に伴って、検査実施記録を検査工程データベース212に登録する登録処理を行う。また、その登録処理と連動して、資格判定部202Aは、撮像作業者50Cの保有資格に対する資格判定処理を行う。
検査工程登録部201は、放射線透過検査工程に含まれる画像判定工程の実施に伴って、検査実施記録を検査工程データベース212に登録する登録処理を行う。また、その登録処理と連動して、資格判定部202Aは、判定士50Dの保有資格に対する資格判定処理を行う。
欠陥分析部202Cは、溶接工程データベース211及び検査工程データベース212に登録された各レコードの情報に基づいて、欠陥発生傾向を分析する欠陥分析処理を行う。
資格不適格分析部202Dは、溶接工程データベース211及び検査工程データベース212に登録された各レコードの情報に基づいて、作業者50A~50Eの保有資格に関する資格不適格発生傾向を分析する資格不適格分析処理を行う。なお、作業者50A~50Eの保有資格が、溶接箇所11の要求資格に対して不適格である場合、ステップS123、S223、S323の資格不適格処理を行うことで、無資格の作業者50A~50Eによる作業を抑制している。そのため、資格不適格分析部202Dによる資格不適格分析処理は、作業者50A~50Eが無資格であるにもかかわらず、誤って作業を実行してしまった場合において、その状況を分析することを想定したものである。
逸脱分析部202Eは、溶接工程データベース211及び検査工程データベース212に登録された各レコードの情報に基づいて、溶接条件に対する溶接実施記録の逸脱に関する逸脱発生傾向を分析する逸脱分析処理を行う。
溶接アシスト部202Gは、アシスト対象とする溶接箇所11における溶接条件と、欠陥分析部202Cが溶接工程データベース211及び検査工程データベース212に登録された情報を分析することで得られた欠陥発生傾向とに基づいて、当該溶接箇所11にて溶接の欠陥が発生すると予測される溶接実施記録の特徴を含むアシスト情報を生成する溶接アシスト処理を行う。アシスト対象とする溶接箇所11は、溶接工程データベース211の溶接箇所テーブル211Aにおいて溶接条件が登録されたレコードに対応する溶接箇所11であればよい。そのため、溶接アシスト処理は、アシスト対象とする溶接箇所における溶接工程の実施前の任意のタイミングにて行われる。
欠陥予測部202Hは、予測対象とする溶接箇所11における溶接条件及び溶接実施記録と、欠陥分析部202Cが溶接工程データベース211及び検査工程データベース212に登録された情報を分析することで得られた欠陥発生傾向とに基づいて、当該溶接箇所11における溶接の欠陥の有無を予測し、その予測結果を含むアドバイス情報を生成する欠陥予測処理を行う。予測対象とする溶接箇所11は、溶接工程データベース211の溶接箇所テーブル211Aにおいて溶接条件及び溶接実施記録が登録されたレコードに対応する溶接箇所11であればよい。そのため、欠陥予測処理は、予測対象とする溶接箇所11における溶接工程の実施後の任意のタイミングにて行われる。
図22は、機械学習処理及び欠陥推論処理の一例を示す概要図である。
本発明は上述した実施形態に制約されるものではなく、本発明の主旨を逸脱しない範囲内で種々変更して実施することが可能である。そして、それらはすべて、本発明の技術思想に含まれるものである。
Claims (18)
- 溶接箇所毎に、溶接条件と、前記溶接条件に従って実施された溶接工程における溶接実施記録とを溶接工程データベースに登録する溶接工程登録部と、
前記溶接箇所毎に、放射線透過検査工程にて取得された前記溶接箇所の画像データに基づいて前記溶接箇所における溶接の欠陥の有無が判定された結果を示す欠陥判定データを検査工程データベースに登録する検査工程登録部と、
前記溶接工程データベース及び前記検査工程データベースに登録された情報に基づいて、所定の処理を行う情報処理部とを備える、
溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接工程にて使用された溶接機の動作状態が記録された溶接機動作データを、前記溶接実施記録として前記溶接工程データベースに登録する、
請求項1に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接箇所の予熱状態が記録された予熱データを、前記溶接実施記録として前記溶接工程データベースに登録する、
請求項1又は2記載の溶接データ処理装置。 - 前記情報処理部は、
前記溶接条件及び前記溶接実施記録の少なくとも一方と、前記欠陥判定データとに基づいて、前記欠陥が発生したときの傾向を示す欠陥発生傾向を分析する欠陥分析部を備える、
請求項1乃至請求項3のいずれか1項に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接工程を実施した溶接士を特定する溶接士識別情報、前記溶接士を管理する溶接管理者を特定する溶接管理者識別情報、及び、前記溶接士が所属する所属先を特定する所属先識別情報の少なくとも1つを前記溶接工程データベースに登録し、
前記欠陥分析部は、
前記溶接士、前記溶接管理者、及び、前記所属先のうち少なくとも1つを分析軸として、前記欠陥発生傾向を分析する、
請求項4に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接箇所が属する溶接現場を特定する溶接現場識別情報、及び、前記溶接現場が複数の溶接エリアに分割されて管理される場合に前記溶接箇所が属する前記溶接エリアを特定する溶接エリア識別情報の少なくとも1つを前記溶接工程データベースに登録し、
前記欠陥分析部は、
前記溶接現場、及び、前記溶接エリアのうち少なくとも1つを分析軸として、前記欠陥発生傾向を分析する、
請求項4又は請求項5に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接条件に従って前記溶接工程が実施されたときに当該溶接条件に対して前記溶接実施記録が逸脱している逸脱量を前記溶接工程データベースに登録し、
前記欠陥分析部は、
前記逸脱量を分析軸として、前記欠陥発生傾向を分析する、
請求項4乃至請求項6のいずれか1項に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接条件に従って前記溶接工程が実施されたときの実施開始日時及び実施終了日時を、前記溶接実施記録として前記溶接工程データベースに登録し、
前記欠陥分析部は、
前記実施開始日時及び前記実施終了日時に基づく作業時間を分析軸として、前記欠陥発生傾向を分析する、
請求項4乃至請求項7のいずれか1項に記載の溶接データ処理装置。 - 前記情報処理部は、
アシスト対象とする前記溶接箇所における前記溶接条件と、前記欠陥発生傾向とに基づいて、当該溶接箇所にて前記欠陥が発生すると予測される前記溶接実施記録の特徴を含むアシスト情報を生成する溶接アシスト部を備える、
請求項4乃至請求項8のいずれか1項に記載の溶接データ処理装置。 - 前記情報処理部は、
予測対象とする前記溶接箇所における前記溶接条件及び前記溶接実施記録と、前記欠陥発生傾向とに基づいて、当該溶接箇所における前記欠陥の有無を予測する欠陥予測部を備える、
請求項4乃至請求項9のいずれか1項に記載の溶接データ処理装置。 - 前記情報処理部は、
前記溶接条件及び前記溶接実施記録を入力データとし、当該溶接条件及び当該溶接実施記録に対する前記欠陥判定データを教師データとして学習データを構成し、
学習モデルに前記学習データを複数組入力することで、前記入力データと前記教師データとの相関関係を前記学習モデルに機械学習させる機械学習部を備える、
請求項1乃至請求項10のいずれか1項に記載の溶接データ処理装置。 - 前記情報処理部は、
推論対象とする前記溶接箇所における前記溶接条件及び前記溶接実施記録を前記入力データとして前記学習モデルに入力することで、当該溶接箇所における前記欠陥の有無を推論する欠陥推論部を備える、
請求項11に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接箇所にて前記溶接工程を実施する溶接士が当該溶接箇所における前記溶接条件に従って前記溶接工程を実施する資格を保有するか否かの前記資格の適否が判定された結果を示す溶接士資格判定データを、前記溶接実施記録として前記溶接工程データベースに登録する、
請求項1乃至請求項12のいずれか1項に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接工程を実施した溶接士を特定する溶接士識別情報、前記溶接士を管理する溶接管理者を特定する溶接管理者識別情報、及び、前記溶接士が所属する所属先を特定する所属先識別情報の少なくとも1つを前記溶接工程データベースに登録し、
前記情報処理部は、
前記溶接実施記録に基づいて、前記溶接士、前記溶接管理者、及び、前記所属先のうち少なくとも1つを分析軸として、前記資格の不適格が発生したときの傾向を示す資格不適格発生傾向を分析する資格不適格分析部を備える、
請求項13に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接実施記録が前記溶接条件に対して所定の逸脱判定基準を超えて逸脱しているか否かの逸脱の有無が判定された結果を示す逸脱判定データを、前記溶接実施記録として前記溶接工程データベースに登録する、
請求項1乃至請求項14のいずれか1項に記載の溶接データ処理装置。 - 前記溶接工程登録部は、
前記溶接工程を実施した溶接士を特定する溶接士識別情報、前記溶接士を管理する溶接管理者を特定する溶接管理者識別情報、及び、前記溶接士が所属する所属先を特定する所属先識別情報の少なくとも1つを前記溶接工程データベースに登録し、
前記情報処理部は、
前記溶接実施記録に基づいて、前記溶接士、前記溶接管理者、及び、前記所属先のうち少なくとも1つを分析軸として、前記逸脱が発生したときの傾向を示す逸脱発生傾向を分析する逸脱分析部を備える、
請求項15に記載の溶接データ処理装置。 - 前記情報処理部は、
前記溶接条件と、前記溶接実施記録と、前記欠陥判定データとに基づいて、前記逸脱判定基準を設定する逸脱判定基準設定部を備える、
請求項15又は請求項16に記載の溶接データ処理装置。 - 溶接箇所毎に、溶接条件と、前記溶接条件に従って実施された溶接工程における溶接実施記録とを溶接工程データベースに登録する溶接工程登録ステップと、
前記溶接箇所毎に、放射線透過検査工程にて取得された前記溶接箇所の画像データに基づいて前記溶接箇所における溶接の欠陥の有無が判定された結果を示す欠陥判定データを検査工程データベースに登録する検査工程登録ステップと、
前記溶接工程データベース及び前記検査工程データベースに登録された情報に基づいて、所定の処理を行う情報処理ステップとを備える、
溶接データ処理方法。
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