阅读说明：本技术 一种无线检测焊接参数的装置及方法 (Device and method for wirelessly detecting welding parameters ) 是由 路林 刘航 陈雁忠 孙志星 董波波 包正义 汤传圣 詹瑜 姚官鑫 刘玉鹏 于 2019-12-19 设计创作，主要内容包括：本发明提供一种无线检测焊接参数的装置及方法,涉及焊接技术领域。该装置及方法首先通过电流、电压传感器采集焊接工作时的电流电压信号；把采集到的电信号通过信号调理电路去除工业干扰波,通过单片机进行A/D转换,把模拟信号转换成数字信号；转换的数字信号通过无线传输模块送至上位机,在上位机存储数据并显示数据波形图等信息。同时,上位机内存储焊接参数范围,当检测到的数据与给定参数范围不同时,上位机实现自动提示、报警等反馈功能。本发明将无线通信技术应用于焊接检测过程中,有效的解决了焊接车间环境复杂,有线检测方法存在布线麻烦、扩展性差、成本高、线路故障难以检查等问题,便于及时发现错误及时调整,从而提高焊接质量。(The invention provides a device and a method for wirelessly detecting welding parameters, and relates to the technical field of welding. The device and the method firstly collect current and voltage signals during welding work through a current sensor and a voltage sensor; removing industrial interference waves from the collected electric signals through a signal conditioning circuit, performing A/D conversion through a single chip microcomputer, and converting analog signals into digital signals; the converted digital signals are sent to an upper computer through a wireless transmission module, and the upper computer stores data and displays information such as a data oscillogram and the like. Meanwhile, the welding parameter range is stored in the upper computer, and when the detected data is different from the given parameter range, the upper computer realizes the feedback functions of automatic prompt, alarm and the like. The invention applies the wireless communication technology to the welding detection process, effectively solves the problems of complex welding workshop environment, troublesome wiring, poor expansibility, high cost, difficult line fault detection and the like of a wired detection method, and is convenient for finding errors in time and adjusting in time, thereby improving the welding quality.)

1. The utility model provides a device of wireless detection welding parameter which characterized in that: the device comprises a TIG welding machine, a TIG welding gun, a voltage acquisition device, a current acquisition device, a wireless transmission device, a main controller and an upper computer; the TIG welding gun is connected with the TIG welding machine to weld a workpiece to be welded; the positive electrode of the voltage acquisition device is connected to a workpiece, the negative electrode of the voltage acquisition device is connected to a terminal of a TIG welding gun, and the voltage at two ends of the TIG welding gun in the welding process is acquired; the current collecting device is connected with the TIG welding machine and is used for collecting the output current of the TIG welding machine in the welding process; the voltage acquisition device and the current acquisition device are connected with the main controller, and the main controller transmits the received voltage signals and current signals to a remote upper computer through the wireless communication module after analog-to-digital conversion; the upper computer judges the received signals and returns the judgment result to the main controller.

2. The device for wirelessly detecting welding parameters according to claim 1, wherein: the voltage acquisition device adopts a Hall voltage sensor, a resistor is connected to the output end of the Hall voltage sensor, the output current is converted into a voltage signal, and the voltage detection range is 0-100V; the current acquisition device adopts a Hall current sensor, and the welding current detection range is 0-600A.

3. The device for wirelessly detecting welding parameters according to claim 2, wherein: the Hall voltage sensor is connected with a ground wire of the TIG welding machine, and the ground wire is clamped by a special chuck; the special chuck is characterized in that adjustable fan-shaped sheets are arranged on the periphery of a hole of the Hall voltage sensor, so that the four fan-shaped sheets are handed over to the center of the hole, and the ground wire of the TIG welding machine is ensured to be arranged at the center of the hole of the Hall voltage sensor; if the diameter of the ground wire of the TIG welding machine changes, the fan-shaped sheet is adjusted along with the change of the diameter of the ground wire, and the ground wire is tightened, so that the output current of the TIG welding machine is always ensured to pass through the center of the perforation of the Hall voltage sensor.

4. The device for wirelessly detecting welding parameters according to claim 3, wherein: the main controller adopts a single chip microcomputer, receives detection signals from the Hall current sensor and the Hall voltage sensor through an A/D unit of the single chip microcomputer, and converts an analog signal value into a digital signal which can be received by the upper computer.

5. The device for wirelessly detecting welding parameters according to claim 4, wherein: the device also comprises a signal conditioning circuit which is connected with the main controller and is used for removing industrial interference waves, and a display screen and a warning lamp which are used for displaying alarm; the signal conditioning circuit is formed by bridging two capacitors C1 and C2 between a positive power supply and a negative power supply which are close to the pins of the single chip microcomputer, and an inductance coil L1 which is connected with the C2 in series; c1 is an electrolytic capacitor for filtering power supply ripples; c2 is a capacitor for filtering burrs on the power supply to interfere with the ceramic chip; l1 is an inductor which acts as a resistor in the ac current for stabilizing the current and which is in circuit with two capacitors for filtering the power supply.

6. The device for wirelessly detecting welding parameters according to claim 1, wherein: the upper computer is internally provided with a program for storing the received detection data, displaying the detection data in a graphical mode and judging whether the received detection data is in a set parameter range, transmitting a display instruction to the main controller when the acquired current value and the acquired voltage value are in the set parameter range, and the main controller receives the instruction and displays the acquired real-time current and voltage data to a user through a display screen; if the collected current value or voltage value exceeds or is lower than the set parameter range, the upper computer sends an alarm instruction to the main controller, the main controller receives the instruction, controls the warning lamp to be on, alarms to prompt a user that the parameters are wrong, and feeds error information back to the user through the display screen.

7. The device for wirelessly detecting welding parameters according to claim 1, wherein: the wireless transmission module adopts a Wifi, 4G or GPRS wireless transmission mode to transmit data.

8. A method for wirelessly detecting welding parameters by using the device of claim 5, wherein the method comprises the following steps: the method comprises the following steps:

step 1: selecting TIG welding process parameters according to the material, plate thickness or wall thickness of a welding workpiece and the requirement of welding speed; the welding process parameters comprise welding current, arc voltage, protective gas flow, tungsten electrode diameter and end shape, and distance between the end of the tungsten electrode and a workpiece;

step 2: respectively connecting the positive electrode and the negative electrode of a tungsten electrode argon arc welding machine to a welding workpiece and a welding gun, wherein the welding gun is vertical to the workpiece; connecting the positive pole of a Hall voltage sensor to a workpiece, and connecting the negative pole of the Hall voltage sensor to a welding gun; the ground wire of the argon tungsten-arc welding machine positively passes through the Hall current sensor and is clamped by a special chuck; turning on a power supply of the argon tungsten-arc welding machine, adjusting the current to a direct current form, setting the current value, and starting arc starting welding; during welding, the welding gun is not moved, and the workpiece moves;

and step 3: analog signals acquired by the voltage acquisition device and the current acquisition device are converted into digital signals through the main controller, the digital signals are transmitted to an upper computer through a wireless module, and the upper computer stores received data and displays the data in real time in an imaging mode;

and 4, step 4: the upper computer judges the received detection data through a built-in program, transmits a display instruction to the main controller when the acquired current value and the acquired voltage value are both in the set parameter range, and the main controller receives the instruction and displays the acquired real-time current and voltage data to a user through a display screen; if the collected current and voltage values exceed or are lower than the set parameter range, the upper computer sends an alarm instruction to the main controller, the main controller receives the instruction, controls the warning lamp to be on, gives an alarm to prompt a user that the parameters are wrong, and feeds error information back to the user through the display screen.

Technical Field

The invention relates to the technical field of welding, in particular to a device and a method for wirelessly detecting welding parameters.

Background

In the welding process, welding process parameters directly influence the quality of welding, so that the correctness of the welding process parameters is ensured in the welding process. For different welding equipment, welding methods and welded workpieces, the welding parameters are required to be detected in real time to control the welding quality to ensure that the welding process parameters are within a specific range. Therefore, real-time monitoring and detection of working parameters in welding work are important guarantees for improving welding quality.

The traditional method for detecting welding quality at present is generally off-line detection, namely the quality of a weldment is detected after welding work is finished, but the detection method has certain delay, welding defects cannot be found in time, and defective workpieces can only be repaired or scrapped. Therefore, the cost is increased, the production efficiency is reduced, and in order to solve the problem of delayed off-line detection, numerous researchers carry out modification and innovative research on the welding quality detection method. The method is characterized in that a student detects welding parameter signals in a welding workshop in a wired transmission mode, and the student applies a serial port communication technology to the design of a distributed control system of a plurality of welding machines. The CAN bus technology is applied to welding parameter detection by students. The scholars and the like apply the Ethernet to the electric welding machine control system, so that the remote monitoring of the working parameters of the electric welding machine is possible. The short-distance wireless communication technology is applied to welding production by students, and the Wi Fi wireless network is applied to a welding production line of a bogie of a CRH380 high-speed motor train unit, so that parameter changes of the motor train unit in the welding process can be monitored in real time. The student applies the Zig Bee technology to a welding power supply monitoring system, monitors the working state of the welding power supply in real time, and inquires the historical working information of the welding power supply, thereby realizing the collection, transmission and storage of the working parameters of the welding power supply.

Disclosure of Invention

The technical problem to be solved by the present invention is to provide a device and a method for wirelessly detecting welding parameters, which are used for detecting welding parameters in a wireless manner.

In order to solve the technical problems, the technical scheme adopted by the invention is as follows: on one hand, the invention provides a device for wirelessly detecting welding parameters, which comprises a TIG welding machine, a TIG welding gun, a voltage acquisition device, a current acquisition device, a wireless transmission device, a main controller and an upper computer; the TIG welding gun is connected with the TIG welding machine to weld a workpiece to be welded; the positive electrode of the voltage acquisition device is connected to a workpiece, the negative electrode of the voltage acquisition device is connected to a terminal of a TIG welding gun, and the voltage at two ends of the TIG welding gun in the welding process is acquired; the current collecting device is connected with the TIG welding machine and is used for collecting the output current of the TIG welding machine in the welding process; the voltage acquisition device and the current acquisition device are connected with the main controller, and the main controller transmits the received voltage signals and current signals to a remote upper computer through the wireless communication module after analog-to-digital conversion; the upper computer judges the received signals and returns the judgment result to the main controller.

Preferably, the voltage acquisition device adopts a Hall voltage sensor, a resistor is connected to the output end of the Hall voltage sensor, the output current is converted into a voltage signal, and the voltage detection range is 0-100V; the current acquisition device adopts a Hall current sensor, and the welding current detection range is 0-600A.

Preferably, the Hall voltage sensor is connected with a ground wire of the TIG welding machine, and the ground wire is clamped by a special chuck; the special chuck is characterized in that adjustable fan-shaped sheets are arranged on the periphery of a hole of the Hall voltage sensor, so that the four fan-shaped sheets are handed over to the center of the hole, and the ground wire of the TIG welding machine is ensured to be arranged at the center of the hole of the Hall voltage sensor; if the diameter of the ground wire of the TIG welding machine changes, the fan-shaped sheet is adjusted along with the change of the diameter of the ground wire, and the ground wire is tightened, so that the output current of the TIG welding machine is always ensured to pass through the center of the perforation of the Hall voltage sensor.

Preferably, the main controller adopts a single chip microcomputer, receives detection signals from the Hall current sensor and the Hall voltage sensor through an A/D unit of the single chip microcomputer, and converts an analog signal value into a digital signal which can be received by an upper computer.

Preferably, the device also comprises a signal conditioning circuit which is connected with the main controller and is used for removing industrial interference waves, a display screen and a warning lamp, wherein the display screen and the warning lamp are used for displaying alarm; the signal conditioning circuit is formed by bridging two capacitors C1 and C2 between a positive power supply and a negative power supply which are close to the pins of the single chip microcomputer, and an inductance coil L1 which is connected with the C2 in series; c1 is an electrolytic capacitor for filtering power supply ripples; c2 is a capacitor for filtering burrs on the power supply to interfere with the ceramic chip; l1 is an inductor which acts as a resistor in the ac current for stabilizing the current and which is in circuit with two capacitors for filtering the power supply.

Preferably, the upper computer is internally provided with a program for storing the received detection data, displaying the detection data in a graphical mode and judging whether the received detection data is in a set parameter range, transmitting a display instruction to the main controller when the acquired current value and the acquired voltage value are both in the set parameter range, and the main controller receives the instruction and displays the acquired real-time current and voltage data to a user through a display screen; if the collected current value or voltage value exceeds or is lower than the set parameter range, the upper computer sends an alarm instruction to the main controller, the main controller receives the instruction, controls the warning lamp to be on, alarms to prompt a user that the parameters are wrong, and feeds error information back to the user through the display screen.

Preferably, the wireless transmission module performs data transmission by using a Wifi, 4G or GPRS wireless transmission mode.

In another aspect, the present invention further provides a method for wirelessly detecting welding parameters, comprising the following steps:

step 1: selecting TIG welding process parameters according to the material, plate thickness or wall thickness of a welding workpiece and the requirement of welding speed; the welding process parameters comprise welding current, arc voltage, protective gas flow, tungsten electrode diameter and end shape, and distance between the end of the tungsten electrode and a workpiece;

step 2: respectively connecting the anode and the cathode of the TIG welding machine to a workpiece to be welded and a TIG welding gun, wherein the TIG welding gun is vertical to the workpiece; connecting the positive electrode of the Hall voltage sensor to a workpiece, and connecting the negative electrode of the Hall voltage sensor to a TIG welding gun; a ground wire of the TIG welding machine passes through the Hall current sensor in the forward direction and is clamped by a special chuck; turning on a power supply of the TIG welding machine, adjusting the current to a direct current form, setting the current value, and starting arc starting welding; during welding, the TIG welding gun is not moved, and the workpiece moves;

and step 3: analog signals acquired by the voltage acquisition device and the current acquisition device are converted into digital signals through the main controller, the digital signals are transmitted to an upper computer through a wireless module, and the upper computer stores received data and displays the data in real time in an imaging mode;

and 4, step 4: the upper computer judges the received detection data through a built-in program, transmits a display instruction to the main controller when the acquired current value and the acquired voltage value are both in the set parameter range, and the main controller receives the instruction and displays the acquired real-time current and voltage data to a user through a display screen; if the collected current and voltage values exceed or are lower than the set parameter range, the upper computer sends an alarm instruction to the main controller, the main controller receives the instruction, controls the warning lamp to be on, gives an alarm to prompt a user that the parameters are wrong, and feeds error information back to the user through the display screen.

Adopt the produced beneficial effect of above-mentioned technical scheme to lie in: according to the device and the method for wirelessly detecting the welding parameters, provided by the invention, the wireless communication technology is applied to the welding detection process, so that the problems of complex welding workshop environment, troublesome wiring, poor expansibility, high cost, difficulty in line fault detection and the like existing in a wired detection method are effectively solved. Meanwhile, the wireless detection technology is adopted, so that the production cost can be reduced, the production efficiency can be improved, and technicians can also monitor the welding working process remotely. Compared with the Bluetooth technology and the Zigbee technology, the wireless communication module does not need a complicated communication protocol, and similar products can communicate freely. The data that utilizes long-range host computer will gather are saved, show data through the figure, can more directly perceived clearly observe the data change. And when the detected data exceeds or is lower than the set parameter range, the system realizes the functions of automatic prompt, alarm and the like and feeds back the functions to the user. In addition, the device has low cost, small volume and convenient use.

Drawings

Fig. 1 is a schematic structural diagram of an apparatus for wirelessly detecting welding parameters according to an embodiment of the present invention;

fig. 2 is a circuit connection diagram of a signal conditioning circuit connected to a single chip microcomputer according to an embodiment of the present invention;

fig. 3 is a flowchart of a method for wirelessly detecting welding parameters according to an embodiment of the present invention.

In the figure, 1, TIG welding machine; 2. a TIG welding gun; 3. the workpiece is to be welded.

Detailed Description

The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.

In this embodiment, a device for wirelessly detecting welding parameters, as shown in fig. 1, includes a TIG (tungsten inert Gas) welding machine 1, a TIG welding gun 2, a voltage acquisition device, a current acquisition device, a wireless transmission device, a main controller, and an upper computer; the TIG welding gun 2 is connected with the TIG welding machine 1 to weld a workpiece 3 to be welded; the positive electrode of the voltage acquisition device is connected to a workpiece, the negative electrode of the voltage acquisition device is connected to a terminal of the TIG welding gun 2, and the voltage at two ends of the TIG welding gun 2 in the welding process is acquired; the current collecting device is connected with the TIG welding machine 1 and is used for collecting the output current of the TIG welding machine 1 in the welding process; the voltage acquisition device and the current acquisition device are connected with the main controller, and the main controller transmits the received voltage signals and current signals to a remote upper computer through the wireless communication module after analog-to-digital conversion; the upper computer judges the received signals and returns the judgment result to the main controller. The device also comprises a signal conditioning circuit which is connected with the main controller and is used for removing industrial interference waves, and a display screen and a warning lamp which are used for displaying alarm; as shown in fig. 2, the signal conditioning circuit is connected between a positive power supply and a negative power supply near the pins of the single chip microcomputer in a bridge connection manner with two capacitors C1 and C2, and an inductance coil L1 connected with C2 in series; c1 is an electrolytic capacitor for filtering power supply ripples; c2 is a capacitor for filtering burrs on the power supply to interfere with the ceramic chip; l1 is an inductor which acts as a resistor in the ac current for stabilizing the current and which is in circuit with two capacitors for filtering the power supply. The voltage acquisition device adopts a Hall voltage sensor, a resistor is connected to the output end of the Hall voltage sensor, the output current is converted into a voltage signal, and the voltage detection range is 0-100V; the current acquisition device adopts a Hall current sensor, and the welding current detection range is 0-600A. In the embodiment, the Hall current sensor is of a CDL-HE-600A type, and the voltage sensor is of a VSM025A series type. The Hall voltage sensor is connected with a ground wire of the TIG welding machine 1, and the ground wire is clamped by a special chuck; the special chuck is characterized in that adjustable fan-shaped sheets are arranged on the periphery of a hole of the Hall voltage sensor, so that the four fan-shaped sheets are handed over to the center of the hole, and the ground wire of the TIG welding machine 1 is ensured to be arranged at the center of the hole of the Hall voltage sensor; if the diameter of the ground wire of the TIG welding machine 1 changes, the fan-shaped sheet is adjusted and the ground wire is tightened, so that the output current of the TIG welding machine 1 is always ensured to pass through the center of the perforation of the Hall voltage sensor.

The main controller adopts a single chip microcomputer, receives detection signals from the Hall current sensor and the Hall voltage sensor through an A/D unit of the single chip microcomputer, and converts an analog signal value into a digital signal which can be received by the upper computer. In this embodiment, the model of singlechip selection is MEGA 328P.

The upper computer is internally provided with a program for storing the received detection data, displaying the detection data in a graphical mode and judging whether the received detection data is in a set parameter range, transmitting a display instruction to the main controller when the acquired current value and the acquired voltage value are in the set parameter range, and the main controller receives the instruction and displays the acquired real-time current and voltage data to a user through a display screen; if the collected current value or voltage value exceeds or is lower than the set parameter range, the upper computer sends an alarm instruction to the main controller, the main controller receives the instruction, controls the warning lamp to be on, alarms to prompt a user that the parameters are wrong, and feeds error information back to the user through the display screen.

The wireless transmission module adopts a Wifi, 4G or GPRS wireless transmission mode to transmit data. In this embodiment, the wireless transceiver module is implemented by integrating the microcontroller, the memory, the a/D converter, the required interface circuit, and the wireless data communication transceiver chip into a very small chip. Working frequency range of the wireless module: 433Mhz, GFSK modulation mode, receiving sensitivity up to-120 dBm, transmission distance 1000-.

A method of wirelessly detecting welding parameters, as shown in fig. 3, comprising the steps of:

step 1: selecting TIG welding process parameters according to the material, plate thickness or wall thickness of a welding workpiece and the requirement of welding speed; the welding process parameters comprise welding current, arc voltage, flow of protective gas (argon), diameter and end shape of a tungsten electrode and distance between the end of the tungsten electrode and a workpiece;

step 2: respectively connecting the anode and the cathode of a TIG welding machine 1 to a workpiece 3 to be welded and a TIG welding gun 2, wherein the TIG welding gun 2 is vertical to the workpiece; connecting the positive electrode of the Hall voltage sensor to a workpiece, and connecting the negative electrode of the Hall voltage sensor to a TIG welding gun 2; a ground wire of the TIG welding machine 1 passes through the Hall current sensor in the forward direction, and is clamped by a special chuck; turning on a power supply of the TIG welding machine 1, adjusting the current to a direct current form, setting the current value, and starting arc starting welding; during welding, the welding gun is not moved, and the workpiece moves;

and step 3: analog signals acquired by a Hall voltage sensor and a Hall current sensor are converted into digital signals through a single chip microcomputer, the digital signals are transmitted to an upper computer through a wireless module, and the upper computer stores received data and displays the data in real time in an imaging mode;

in this embodiment, the single chip transmits the acquired data to the wireless transceiver module through the serial port, the acquired data is displayed at the PC, and the wireless transceiver module and the upper computer perform data transmission in a USB-TTL manner.

And 4, step 4: the upper computer judges the received detection data through a built-in program, transmits a display instruction to the main controller when the acquired current value and the acquired voltage value are both in the set parameter range, and the main controller receives the instruction and displays the acquired real-time current and voltage data to a user through a display screen; if the collected current and voltage values exceed or are lower than the set parameter range, the upper computer sends an alarm instruction to the main controller, the main controller receives the instruction, controls the warning lamp to be on, gives an alarm to prompt a user that the parameters are wrong, and feeds error information back to the user through the display screen.

Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit of the corresponding technical solutions and scope of the present invention as defined in the appended claims.