阅读说明：本技术 基于质量的焊丝余量检测与焊接过程控制系统及方法 (Welding wire allowance detection and welding process control system and method based on quality ) 是由 潘慧君 顾胜 雷雨雨 于津伟 缪逢吉 唐兴华 郑兴 巫江祥 于 2021-08-18 设计创作，主要内容包括：本发明公开基于质量的焊丝余量检测与焊接过程控制系统及方法,包括质量传感器、焊丝桶、焊枪、控制器和显示器,焊丝桶放置在质量传感器的上端,焊丝桶容纳焊丝,焊枪的头部与焊丝连接,质量传感器与控制器连接,控制器与显示器连接,控制器根据质量传感器信息、当前焊丝规格、焊丝桶本体重量计算出当前焊丝剩余量,控制器将焊丝余量信息和其他提示信息显示在显示器上,控制器根据当前焊丝余量和剩余的焊接任务进行焊接顺序规划,剩余焊丝量无法进行任何焊缝焊接时,控制器发出信息提示人员更换；本发明能够精确完成焊丝余量的计算,基于焊丝余量完成焊接任务的规划与调整,在保证焊接质量的前提下,使焊丝利用率达到最大。(The invention discloses a quality-based welding wire allowance detection and welding process control system and method, which comprises a quality sensor, a welding wire barrel, a welding gun, a controller and a display, wherein the welding wire barrel is arranged at the upper end of the quality sensor, the welding wire barrel contains a welding wire, the head of the welding gun is connected with the welding wire, the quality sensor is connected with the controller, the controller is connected with the display, the controller calculates the current welding wire allowance according to the information of the quality sensor, the specification of the current welding wire and the weight of a welding wire barrel body, the controller displays the welding wire allowance information and other prompt information on the display, the controller carries out welding sequence planning according to the current welding wire allowance and the rest welding tasks, and when the rest welding wire amount cannot carry out any welding seam welding, the controller sends information to prompt a person to replace; the invention can accurately complete the calculation of the welding wire allowance, complete the planning and adjustment of the welding task based on the welding wire allowance, and maximize the utilization rate of the welding wire on the premise of ensuring the welding quality.)

1. Welding wire surplus detects and welding process control system based on quality, its characterized in that, including quality sensor, welding wire bucket, welder, controller and display, the upper end at quality sensor is placed to the welding wire bucket, the welding wire bucket holds the welding wire, welder's head is connected with the welding wire, quality sensor's output is connected with the controller, the controller is connected with the display.

2. The quality-based welding wire allowance detection and welding process control method is characterized by comprising the following steps of:

step S1) the quality sensor measures the total quality information of the welding wire barrel and the welding wire, and the step S2 is skipped;

step S2) the quality sensor transmits the total quality information to the controller, the controller processes the total quality information according to the current welding wire specification and the quality of the welding wire barrel to obtain the current welding wire allowance, the step S3 is skipped,

the welding wire allowance is the residual welding wire quality, the computing mode of the welding wire allowance is as follows,

M_{quality of welding wire}＝M_{Total mass}-M_{Quality of welding wire barrel}。L_{Length of welding wire}＝M_{Quality of welding wire}/((D_{Diameter of welding wire}/2)²*π*ρ_{Density of welding wire}))；

Step S3), the controller compares the current welding wire allowance with the welding wire amount required by the next welding seam in the original sequence, if the welding wire allowance is smaller than the required welding wire amount, the step S4 is skipped, and if the welding wire allowance is larger than or equal to the required welding wire amount, the step S6 is skipped;

step S4), comparing the current welding wire allowance with the welding wire amount required by other welding seams, if a welding seam meeting the requirement exists, skipping to step S5, and if no welding seam meeting the requirement exists, skipping to step S7;

step S5), adjusting the welding sequence, preferentially welding the welding seams meeting the requirements, and skipping to the step S6;

step S6), the welding operation is performed, and the process goes to step S1;

step S7) the controller sends out prompt information to the display, the prompt information is displayed on the display, and the personnel is prompted to change the welding wire barrel.

3. The quality-based wire residue detection and welding process control method of claim 2, wherein said step S2 further comprises the controller transmitting the current wire residue to a display, the display displaying the current wire residue.

Technical Field

The invention relates to the technical field of automatic welding, in particular to a welding wire allowance detection and welding process control system and method based on quality.

Background

The welding wire barrel is the best choice when mass production is carried out in the field of automatic welding, but when carrying out automatic welding, control system and operating personnel can not accurately calculate the surplus of welding wire in the welding wire barrel. When some important structural parts are welded, the welding seam must be welded once, and a welding joint is not allowed to exist in the middle, so that welding defects or welding wire waste are easily caused if the welding wire allowance is not accurately estimated.

Disclosure of Invention

The invention aims to provide a quality-based welding wire allowance detection and welding process control system and method.

In order to achieve the purpose, the technical scheme of the invention is as follows:

welding wire surplus detects and welding process control system based on quality, its characterized in that, including quality sensor, welding wire bucket, welder, controller and display, the upper end at quality sensor is placed to the welding wire bucket, the welding wire bucket holds the welding wire, welder's head is connected with the welding wire, quality sensor's output is connected with the controller, the controller is connected with the display.

2. The quality-based welding wire allowance detection and welding process control method is characterized by comprising the following steps of:

step S1) the quality sensor measures the total quality information of the welding wire barrel and the welding wire, and the step S2 is skipped;

step S2) the quality sensor transmits the total quality information to the controller, the controller processes the total quality information according to the current welding wire specification and the quality of the welding wire barrel to obtain the current welding wire allowance, the step S3 is skipped,

the welding wire allowance is the residual welding wire quality, the computing mode of the welding wire allowance is as follows,

M_{quality of welding wire}＝M_{Total mass}-M_{Quality of welding wire barrel}。L_{Length of welding wire}＝M_{Quality of welding wire}/((D_{Diameter of welding wire}/2)²*π*ρ_{Density of welding wire}))；

Step S3), the controller compares the current welding wire allowance with the welding wire amount required by the next welding seam in the original sequence, if the welding wire allowance is smaller than the required welding wire amount, the step S4 is skipped, and if the welding wire allowance is larger than or equal to the required welding wire amount, the step S6 is skipped;

step S4), comparing the current welding wire allowance with the welding wire amount required by other welding seams, if a welding seam meeting the requirement exists, skipping to step S5, and if no welding seam meeting the requirement exists, skipping to step S7;

step S5), adjusting the welding sequence, preferentially welding the welding seams meeting the requirements, and skipping to the step S6;

step S6), the welding operation is performed, and the process goes to step S1;

step S7) the controller sends out prompt information to the display, the prompt information is displayed on the display, and the personnel is prompted to change the welding wire barrel.

Further, the step S2 includes the controller transmitting the current wire remaining amount to a display, and the display displaying the current wire remaining amount.

The invention can accurately complete the calculation of the welding wire allowance, complete the planning and adjustment of the welding task based on the welding wire allowance, and maximize the utilization rate of the welding wire on the premise of ensuring the welding quality.

Drawings

FIG. 1 is a schematic diagram of a welding wire residue detection and welding process control system according to the present invention;

FIG. 2 is a flow chart illustrating a method for detecting a welding wire remaining amount and controlling a welding process according to the present invention.

Reference numerals:

1 quality sensor, 2 welding wire barrels, 3 welding guns, 4 controllers and 5 displays.

Detailed Description

The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

The invention discloses a welding wire allowance detection and welding process control system based on quality, which comprises a quality sensor 1, a welding wire barrel 2, a welding gun 3, a controller 4 and a display 5, wherein the welding wire barrel 2 is placed at the upper end of the quality sensor 1, the welding wire barrel 2 contains a welding wire, the head of the welding gun 3 is connected with the welding wire, the output end of the quality sensor 1 is connected with the controller 4, and the controller 4 is connected with the display 5.

The controller 4 calculates the current welding wire residual quantity according to the information of the quality sensor 1, the current welding wire specification, the weight of the welding wire barrel 2 body and the like, and the controller 4 can display the welding wire residual quantity information and other prompt information on the display 5.

And the controller 4 carries out welding sequence planning according to the current welding wire allowance and the residual welding tasks, and when the residual welding wire amount cannot carry out any welding seam welding, the controller 4 sends out information to prompt personnel to carry out replacement.

The quality-based welding wire remaining amount detection and welding process control method, as shown in fig. 2, includes the following steps:

step S1) the quality sensor 1 measures the quality information, and the step S2 is skipped;

step S2) the quality sensor 1 transmits the total quality information to the controller 4, the controller 4 processes the total quality information according to the current welding wire specification and the quality of the welding wire barrel 2 to obtain the current welding wire allowance, and the step S3 is skipped;

the welding wire allowance is the residual welding wire quality, the computing mode of the welding wire allowance is as follows,

M_{quality of welding wire}＝M_{Total mass}-M_{Quality of welding wire barrel}。L_{Length of welding wire}＝M_{Quality of welding wire}/((D_{Diameter of welding wire}/2)²*π*ρ_{Density of welding wire}))；

Step S3) the controller 4 compares the current welding wire allowance with the welding wire amount required by the next welding seam in the original sequence, if the welding wire allowance is smaller than the required welding wire amount, the step S4 is skipped, and if the welding wire allowance is larger than or equal to the required welding wire amount, the step S6 is skipped;

step S4), comparing the current welding wire allowance with the welding wire amount required by other welding seams, if a welding seam meeting the requirement exists, skipping to step S5, and if no welding seam meeting the requirement exists, skipping to step S7;

step S5), adjusting the welding sequence, preferentially welding the welding seams meeting the requirements, and skipping to the step S6;

step S6), the welding operation is performed, and the process goes to step S1;

step S7) the controller 4 sends a prompt message to the display 5, and the display 5 displays the prompt message to prompt the personnel to replace the welding wire barrel 2.

Step S2 further includes the controller 4 transmitting the current wire remaining amount to the display 5, the display 5 displaying the current wire remaining amount.

Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled 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; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.