CN103170714B - Welding machine, welding machine electronic management system and management method - Google Patents

Abstract

The invention relates to a welding machine. In order to monitor and manage the welding machine at a low cost and in the whole process under an electromagnetic interference environment, a welding machine, a welding machine electronic management system and a method are proposed. The welding machine reads the user information from the radio frequency card by setting an information identification device on the welding machine body that can read the internal information of the radio frequency card, and judges whether the welder's identity is qualified according to the user information; receives the operation password and dynamic password input by the user To judge whether the user's operation is legal, if it meets the requirements, it will unlock and enter the working state; when working, collect and store the state of the welding torch switch and welding parameters. The invention has the advantages of simple operation, no need to make major changes to the original welding machine, and only needs to connect related devices with some control lines; it also has the advantages of flexible use, convenient monitoring, and convenient review of welding quality.

Description

Welding machine, welding machine electronic management system and management method

technical field

The invention relates to a welding machine, in particular to an electronic management system for a welding machine, a welding machine and a welding machine management method.

Background technique

As a widely used equipment, arc welding machine has been widely used in aerospace, ships, automobiles, pressure vessels and other industrial fields, and has played an important role in the progress of my country's national economy. However, it is easy to cause electric shock, fire, and desoldering when used in the harsh environment of the construction site, which will endanger personal safety and property safety. Because of poor welding quality, it often leads to "tofu dregs" projects; in addition, in the key parts of ships, nuclear reactors, and spacecraft, welders are required to weld in strict accordance with welding specifications, but there is no effective monitoring of welders' on-site operations. If it is difficult to find out in time In order to speed up the progress, the welder changes the welding parameters without authorization, and the welding quality can only be guaranteed through post-weld inspection. Once welding defects are caused by incorrect welding specifications, it will take time and labor to make up for it, and it will lead to product scrapping or even major accidents. Therefore, in large-scale welding occasions with strict quality requirements, personnel with corresponding welder qualifications are required to strictly Operate according to established specifications.

In order to ensure the welding quality, three measures can generally be adopted: first, welding robots can be used for welding, which can avoid the shortcomings of welding specifications being tampered with, but the cost is expensive, the adaptability to welding occasions is poor, and the requirements for welders are high; The second is manual operation by skilled welders, which is low in cost and high in flexibility, but the on-site manual monitoring is cumbersome; the third is the use of welding machine group control technology, such as the electric fusion welding of polyethylene pipes. It is a method to monitor the welding quality through the network, but in the face of many welder parameters in complex sites that are different and need to be adjusted continuously, or when the welding site is too scattered and the wireless interference is serious, this method is difficult to give full play to the flexibility of the welder's manual operation The advantages.

Contents of the invention

Purpose of the invention: To provide a low-cost, Devices, systems and methods for locking and controlling welders' illegal operations and recording the welder's operation process, so that production can be carried out in accordance with established welding specifications to ensure welding quality.

Technical solution: The present invention provides a welding machine, including a welding machine body and an information identification device that is arranged on the welding machine body and can read the internal information of the radio frequency card. The information identification device includes a data processing unit, and is connected with the The first information reading and writing unit connected to the data processing unit, the password input device, the welding torch switch state collector, the welding setting parameter collector and the locking unit, the locking unit is connected with part of the control signal line of the welding machine; the data The processing unit reads the user information from the radio frequency card through the first information reading and writing unit, and judges whether the identity of the welder meets the requirements according to the user information; the data processing unit reads the password through the password input device and checks the legality Judging, if the password meets the requirements, then unlock and enter the working state; when working, the state collector of the welding torch switch and the welding setting parameter collector collect the state of the welding torch switch and welding parameters respectively, and send them to the data processing unit .

The locking unit is connected in series with the control line of the welding torch switch or the PWM pulse circuit of the welding machine.

The welding parameters include welding current setting value, welding voltage setting value and no-load voltage setting value.

The present invention also provides an electronic management system for welding machines, which includes an information identification device arranged on the welding machine, a radio frequency card compatible with the information identification device, and a radio frequency card capable of writing and reading information in the radio frequency card. The second information reading and writing unit, and the radio frequency card data processing unit that is connected with described second information reading unit communication; Described information identification device comprises data processing unit, and the first information reading and writing that is connected with shown data processing unit unit, a password input device, a welding torch switch state collector, a welding setting parameter collector and a locking unit; the locking unit is connected to a part of the control signal line of the welding machine; the data processing unit passes through the first information reading and writing unit Read the user information from the radio frequency card, and judge whether the identity of the welder meets the requirements according to the user information; the data processing unit reads the password through the password input device and compares it. If the password meets the requirements, it unlocks and enters the work state; when working, the welding torch switch state collector and welding setting parameter collector respectively collect the welding torch switch state and welding parameters, and send them to the data processing unit.

The locking unit is connected in series with the control line of the welding torch switch or the PWM pulse circuit of the welding machine.

The welding parameters include welding current setting value, welding voltage setting value and no-load voltage setting value.

When working, the data processing unit regularly judges whether the parameters collected by the welding setting parameter collector meet the setting requirements, and if not, locks the welding machine through the locking unit.

The present invention further provides a welding machine electronic management method, comprising the following steps:

S1. Read the user's radio frequency card through the information identification device installed on the welding machine, and judge whether the welder's qualification meets the requirements according to the information in the radio frequency card and the information stored on the welding machine;

S2. Receive the operation password and dynamic password input by the user, and verify the legitimacy of the user; if the verification fails, lock the welding machine, otherwise proceed to step S3;

S3. Unlock the welding machine, receive the parameter input by the user, and lock the welding machine if the parameter exceeds the preset range;

S4. Record the welding current setting value, welding voltage setting value and no-load voltage setting value on the welding machine panel.

The method also includes step S0: writing welder qualification requirements and welding parameters into the radio frequency card through the radio frequency card data processing unit and the information reading and writing unit. Step S5 is also included: after each welding is completed, the dynamic password is automatically invalidated.

Beneficial effects: the present invention greatly promotes the welder's operation specification, while ensuring the flexibility of manual welding, the operation process of the welding machine is monitored, which greatly facilitates the quality review after welding; the present invention also has the advantages of low cost, flexible use, Save manpower for monitoring, the welding site does not need to build a wireless network, nor does it need complex group control technology and equipment or the advantages of using robots for welding; in addition, the device of the present invention is easy to operate and does not require major changes to the original welding machine , It only needs to connect the locking unit to some control signal lines on the basis of the ready-made welding machine, which has important practical significance for welding machine monitoring in shipbuilding, nuclear power and other large-scale welding occasions.

Description of drawings

Fig. 1 is a kind of manual/automatic welder electronic management system structural representation of the present invention;

Fig. 2 is a schematic diagram of reading and writing radio frequency card data of the management system of the present invention;

Fig. 3 is a flow chart of verifying the identity of the welder and whether the welding machine is locked according to the present invention;

Fig. 4 is the motherboard circuit of the electronic management system of the manual/semi-automatic welding machine of the present invention.

detailed description:

The technical solutions of the present invention will be described in detail below, but the protection scope of the present invention is not limited to the embodiments.

As shown in Figure 1, the manual/semi-automatic welding machine electronic management system of the present invention is mainly made up of following parts: password input device 13, welding torch switch status collector 14, welding setting parameter collector 15, data processing unit 11, first Information reading and writing unit 12, locking unit 16, radio frequency card 2.

In order to facilitate the recording of the operation process, the radio frequency card 2 is a readable and writable IC card, not an ID card; in the radio frequency card 2, the identity information of the welder is recorded in initialization: name, qualification, training time, and operation password; in order to prevent the radio frequency card from Each RF card can only log in to the same welding machine at the same time. After welding, the relevant operation information can only be written into this RF card. During this period, other RF cards cannot log in to this welding machine.

The password input device is used for inputting operation password and dynamic password. In order to prevent qualified welders from stealing or borrowing the radio frequency card, the following two methods are adopted: when using the radio frequency card to log in to the welding machine, it is necessary to enter the operation password, which can be applied by the welder himself and modified by the management personnel; after entering the operation password Finally, it is also necessary to input a dynamic password. When accepting a task each time, the dynamic password is updated by the management personnel. After the welding task is finished, the dynamic password becomes invalid after the second information reading and writing unit reads the data in the radio frequency card. The welding torch switch state collector is used to collect the state of the welding torch switch and transmit it to the data processing unit. The welding setting parameter collector is used to collect parameters such as welding current setting value, welding voltage setting value, and no-load voltage setting value on the welding machine panel, and transmit them to the data processing unit. The data processing unit is used to process the information in the radio frequency card, receive and store the welding setting parameters of the welder and the switch state of the welding torch. The first information reading and writing unit is used for reading and writing the information of the radio frequency card.

The working principle of the locking unit is as follows: connect the locking unit in series in the control signal circuit of the welding machine, when the locking unit is locked, the control signal circuit is cut off, so that the welding machine cannot complete the operation; when the locking unit is unlocked, the control signal circuit is connected The welder can operate normally. The control signal circuits that can be selected are: welding torch switch, welding machine PWM pulse circuit. In a further embodiment, the welding machine locking action works in the following five situations: a person without welder qualification uses the welding machine; although the identity information in the radio frequency card is correct, the operation password or dynamic password is wrong for three consecutive times; In the process, the welder set the welding parameters beyond the specified range, but still welded; after the welding machine was turned on, although the identity information in the radio frequency card was correct and the operation password was correct, there was no welding operation for a certain period of time; the radio frequency card 2 was Complete the process of successful login --> welding operation --> read operation data.

Turn to Fig. 2, after the welder completes the welding task, use the radio frequency card 2 to read the operation process data in the monitoring device, and then go to the manager to upload the data through the second information reading and writing unit 3 and the radio frequency card data processing unit 4.

The basic flow of the welding machine management method of the present invention is as follows:

S0, write the welder qualification requirements and welding parameters into the radio frequency card through the radio frequency card data processing unit and the information reading and writing unit;

S1. Read the user's radio frequency card through the information identification device installed on the welding machine, and judge whether the welder's qualification meets the requirements according to the information in the radio frequency card and the information stored on the welding machine;

S2. Receive the operation password and dynamic password input by the user, and verify the legitimacy of the user; if the verification fails, lock the welding machine, otherwise proceed to step S3;

S3. Unlock the welding machine, receive the parameter input by the user, and lock the welding machine if the parameter exceeds the preset range;

S4. Record the welding current setting value, welding voltage setting value and no-load voltage setting value on the welding machine panel.

S5. After each welding is completed, the dynamic password is automatically invalidated.

Specifically, the workflow shown in Figure 3 can be adopted:

(1) The radio frequency card is close to the monitoring device;

(2) The data processing unit reads the information in the card through the first information reading and writing unit, and judges whether the identity of the welder meets the requirements according to the information stored in it;

(3) Receive the operation password input by the welder through the password input keyboard;

(4) Receive the dynamic password input by the welder through the password input keyboard;

(5) If the verification of the welder's identity, operation password, and dynamic password is successful, the welder can proceed to the next step by unlocking the lock unit. If the requirements are not met, the lock unit continues to be locked and the welder cannot proceed to the next step.

As shown in Figure 4, the motherboard circuit in the welding machine electronic management system of the present invention includes the following parts:

Password input device 13 is made up of S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, represents button 1, 2, 3, 4, 5 respectively , 6, 7, 8, 9, 0, operation password, dynamic password, login, output, cancel, confirm. Based on the password input keyboard, the operation password and dynamic password can be input.

The welding gun switch state collector is composed of chip U8 and its corresponding peripheral circuits. The model of U8 is HCNR200 linear optocoupler. The welding torch switch signal is used as the input of the optocoupler chip U8, and the output of U8 is connected to the fourth pin of the chip U3.

The welding setting parameter collector is mainly composed of chips U2, U4, U6, U7, U1, U5 and their peripheral circuits. Among them, the models of U2, U4, U6, and U7 chips are LM258 operational amplifiers, and the U1 and U5 chips use HCNR200 linear isolation Optocoupler; after the welding current setting is connected to the operational amplifier U4, it is used as the input of the linear isolation optocoupler U1, the output of U1 is used as the input of the chip U2, and the output of U2 is connected to the second pin of the chip U3; the welding voltage is connected to the After the operational amplifier U7, it is used as the input of the linear isolation optocoupler U5, the output of U5 is used as the input of the chip U6, and the output of U6 is connected to the third pin of the chip U3.

The core chips of the data processing unit adopt U3 and U12 respectively, the model of U3 is PIC16F877 single-chip microcomputer, and the model of U12 is FM3316 iron-fixed memory. Pins 3, 4, and 5 of the chip U12 are respectively connected to pins 22, 27, and 28 of the chip U3.

The first information reading and writing unit: composed of module U9, U9 is connected to the 29th and 30th pins of U3 through the 232 interface, U9 adopts a stable RF non-contact radio frequency card reader, its working frequency is 13.56MHz, and the reading and writing distance is 0 -70mm, can read and write radio frequency cards conforming to ISO14443 standard, such as MIFARE and MIFREPRO series radio frequency memory cards. The locking unit is mainly composed of chips U10, U11, U13, U14, U15 and their peripheral circuits. These 5 chips can all be optional TLP250 optocouplers. The 5th, 6th, 7th, 21st, and 20th pins of U3 are respectively connected to U10, U11, U13, U14, and U15 chips through resistors R12, R14, R16, R18, and R20; U10, U11, U13, U14, The chip outputs of U15 are locking unit terminal 1, locking unit terminal 2, locking unit terminal 3, locking unit terminal 4, and locking unit terminal 5; these 5 terminals can be connected in series to control signals such as welding machine PWM pulse signal line and welding torch switch Among them, it is used to control the use of the welding machine; when the radio frequency card 2 is close to the electronic management system of the manual/semi-automatic welding machine, the information in the radio frequency card 2 is read by the U9RF radio frequency reader and transmitted to the U3PIC16F877 single-chip microcomputer, and the welder identity verification work It is completed by the program in the U3PIC16F877 single-chip microcomputer. If the identity of the welder meets the relevant requirements, the U3PIC16F877 single-chip microcomputer sends an unlocking command to the locking unit 16; otherwise, it continues to lock.

After the +5V power supply is connected to the light-emitting diodes DS1, DS2, DS3, and DS4 through resistors R21, R22, R23, and R24, it is connected to the 35th, 34th, 36th, and 33rd pins of U3; these four The light-emitting diodes are used to display identity verification status, operation password status, dynamic password status, and data record output status; when the identity information is verified, DS1 is lit, otherwise DS1 flashes to warn; when the operation password is verified, DS2 is turned on Light on, otherwise DS2 flashes to warn; when the dynamic password is verified, DS3 is lit, otherwise DS3 flashes to warn; when the recorded data is output to the RF card, DS4 is lit, otherwise DS4 is off.

In a further embodiment, in order to facilitate the operation of the system, when the radio frequency card is initialized, the management personnel pass the radio frequency card data processing unit and the second information reading and writing unit to the welder's identity information: welder name, welder qualification, training time, The operation password is written into the radio frequency card; when the welder accepts the task each time, the manager writes the relevant welding parameters into the radio frequency card through the radio frequency card data processing unit and the second information reading and writing unit, such as the welding current setting value range, welding Voltage setting range, no-load voltage setting range, dynamic password.

When the welder uses the radio frequency card to log in to the welder, the device checks the identity information of the welder, and only those who meet the corresponding welder qualifications can perform the next password verification.

In a word, the manual/automatic welding machine electronic management system and method of the present invention, after the welding machine is turned on every time, the device first reads the identity of the welder through the radio frequency card reader, confirms the identity of the welder, and meets the qualification requirements and operation The welder with password and dynamic password can continue to operate the welding machine; every time the welder welds, the device records the following operation information: welding machine number, starting time of each welding, welding current setting value, welding voltage setting value, no-load Voltage setting value, welding end time; if the welder’s setting parameters do not meet the specified range, the welding machine will automatically warn and record the corresponding parameters. If there are too many warnings, the welding machine will automatically enter the locked state; At this time, the radio frequency card can only be used again to read the welding machine operation information recorded in the device, and only after completing the complete process of "successful login->welding operation->reading operation data" can the special radio frequency card data The processor reads and records the operation information of the welding machine during the working hours for review after welding.

As stated above, while the invention has been shown and described with reference to certain preferred embodiments, this should not be construed as limiting the invention itself. Various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (1)

1. An electronic management system for welding machines, including an information identification device (1) set on the welding machine, a radio frequency card (2) compatible with the information identification device (1), capable of writing and reading all The second information reading and writing unit (3) of the information in the radio frequency card (2), and the radio frequency card data processing unit (4) communicatively connected with the second information reading unit (3); the information identification device ( 1) It includes a data processing unit (11), a first information reading and writing unit (12) connected to the shown data processing unit (11), a password input device (13), a welding torch switch status collector (14), a welding device A parameter collector (15) and a locking unit (16); the locking unit (16) is connected to some control signal lines of the welding machine; the data processing unit (11) passes through the first information reading and writing unit (12 ) read the user information from the radio frequency card, and judge whether the identity of the welder meets the requirements according to the user information; the data processing unit (11) reads the password through the password input device (13) and compares it, if the password meets the requirements If required, unlock and enter the working state; when working, the welding torch switch state collector (14) and welding setting parameter collector (15) respectively collect the welding torch switch status and welding parameters, and send them to the data processing unit(11); The radio frequency card is a readable and writable IC card; in the radio frequency card, the identity information of the welder is recorded in the initialization: name, qualification, training time, and operation password; in order to prevent the diversion of the radio frequency card, each radio frequency card can only log in at the same time For the same welding machine, after welding, the relevant operation information can only be written into the radio frequency card, during this period, other radio frequency cards cannot log into this welding machine; The password input device is used to input the operation password and dynamic password. In order to prevent qualified welders from stealing or borrowing the radio frequency card, the following two methods are adopted: When using the radio frequency card to log in to the welding machine, it is necessary to input the operation password, which is determined by the welder. I apply for it and amend it by the management personnel; after inputting the operation password, it is also necessary to enter a dynamic password, which is updated by the management personnel each time a task is accepted, and after the welding task is completed, when the second information reading and writing unit reads the radio frequency After the data in the card, the dynamic password becomes invalid; The welding torch switch state collector is used to collect the state of the welding torch switch and transmit it to the data processing unit; The welding setting parameter collector is used to collect the welding current setting value, welding voltage setting value and no-load voltage setting value on the welding machine panel, and transmit them to the data processing unit; The data processing unit is used to process the information in the radio frequency card, receive and store the welding setting parameters of the welder and the switch state of the welding torch, and the first information reading and writing unit is used to read and write the information of the radio frequency card; The working process of the locking unit is as follows: connect the locking unit in series to the control signal circuit of the welding machine, when the locking unit is locked, the control signal circuit is cut off, so that the welding machine cannot complete the operation; when the locking unit is unlocked, the control signal circuit is connected The welding machine is in normal operation; the selected control signal circuits are: welding torch switch, welding machine PWM pulse circuit; the welding machine locking action works in the following five situations: personnel without welding qualification use the welding machine; The identity information is correct, but the operation password or dynamic password is incorrect for three consecutive times; during the welding operation, the welder’s setting value of the welding parameters exceeds the specified range, but still welds; after the welding machine is turned on, although the identity information in the radio frequency card is correct, The operation password is correct, but there is no welding operation for a certain period of time; the RF card has completed the process of successful login, welding operation, and reading operation data; The welding machine management process is as follows: (1) The radio frequency card is close to the monitoring device; (2) The data processing unit reads the information in the card through the first information reading and writing unit, and judges whether the identity of the welder meets the requirements according to the information stored in it; (3) Receive the operation password input by the welder through the password input keyboard; (4) Receive the dynamic password input by the welder through the password input keyboard; (5) If the verification of the welder's identity, operation password, and dynamic password is successful, the lock unit is unlocked, and the welder continues to the next operation. If the requirements are not met, the lock unit continues to be locked, and the welder cannot proceed to the next operation; The main board circuit in the welding machine electronic management system includes the following parts: The password input device is composed of S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, and S16, respectively representing buttons 1, 2, 3, 4, 5, 6, 7, 8, 9, 0, operation password, dynamic password, login, output, cancel, confirm; Based on the password input keyboard, input the operation password and dynamic password; The welding torch switch status collector is composed of chip U8 and its corresponding peripheral circuits. The model of U8 is HCNR200 linear optocoupler; The welding torch switch signal is used as the input of the optocoupler chip U8, and the output of U8 is connected to the fourth pin of the chip U3; The welding setting parameter collector is mainly composed of chips U2, U4, U6, U7, U1, U5 and their peripheral circuits. Among them, the models of U2, U4, U6, and U7 chips are LM258 operational amplifiers, and the U1 and U5 chips use HCNR200 linear isolation Optocoupler; after the welding current setting is connected to the operational amplifier U4, it is used as the input of the linear isolation optocoupler U1, the output of U1 is used as the input of the chip U2, and the output of U2 is connected to the second pin of the chip U3; the welding voltage is connected to the After the operational amplifier U7, it is used as the input of the linear isolation optocoupler U5, the output of U5 is used as the input of the chip U6, and the output of U6 is connected to the third pin of the chip U3; The core chips of the data processing unit adopt U3 and U12 respectively, the model of U3 is PIC16F877 single-chip microcomputer, and the model of U12 is FM3316 iron-fixed memory; The 3rd, 4th, and 5th pins of the chip U12 are respectively connected to the 22nd, 27th, and 28th pins of the chip U3; The first information reading and writing unit: composed of module U9, U9 is connected to the 29th and 30th pins of U3 through the 232 interface, U9 adopts a stable RF non-contact radio frequency card reader, its working frequency is 13.56MHz, and the reading and writing distance is 0 -70mm, can read and write radio frequency cards conforming to the ISO14443 standard, including MIFARE and MIFREPRO series radio frequency memory cards; the locking unit is mainly composed of chips U10, U11, U13, U14, U15 and their peripheral circuits. These five chips are all selected TLP250 light coupling; The 5th, 6th, 7th, 21st, and 20th pins of U3 are respectively connected to U10, U11, U13, U14, and U15 chips through resistors R12, R14, R16, R18, and R20; U10, U11, U13, U14, The chip outputs of U15 are locking unit terminal 1, locking unit terminal 2, locking unit terminal 3, locking unit terminal 4, and locking unit terminal 5; these 5 terminals are connected in series to the PWM pulse signal line of the welding machine or the welding torch switch control signal, Used to control the use of the welding machine; when the radio frequency card is close to the electronic management system of the manual/semi-automatic welding machine, the information in the radio frequency card (2) is read by the U9RF radio frequency reader and transmitted to the U3PIC16F877 single-chip microcomputer, and the identity verification of the welder is performed by The program in the U3PIC16F877 single-chip microcomputer is completed. If the identity of the welder meets the relevant requirements, the U3PIC16F877 single-chip microcomputer sends an unlocking command to the locking unit 16; otherwise, it continues to lock; After the +5V power supply is connected to the light-emitting diodes DS1, DS2, DS3, and DS4 through resistors R21, R22, R23, and R24, it is connected to the 35th, 34th, 36th, and 33rd pins of U3; these four The light-emitting diodes are used to display identity verification status, operation password status, dynamic password status, and data record output status; when the identity information is verified, DS1 is lit, otherwise DS1 flashes to warn; when the operation password is verified, DS2 is turned on Light on, otherwise DS2 flashes to warn; when the dynamic password is verified, DS3 is lit, otherwise DS3 flashes to warn; when the recorded data is output to the RF card, DS4 is lit, otherwise DS4 is off; In a further embodiment, in order to facilitate the operation of the system, when the radio frequency card is initialized, the management personnel pass the radio frequency card data processing unit and the second information reading and writing unit to the welder's identity information: welder name, welder qualification, training time, The operation password is written into the radio frequency card; when the welder accepts the task each time, the management personnel writes the relevant welding parameters into the radio frequency card through the radio frequency card data processing unit and the second information reading and writing unit, including the welding current setting value range, welding Voltage setting range, no-load voltage setting range and dynamic password; When the welder uses the radio frequency card to log in to the welder, the device checks the identity information of the welder, and only those who meet the corresponding welder qualifications can perform the next password verification.