CN118075640A - Electric welding construction data monitoring system - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
The invention relates to the technical field of industrial automation, in particular to an electric welding construction data monitoring system which comprises an information acquisition module, an information analysis module, a data monitoring module, an image monitoring module, a welding position state analysis module, a welding analysis module and a welding management module, wherein the information acquisition module is used for acquiring base metal parameter information and welding standard parameter information, acquiring a welding area image, the information analysis module is used for analyzing welding parameter information, the data monitoring module is used for analyzing welding quality, the image monitoring module is used for analyzing a welding position state, further analyzing a welding area and an actual welding seam penetration, optimizing a welding quality analysis process, and judging a welding state in a monitoring period, and the welding management module is used for giving an alarm to a user and adjusting a welding position of a welding gun in the next monitoring period. The invention effectively improves the monitoring efficiency and the accuracy of the electric welding quality judgment in the electric welding construction process.
Description
Technical Field
The invention relates to the technical field of industrial automation, in particular to an electric welding construction data monitoring system.
Background
With the improvement of the industrial automation level, the quality control requirements for the electric welding operation are higher and higher. Traditional electric welding operation relies on the skill and experience of welder, and consistency and traceability of welding quality are difficult to ensure. In addition, a large amount of data generated during the welding process is not effectively utilized, resulting in waste of resources and low production efficiency. Therefore, it is necessary to develop a system capable of monitoring and analyzing the welding construction data in real time to improve welding quality and work efficiency.
Chinese patent publication No.: CN112355520B discloses an intelligent acquisition and monitoring system for welding data, which comprises an operation information input device, a welding interlayer temperature and welding position acquisition device, a welding data acquisition device, a cloud server and a monitoring terminal, wherein the operation information input device is electrically connected with a data transmission device; the operation information input device is used for acquiring operation preset information and the preheating temperature of the pipeline to be welded; the welding interlayer temperature and welding position acquisition device is used for acquiring welding interlayer temperature and welding position data; the welding data acquisition device is used for acquiring real-time welding data; the data transmission device transmits the data information to the cloud server through a wireless network for storage, and calculates and compares the preheating temperature, the welding interlayer temperature, the welding position data and the real-time welding data with operation preset information so as to send out warning information for the result which does not accord with the welding process; the monitoring terminal is electrically connected with the cloud server through a wireless network to acquire welding operation data and warning information. Therefore, the informatization monitoring of the welding process is realized; therefore, the invention monitors the temperature and the position in the electric welding process to judge the quality state of the welding process, does not carry out preliminary setting on specific construction data in the welding process, and only depends on the welding temperature and the welding position, so that the judging process of the quality state of the welding process is inaccurate, and the problems of low monitoring efficiency and inaccurate quality judgment in the electric welding construction process exist.
Disclosure of Invention
Therefore, the invention provides an electric welding construction data monitoring system which is used for solving the problems of low monitoring efficiency and inaccurate quality judgment in the electric welding construction process in the prior art.
In order to achieve the above object, the present invention provides an electric welding construction data monitoring system, comprising,
The information acquisition module is used for acquiring the parameter information of the base metal and the welding standard parameter information and periodically acquiring a welding area image according to the monitoring period;
the information analysis module is used for analyzing welding parameter information according to the base metal parameter information and the welding standard parameter information and outputting the welding parameter information to a user;
the data monitoring module is used for acquiring welding data in a monitoring period and analyzing welding quality according to the welding data and welding parameter information in the monitoring period;
The image monitoring module is used for analyzing the welding position state according to the top view of the welding area, analyzing the welding area and the actual welding seam penetration according to the top view and the welding view, and optimizing the welding quality analysis process according to the welding area and the actual welding seam penetration;
the welding analysis module is used for judging the welding state in the monitoring period according to the welding quality and the welding position state and storing the welding state;
And the welding management module is used for alarming the user according to the stored judging result of the welding state and adjusting the analysis process of the welding parameter information of the next monitoring period and the welding position of the welding gun of the next monitoring period according to the alarming result.
Further, the information analysis module is provided with a power analysis unit, and the power analysis unit is used for calculating a welding stable temperature range [ Tmin, tmax ] according to the base metal parameter information and the welding standard parameter information, and the calculation formula of the welding stable temperature range [ Tmin, tmax ] is as follows:
Tmin=v/k+Tm-W1；
Tmax=v/k+Tm+W1；
v=（0.01×h×hd）/（d/hv）；
wherein Tmin is the left value of the stable temperature range, tmax is the right value of the temperature range, tmin < Tmax, tm is the melting point of the base metal, k is the melting constant of the base metal, v is the melting speed of the base metal, W1 is the temperature allowable error value, hv is the welding speed;
the power supply analysis unit is configured to set welding power to P according to a welding stable temperature range, and set p=ρ× (0.01×h×hd) × (tmin+w1) ×hv/η;
Where η is the coefficient of thermal efficiency during the welding process and ρ is the density of the base metal.
Further, the information analysis module is further provided with an air injection analysis unit, the air injection analysis unit is used for comparing the welding speed HV with a preset welding speed HV, and setting a gas flow according to a comparison result, wherein:
when HV is less than HV, the jet analysis unit determines that the welding speed is normal, and sets the gas flow as Qv1, and sets qv1=qv;
when HV is more than or equal to HV, the jet analysis unit determines that the welding speed is abnormal, sets the gas flow as Qv2, and sets qv2=qv× {1+arctan [ (HV-HV)/HV ] };
Wherein QV is a gas flow preset value.
Further, the data monitoring module is provided with a power monitoring unit, and the power monitoring unit is used for calculating average welding power Pmon in a monitoring period according to average welding current I and average welding voltage U in the monitoring period, and setting Pmon =I×U;
the power supply monitoring unit compares the average welding power Pmon in the monitoring period with the welding power P and analyzes the welding quality according to the comparison result, wherein:
When P-P1 is not less than Pmon and not more than P+P1, the power supply monitoring unit judges that the welding quality is normal in the monitoring period, the welding quality index is set to alpha 1, and alpha 1 = 1 is set;
When Pmon is smaller than P-P1, the power supply monitoring unit judges that the welding quality is abnormal in the monitoring period, the welding quality index is set to alpha 2, and alpha 2 = exp { P-P1-Pmon };
When Pmon is more than P+P1, the power supply monitoring unit judges that the welding quality is abnormal in the monitoring period, the welding quality index is set to be alpha 3, and alpha 3 = 1+ln [ (Pmon-P+P1)/(P+P1) ];
Where P1 is the power error value.
Further, the data monitoring module is further provided with a jet monitoring unit, the jet monitoring unit is configured to compare an average gas flow qv and a gas flow Qvc in a monitoring period, set c=1, 2, and adjust an analysis process of welding quality according to a comparison result, wherein:
when qv is less than Qvc, the gas injection monitoring unit judges that the average gas flow is abnormal in the monitoring period, adjusts the power error value to be P1', and sets P1' =P1×cos [ (Qvc-qv)/Qvc ];
When qv=qvc, the gas injection monitoring unit determines that the average gas flow is normal in the monitoring period, and does not adjust;
When qv > Qvc, the gas injection monitoring unit determines that the average gas flow is abnormal in the monitoring period, and adjusts the power error value to P1", setting P1" =p1× {1+cos [ (Qvc-qv)/Qvc ] }/2.
Further, the image monitoring module is provided with a position monitoring unit, and the position monitoring unit is used for analyzing the welding position according to the top view of the welding area in the monitoring period;
the position monitoring unit performs cluster analysis on the top view of the welding area according to pixel gray values, and divides the top view pixels after the cluster analysis into welding pixels and non-welding pixels;
The position monitoring unit takes a pixel starting point of a top view of a welding area as a coordinate origin, takes a transverse positive arrangement direction of pixels as an x axis, takes a longitudinal positive arrangement direction of pixels as a y axis, and takes a pixel length r as a unit length to establish a plane rectangular coordinate system; the position monitoring unit projects the welding pixel points after cluster analysis into a plane rectangular coordinate system, calculates sample point coordinates (a, b), and sets:
The position monitoring unit calculates an offset vector (X, Y) according to the sample point coordinates (a, B) and preset welding sample point coordinates (A, B), and is set with X=A-a and Y=B-B;
wherein i=1, 2..n, N is the number of welding pixels, X (i) is the abscissa of the ith welding pixel, Y (i) is the ordinate of the ith welding pixel, X is the lateral amount of the offset vector, Y is the longitudinal amount of the offset vector;
The position monitoring unit calculates a module D of the offset vector, sets d=x 2+Y2, compares the module D of the offset vector with a preset offset vector module D, and analyzes the welding position state according to the comparison result, wherein:
when D is smaller than D, the position monitoring unit judges that the welding position state is normal;
and when D is more than or equal to D, the position monitoring unit judges that the welding position state is abnormal.
Further, the image monitoring unit is further provided with a quality optimizing unit, the quality optimizing unit is used for acquiring the actual weld penetration sh in the monitoring period according to the welding view of the welding area, and calculating a welding abnormality index beta according to the actual weld penetration sh in the monitoring period and the number N of welding pixels of the top view of the welding area, and a calculation formula of the welding abnormality index beta is as follows:
β=exp{S-SY/SY+sh-h/h}；
S=r2×N；
wherein S is the welding area, SY is the welding seam coverage area;
The quality optimization unit is used for comparing the welding abnormality index beta with a preset abnormality index G, analyzing the welding process according to the comparison result, and optimizing the welding quality analysis process according to the welding process analysis result, wherein:
When beta is more than or equal to G, the quality optimization unit judges that the welding process is abnormal and optimizes the analysis process of welding quality, the quality optimization unit optimizes the power error value to be P1', and P1' =P1×exp [ (G-beta)/G ];
And when beta is smaller than G, the quality optimization unit judges that the welding process is normal and does not perform optimization.
Further, the welding analysis module judges a welding state according to a welding quality index αj and a welding position analysis result, and j=1, 2,3 is set, wherein:
When alpha j is more than F or the welding position state is abnormal, the welding analysis module judges that the welding state in the monitoring period is unqualified;
When alpha j is smaller than F and the welding position state is normal, the welding analysis module judges that the welding state in the monitoring period is qualified;
wherein F is a welding quality index threshold value, and F is more than or equal to 1.2 and less than or equal to 1.6.
Further, the welding management unit is provided with an alarm unit, and the alarm unit is used for counting the number M of monitoring periods that the continuous welding state is unqualified according to the stored judging result of the welding state;
The alarm unit compares the continuous monitoring period number M with the unqualified number of each preset, and alarms the user according to the comparison result, wherein the continuous monitoring period number M is unqualified in the welding state, and the alarm unit comprises the following steps:
when M is less than M1, the alarm unit does not alarm to the user;
when M1 is more than or equal to M2, the alarm unit alarms the user with low risk;
when M is more than M2, the alarm unit gives a high-risk alarm to a user;
Wherein M1 is a first preset number of failures, M2 is a second preset number of failures, and M1 is more than 0 and less than M2.
Further, the welding management unit is further provided with a welding management unit, and the welding management unit is used for adjusting the analysis process of the welding parameter information of the next monitoring period and the welding position of the welding gun of the next monitoring period according to the alarm result, wherein:
When the alarm result is that the alarm is not given, the welding management unit does not adjust the analysis process of the welding parameter information of the next monitoring period; the welding management unit adjusts the welding position (X Original source ,Y Original source ) of a welding gun in the next monitoring period according to the offset vector (X, Y) of the current monitoring period, adjusts (X Original source ,Y Original source ) to be (X1 Original source ,Y1 Original source ), and sets X Original source =X Original source +X,Y1 Original source =Y Original source +Y; the welding management unit outputs a welding position (X1 Original source ,Y1 Original source ) of a welding gun in the next monitoring period to a user;
When the alarm result is low risk alarm, the welding management unit adjusts the welding power of the next monitoring period to P 'and sets P' =Px [1+ln (alpha j) ]forthe analysis process of the welding parameter information of the next monitoring period; the welding management unit adjusts the welding position (X Original source ,Y Original source ) of the welding gun in the next monitoring period according to the offset vector (Xz, yz) of the monitoring period of unqualified continuous welding process, setting z=1, 2..m, (X Original source ,Y Original source ) is adjusted to (X2 Original source ,Y2 Original source ), and x2 Original source =X Original source +（X1+X2+...+XM）/M,Y2 Original source =Y Original source + (y1+y2+, +ym)/M; the welding management unit outputs a welding position (X2 Original source ,Y2 Original source ) of a welding gun in the next monitoring period to a user;
When the alarm result is high risk alarm, the welding management unit adjusts the welding power of the next monitoring period to P 'in the analysis process of the welding parameter information of the next monitoring period, sets P' = P multiplied by alpha j, and recommends a user to overhaul the welding position of the welding gun;
Wherein X1 is the lateral amount of the offset vector of the first monitoring period in the monitoring period of failed continuous welding process, X2 is the lateral amount of the offset vector of the second monitoring period in the monitoring period of failed continuous welding process, XM is the lateral amount of the offset vector of the third monitoring period in the monitoring period of failed continuous welding process, Y1 is the longitudinal amount of the offset vector of the first monitoring period in the monitoring period of failed continuous welding process, Y2 is the longitudinal amount of the offset vector of the second monitoring period in the monitoring period of failed continuous welding process, YM is the longitudinal amount of the offset vector of the third monitoring period in the monitoring period of failed continuous welding process.
Compared with the prior art, the invention has the beneficial effects that the information acquisition module is used for acquiring the information required by the system, the integrity and accuracy of information acquisition are improved, the accuracy of welding parameter information analysis is further improved, the accuracy of welding data monitoring analysis in a monitoring period is further improved, the accuracy of welding state judgment is further improved, the monitoring efficiency in the welding construction process and the accuracy of welding quality judgment are finally improved, the information analysis module is used for analyzing a welding stable temperature interval, the welding power of a welding gun in the welding process is set according to the analysis result of the welding stable temperature interval, the accuracy of welding power analysis is improved, the accuracy of welding data monitoring analysis in the monitoring period is further improved, and the accuracy of welding state judgment is further improved, finally, the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are improved, the data monitoring module monitors the power voltage and the power current in the monitoring period, the accuracy of monitoring and analyzing the welding data in the monitoring period is improved, the accuracy of judging the welding state is further improved, the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are finally improved, the image monitoring module processes and analyzes the top view and the left view welding view of the welding area, the welding offset vector is calculated according to the analysis result, the accuracy of monitoring and analyzing the welding data in the monitoring period is improved, the accuracy of judging the welding state is further improved, the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are finally improved, the welding analysis module is used for judging the state of the welding state in the monitoring period according to the welding quality analysis result and the welding position state analysis result, so that the accuracy of the welding state judgment is improved, the monitoring efficiency in the electric welding construction process and the accuracy of the electric welding quality judgment are finally improved, the welding management module is used for analyzing the stored analysis result of the welding state and alarming the user according to the analysis result, the accuracy of alarming the user in the welding process is improved, the analysis process of the welding parameter information in the next monitoring period and the welding position of the welding gun in the next monitoring period are adjusted according to the alarm result, the accuracy of the welding state judgment is improved, and the monitoring efficiency in the electric welding construction process and the accuracy of the electric welding quality judgment are finally improved.
Drawings
Fig. 1 is a schematic structural diagram of an electric welding construction data monitoring system according to the present embodiment;
fig. 2 is a schematic structural diagram of an information analysis module according to the present embodiment;
FIG. 3 is a schematic diagram of a data monitoring module according to the present embodiment;
FIG. 4 is a schematic diagram of an image analysis module according to the present embodiment;
Fig. 5 is a schematic structural diagram of a welding management module according to this embodiment.
Detailed Description
In order that the objects and advantages of the invention will become more apparent, the invention will be further described with reference to the following examples; it should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are merely for explaining the technical principles of the present invention, and are not intended to limit the scope of the present invention.
It should be noted that, in the description of the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those skilled in the art according to the specific circumstances.
Referring to fig. 1, which is a schematic structural diagram of an electric welding construction data monitoring system according to the present embodiment, includes,
The information acquisition module is used for acquiring the parameter information of the base metal and the welding standard parameter information and periodically acquiring a welding area image according to the monitoring period; the base metal parameter information comprises a melting point of the base metal, a melting constant of the base metal and a material thickness of the base metal, wherein the melting constant is a ratio between a melting speed and a temperature of the base metal; the welding standard parameter information comprises weld penetration, weld coverage area and welding speed, wherein the welding speed is the length of a welded joint welded per second; the welding area image comprises a top view and a welding view of the welding area; in this embodiment, the method for obtaining the parameter information of the base metal is not specifically limited, and a person skilled in the art can freely set the method and the device only need to meet the requirement for obtaining the parameter information of the base metal, for example, the method and the device can be obtained from a technical data table of a provider of the base metal; in this embodiment, the method for acquiring the welding standard parameter information is not specifically limited, and a person skilled in the art can freely set the method only by meeting the requirement for acquiring the welding standard parameter information, for example, the method can be used for acquiring the welding standard parameter information through user interaction input; in this embodiment, the value of the monitoring period is not specifically limited, and a person skilled in the art can freely set the value of the monitoring period only by meeting the value requirement of the monitoring period, for example, the monitoring period can be set to be 5 seconds; the method for acquiring the welding area image is not specifically limited, and a person skilled in the art can freely set the method, and only needs to meet the acquisition requirement of the welding area image, if a top view of the welding area can be shot by arranging a camera at a fixed height above a welding point, a welding view of the welding area can be shot by arranging the camera in a welding line visible area, in the embodiment, the welding area image is a gray level image, and the ratio of the size of an object in the welding area image to the size of an actual object is 1:1, a step of;
The information analysis module is used for analyzing welding parameter information according to the base metal parameter information and the welding standard parameter information, outputting the welding parameter information to a user, and connecting the information analysis module with the information acquisition module; the welding parameter information comprises welding voltage, welding current, wire feeding speed and gas flow, and is parameter information required to be set by machine welding; the gas flow is the volume of inert gas sprayed from a welding gun in unit time, and a default value exists in the gas flow in the embodiment, and the gas flow is not matched in the embodiment;
The data monitoring module is used for acquiring welding data in a monitoring period, analyzing welding quality according to the welding data and welding parameter information in the monitoring period, and is connected with the information analysis module; the welding data includes an average welding current, an average welding voltage, and an average gas flow;
The image monitoring module is used for analyzing the welding position state according to the top view of the welding area, optimizing the analysis process of welding quality according to the top view and the welding view of the welding area, and connecting with the data monitoring module;
The welding analysis module is used for judging the welding process in the monitoring period according to the welding quality analysis result and the welding position state analysis result, and is connected with the image monitoring module;
And the welding management module is used for alarming a user according to the stored judging result of the welding state, adjusting the analysis process of the welding parameter information of the next monitoring period and the welding position of the welding gun of the next monitoring period according to the alarming result, and is connected with the welding analysis module.
Fig. 2 is a schematic structural diagram of an information analysis module according to the present embodiment, which includes,
The power supply analysis unit is used for calculating a welding stable temperature range according to the base metal parameter information and the welding standard parameter information and analyzing welding power according to the welding stable temperature range;
The jet analysis unit is used for analyzing the gas flow according to the welding standard parameter information degree, and is connected with the power supply analysis unit;
And the output unit is used for outputting welding power and gas flow to a user and is connected with the jet analysis unit.
Fig. 3 is a schematic structural diagram of a data monitoring module according to the present embodiment, which includes,
The power supply monitoring unit is used for analyzing welding quality according to the average welding current, the average welding voltage and the welding voltage in the monitoring period;
And the jet monitoring unit is used for adjusting the analysis process of welding quality according to the average gas flow and the gas flow in the monitoring period and is connected with the power supply monitoring unit.
Fig. 4 is a schematic structural diagram of an image monitoring module according to the present embodiment, which includes,
The position monitoring unit is used for analyzing the welding position according to the top view of the welding area in the monitoring period;
And the quality optimization unit is used for analyzing the welding area and the actual welding seam penetration according to the top view and the welding view of the welding area in the monitoring period, analyzing the welding process according to the welding area and the actual welding seam penetration, optimizing the analysis process of the welding quality according to the analysis result of the welding process and connecting the quality optimization unit with the position monitoring unit.
Referring to fig. 5, a schematic structural diagram of a welding management module according to the present embodiment includes,
The alarm unit is used for alarming the user according to the stored judging result of the welding state;
and the welding management unit is used for adjusting the analysis process of the welding parameter information of the next monitoring period and the welding position of the welding gun of the next monitoring period according to the alarm result, and is connected with the alarm unit.
Specifically, the electric welding construction data monitoring system of the embodiment is applied to intelligent plane welding construction data monitoring; the specific welding method of the electric welding in the embodiment is mechanized MIG welding; according to the embodiment, the welding quality and the welding position are analyzed according to the welding parameter data and the welding area image in the monitoring period, the user is warned according to the analysis result, and management schemes with different warning grades are provided.
Specifically, the power supply analysis unit calculates a welding stable temperature range [ Tmin, tmax ] according to the base metal parameter information and the welding standard parameter information, and the calculation formula of the welding stable temperature range [ Tmin, tmax ] is as follows:
Tmin=v/k+Tm-W1；
Tmax=v/k+Tm+W1；
v=（0.01×h×hd）/（d/hv）；
Wherein Tmin is the left value of the stable temperature range, tmax is the right value of the temperature range, tmin < Tmax, tm is the melting point of the base metal, k is the melting constant of the base metal, v is the melting speed of the base metal, W1 is the temperature allowable error value, hv is the welding speed, h is the weld penetration, hd is the caliber diameter of the welding gun;
The power supply analysis unit sets the welding power to P according to the welding stable temperature range, and sets p=ρ× (0.01×h×hd) × (tmin+w1) ×hv/η;
Where η is the coefficient of thermal efficiency during the welding process and ρ is the density of the base metal.
Specifically, the power supply analysis unit analyzes the welding stability temperature interval, sets welding power of a welding gun in the welding process according to the analysis result of the welding stability temperature interval, and improves the accuracy of welding power analysis, so that the accuracy of welding data monitoring analysis in a monitoring period is improved, the accuracy of welding state judgment is further improved, and finally the monitoring efficiency in the welding construction process and the accuracy of welding quality judgment are improved; in this embodiment, the method for obtaining the thermal efficiency coefficient η and the density ρ of the base metal in the welding process is not specifically limited, and a person skilled in the art can freely set the method only by meeting the requirement for obtaining the thermal efficiency coefficient η and the density ρ of the base metal, for example, the method can be obtained through a technical data table of a base metal supplier.
Specifically, the jet analysis unit compares the welding speed HV with a preset welding speed HV, and sets a gas flow according to a comparison result, where:
when HV is less than HV, the jet analysis unit determines that the welding speed is normal, and sets the gas flow as Qv1, and sets qv1=qv;
when HV is more than or equal to HV, the jet analysis unit determines that the welding speed is abnormal, sets the gas flow as Qv2, and sets qv2=qv× {1+arctan [ (HV-HV)/HV ] };
Wherein QV is a gas flow preset value.
Specifically, the jet analysis unit analyzes the gas flow, so that the accuracy of analyzing the gas flow is improved, the accuracy of monitoring and analyzing welding data in a monitoring period is improved, the accuracy of judging the welding state is further improved, and the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are finally improved; it can be understood that, in this embodiment, the method for acquiring the preset gas flow value QV is not specifically limited, and a person skilled in the art can freely set the method and the device only need to meet the requirement for acquiring the preset gas flow value QV, for example, the historical average value of the welding gas flow of the user can be set as the preset gas flow value QV.
Specifically, the power supply monitoring unit calculates an average welding power Pmon in a monitoring period according to an average welding current I and an average welding voltage U in the monitoring period, and sets Pmon =i×u;
the power supply monitoring unit compares the average welding power Pmon in the monitoring period with the welding power P and analyzes the welding quality according to the comparison result, wherein:
When P-P1 is not less than Pmon and not more than P+P1, the power supply monitoring unit judges that the welding quality is normal in the monitoring period, the welding quality index is set to alpha 1, and alpha 1 = 1 is set;
When Pmon is smaller than P-P1, the power supply monitoring unit judges that the welding quality is abnormal in the monitoring period, the welding quality index is set to alpha 2, and alpha 2 = exp { P-P1-Pmon };
When Pmon is more than P+P1, the power supply monitoring unit judges that the welding quality is abnormal in the monitoring period, the welding quality index is set to be alpha 3, and alpha 3 = 1+ln [ (Pmon-P+P1)/(P+P1) ];
Where P1 is the power error value.
Specifically, the power supply monitoring unit monitors the power supply voltage and the power supply current in the monitoring period, so that the accuracy of monitoring and analyzing the welding data in the monitoring period is improved, the accuracy of judging the welding state is further improved, and the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are finally improved; it can be understood that the value of the power error value P1 is not specifically limited in this embodiment, and a person skilled in the art can freely set the value of the power error value P1 only by meeting the value requirement of the power error value P1, for example, the power error value P1 can be set to p×3%.
Specifically, the jet monitoring unit compares the average gas flow qv and the gas flow Qvc in the monitoring period, sets c=1, 2, and adjusts the analysis process of the welding quality according to the comparison result, wherein:
when qv is less than Qvc, the gas injection monitoring unit judges that the average gas flow is abnormal in the monitoring period, adjusts the power error value to be P1', and sets P1' =P1×cos [ (Qvc-qv)/Qvc ];
When qv=qvc, the gas injection monitoring unit determines that the average gas flow is normal in the monitoring period, and does not adjust;
when qv > Qvc, the gas injection monitoring unit determines that the average gas flow is abnormal in the monitoring period, and adjusts the power error value to P1 ', setting P1' = P1× {1+cos [ (Qvi-qv)/Qvi ] }/2.
Specifically, the jet monitoring unit monitors and analyzes the average gas flow in the monitoring period, adjusts the analysis process of welding quality according to the analysis result, improves the accuracy of monitoring and analyzing the welding data in the monitoring period, further improves the accuracy of judging the welding state, and finally improves the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality.
Specifically, the position monitoring unit analyzes the welding position according to the top view of the welding area in the monitoring period;
the position monitoring unit performs cluster analysis on the top view of the welding area according to pixel gray values, and divides the top view pixels after the cluster analysis into welding pixels and non-welding pixels;
The position monitoring unit takes a pixel starting point of a top view of a welding area as a coordinate origin, takes a transverse positive arrangement direction of pixels as an x axis, takes a longitudinal positive arrangement direction of pixels as a y axis, and takes a pixel length r as a unit length to establish a plane rectangular coordinate system; the position monitoring unit projects the welding pixel points after cluster analysis into a plane rectangular coordinate system, calculates sample point coordinates (a, b), and sets:
The position monitoring unit calculates an offset vector (X, Y) according to the sample point coordinates (a, B) and preset welding sample point coordinates (A, B), and is set with X=A-a and Y=B-B;
wherein i=1, 2..n, N is the number of welding pixels, X (i) is the abscissa of the ith welding pixel, Y (i) is the ordinate of the ith welding pixel, X is the lateral amount of the offset vector, Y is the longitudinal amount of the offset vector;
The position monitoring unit calculates a module D of the offset vector, sets d=x 2+Y2, compares the module D of the offset vector with a preset offset vector module D, and analyzes the welding position state according to the comparison result, wherein:
when D is smaller than D, the position monitoring unit judges that the welding position state is normal;
and when D is more than or equal to D, the position monitoring unit judges that the welding position state is abnormal.
Specifically, the position monitoring unit processes and analyzes the top view of the welding area, calculates a welding offset vector according to an analysis result, improves the accuracy of monitoring and analyzing welding data in a monitoring period, further improves the accuracy of judging the welding state, and finally improves the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality; it can be understood that in this embodiment, the welding base metal is a flat metal material, so that only a welding region and a non-welding region exist on the gray level value of the image after welding, and no other region exists, so that only two types of pixel points exist after cluster analysis; in this embodiment, the process of classifying the top-view pixels after the cluster analysis is not specifically limited, and a person skilled in the art can freely set the process of classifying the top-view pixels after the cluster analysis only by meeting the requirement of classifying the top-view pixels after the cluster analysis, for example, the pixels can be classified according to the gray value of the metal image after the oxidation of the welding, if the gray value after the welding is lower than the gray value of the original parent metal, the clustered pixels with low gray value are classified as welding pixels, and the clustered pixels with high gray value are classified as non-welding pixels; in this embodiment, the method for acquiring the preset welding sample point coordinates (a, B) is not specifically limited, and a person skilled in the art can freely set the method and the device only needs to meet the requirement for acquiring the preset welding sample point coordinates (a, B), for example, the method and the device can be used for acquiring the preset welding sample point coordinates (a, B) through user interaction input.
Specifically, the quality optimization unit obtains the actual weld penetration sh in the monitoring period according to the welding view of the welding area, and calculates the welding abnormality index beta according to the actual weld penetration sh in the monitoring period and the number N of welding pixels of the top view of the welding area, wherein the calculation formula of the welding abnormality index beta is as follows:
β=exp{S-SY/SY+sh-h/h}；
S=r2×N；
wherein S is the welding area, SY is the welding seam coverage area;
the quality optimization unit compares the welding abnormality index beta with a preset abnormality index G, analyzes the welding process according to the comparison result, and optimizes the welding quality analysis process according to the analysis result of the welding process, wherein:
When beta is more than or equal to G, the quality optimization unit judges that the welding process is abnormal and optimizes the analysis process of welding quality, the quality optimization unit optimizes the power error value to be P1', and P1' =P1×exp [ (G-beta)/G ];
And when beta is smaller than G, the quality optimization unit judges that the welding process is normal and does not perform optimization.
Specifically, the quality optimization unit obtains the welding area and the actual welding seam penetration through the top view and the welding view of the welding area, analyzes the welding process according to the welding area and the actual welding seam penetration, optimizes the analysis process of welding quality according to the analysis result of the welding process, improves the accuracy of monitoring and analyzing the welding data in the monitoring period, further improves the accuracy of judging the welding state, and finally improves the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality; it can be understood that, in this embodiment, the value of the preset abnormality index G is not specifically limited, and a person skilled in the art can freely set the value of the preset abnormality index G only by meeting the value requirement of the preset abnormality index G, for example, the preset abnormality index G can be set to 2; in this embodiment, the process of acquiring the actual weld penetration sh in the monitoring period according to the welding view of the welding area is not specifically limited, and a person skilled in the art can freely set the process of acquiring the actual weld penetration sh in the monitoring period according to the welding view of the welding area, for example, the actual weld penetration sh can be obtained according to the process analysis of analyzing the top view by the position monitoring unit, the welding view of the welding area is firstly subjected to cluster analysis and is divided into a welding pixel point and a non-welding pixel point, then the projection of the welding pixel point is performed into a plane rectangular coordinate system, the maximum y coordinate difference value ymax of the welding pixel point in the plane rectangular coordinate system is calculated, and sh=ymax is set.
Specifically, the welding analysis module determines a welding state according to a welding quality index αj and a welding position analysis result, and sets j=1, 2,3, where:
When alpha j is more than F or the welding position state is abnormal, the welding analysis module judges that the welding state in the monitoring period is unqualified;
When alpha j is smaller than F and the welding position state is normal, the welding analysis module judges that the welding state in the monitoring period is qualified;
wherein F is a welding quality index threshold value, and F is more than or equal to 1.2 and less than or equal to 1.6.
Specifically, the welding analysis module judges the welding state in the monitoring period according to the welding quality analysis result and the welding position state analysis result, so that the accuracy of the welding state judgment is improved, and finally the monitoring efficiency in the electric welding construction process and the accuracy of the electric welding quality judgment are improved; it can be understood that the value of the welding quality index threshold F is not specifically limited in this embodiment, and a person skilled in the art can freely set the value of the welding quality index threshold F only by meeting the value requirement of the welding quality index threshold F, and the optimal value of the welding quality index threshold F in this embodiment is 1.4.
Specifically, the alarm unit counts the number M of monitoring periods that the continuous welding state is unqualified according to the stored judging result of the welding state;
The alarm unit compares the continuous monitoring period number M with the unqualified number of each preset, and alarms the user according to the comparison result, wherein the continuous monitoring period number M is unqualified in the welding state, and the alarm unit comprises the following steps:
when M is less than M1, the alarm unit does not alarm to the user;
when M1 is more than or equal to M2, the alarm unit alarms the user with low risk;
when M is more than M2, the alarm unit gives a high-risk alarm to a user;
Wherein M1 is a first preset number of failures, M2 is a second preset number of failures, and M1 is more than 0 and less than M2.
Specifically, the alarm unit analyzes the stored analysis result of the welding state and alarms the user according to the analysis result, so that the accuracy of alarming the user in the welding process is improved, and finally the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are improved; it can be understood that, in this embodiment, the values of the first preset reject number M1 and the second preset reject number M2 are not specifically limited, and can be freely set by a person skilled in the art, and only the value requirements of the first preset reject number M1 and the second preset reject number M2 need to be met, for example, the first preset reject number M1 can be set to 1, and the second preset reject number M2 can be set to 3.
Specifically, the welding management unit adjusts an analysis process of welding parameter information of a next monitoring period and a welding position of a welding gun of the next monitoring period according to an alarm result, wherein:
When the alarm result is that the alarm is not given, the welding management unit does not adjust the analysis process of the welding parameter information of the next monitoring period; the welding management unit adjusts the welding position (X Original source ,Y Original source ) of a welding gun in the next monitoring period according to the offset vector (X, Y) of the current monitoring period, adjusts (X Original source ,Y Original source ) to be (X1 Original source ,Y1 Original source ), and sets X Original source =X Original source +X,Y1 Original source =Y Original source +Y; the welding management unit outputs a welding position (X1 Original source ,Y1 Original source ) of a welding gun in the next monitoring period to a user;
When the alarm result is low risk alarm, the welding management unit adjusts the welding power of the next monitoring period to P 'and sets P' =Px [1+ln (alpha j) ]forthe analysis process of the welding parameter information of the next monitoring period; the welding management unit adjusts the welding position (X Original source ,Y Original source ) of the welding gun in the next monitoring period according to the offset vector (Xz, yz) of the monitoring period of unqualified continuous welding process, setting z=1, 2..m, (X Original source ,Y Original source ) is adjusted to (X2 Original source ,Y2 Original source ), and x2 Original source =X Original source +（X1+X2+...+XM）/M,Y2 Original source =Y Original source + (y1+y2+, +ym)/M; the welding management unit outputs a welding position (X2 Original source ,Y2 Original source ) of a welding gun in the next monitoring period to a user;
When the alarm result is high risk alarm, the welding management unit adjusts the welding power of the next monitoring period to P 'in the analysis process of the welding parameter information of the next monitoring period, sets P' = P multiplied by alpha j, and recommends a user to overhaul the welding position of the welding gun;
Wherein X1 is the lateral amount of the offset vector of the first monitoring period in the monitoring period of failed continuous welding process, X2 is the lateral amount of the offset vector of the second monitoring period in the monitoring period of failed continuous welding process, XM is the lateral amount of the offset vector of the third monitoring period in the monitoring period of failed continuous welding process, Y1 is the longitudinal amount of the offset vector of the first monitoring period in the monitoring period of failed continuous welding process, Y2 is the longitudinal amount of the offset vector of the second monitoring period in the monitoring period of failed continuous welding process, YM is the longitudinal amount of the offset vector of the third monitoring period in the monitoring period of failed continuous welding process.
Specifically, the welding management unit adjusts the analysis process of welding parameter information of the next monitoring period and the welding position of the welding gun of the next monitoring period according to the alarm result, so that the accuracy of judging the welding state is improved, and finally the monitoring efficiency in the electric welding construction process and the accuracy of judging the electric welding quality are improved.
Thus far, the technical solution of the present invention has been described in connection with the preferred embodiments shown in the drawings, but it is easily understood by those skilled in the art that the scope of protection of the present invention is not limited to these specific embodiments. Equivalent modifications and substitutions for related technical features may be made by those skilled in the art without departing from the principles of the present invention, and such modifications and substitutions will be within the scope of the present invention.
Claims (10)
1. A system for monitoring electric welding construction data is characterized by comprising,
The information acquisition module is used for acquiring the parameter information of the base metal and the welding standard parameter information and periodically acquiring a welding area image according to the monitoring period;
the information analysis module is used for analyzing welding parameter information according to the base metal parameter information and the welding standard parameter information and outputting the welding parameter information to a user;
the data monitoring module is used for acquiring welding data in a monitoring period and analyzing welding quality according to the welding data and welding parameter information in the monitoring period;
The image monitoring module is used for analyzing the welding position state according to the top view of the welding area, analyzing the welding area and the actual welding seam penetration according to the top view and the welding view, and optimizing the welding quality analysis process according to the welding area and the actual welding seam penetration;
the welding analysis module is used for judging the welding state in the monitoring period according to the welding quality and the welding position state and storing the welding state;
And the welding management module is used for alarming the user according to the stored judging result of the welding state and adjusting the analysis process of the welding parameter information of the next monitoring period and the welding position of the welding gun of the next monitoring period according to the alarming result.
2. The electric welding construction data monitoring system according to claim 1, wherein the information analysis module is provided with a power analysis unit for calculating a welding stability temperature range [ Tmin, tmax ] from the base metal parameter information and the welding standard parameter information, and the calculation formula of the welding stability temperature range [ Tmin, tmax ] is as follows:
Tmin=v/k+Tm-W1；
Tmax=v/k+Tm+W1；
v=（0.01×h×hd）/（d/hv）；
wherein Tmin is the left value of the stable temperature range, tmax is the right value of the temperature range, tmin < Tmax, tm is the melting point of the base metal, k is the melting constant of the base metal, v is the melting speed of the base metal, W1 is the temperature allowable error value, hv is the welding speed;
the power supply analysis unit is configured to set welding power to P according to a welding stable temperature range, and set p=ρ× (0.01×h×hd) × (tmin+w1) ×hv/η;
Where η is the coefficient of thermal efficiency during the welding process and ρ is the density of the base metal.
3. The electric welding construction data monitoring system according to claim 2, wherein the information analysis module is further provided with an air injection analysis unit for comparing the welding speed HV with a preset welding speed HV, and setting a gas flow according to the comparison result, wherein:
when HV is less than HV, the jet analysis unit determines that the welding speed is normal, and sets the gas flow as Qv1, and sets qv1=qv;
when HV is more than or equal to HV, the jet analysis unit determines that the welding speed is abnormal, sets the gas flow as Qv2, and sets qv2=qv× {1+arctan [ (HV-HV)/HV ] };
Wherein QV is a gas flow preset value.
4. The electric welding construction data monitoring system according to claim 1, wherein the data monitoring module is provided with a power supply monitoring unit for calculating an average welding power Pmon in a monitoring period according to an average welding current I and an average welding voltage U in the monitoring period, and setting Pmon =i×u;
the power supply monitoring unit compares the average welding power Pmon in the monitoring period with the welding power P and analyzes the welding quality according to the comparison result, wherein:
When P-P1 is not less than Pmon and not more than P+P1, the power supply monitoring unit judges that the welding quality is normal in the monitoring period, the welding quality index is set to alpha 1, and alpha 1 = 1 is set;
When Pmon is smaller than P-P1, the power supply monitoring unit judges that the welding quality is abnormal in the monitoring period, the welding quality index is set to alpha 2, and alpha 2 = exp { P-P1-Pmon };
When Pmon is more than P+P1, the power supply monitoring unit judges that the welding quality is abnormal in the monitoring period, the welding quality index is set to be alpha 3, and alpha 3 = 1+ln [ (Pmon-P+P1)/(P+P1) ];
Where P1 is the power error value.
5. The electric welding construction data monitoring system according to claim 4, wherein the data monitoring module is further provided with an air injection monitoring unit for comparing the average gas flow qv and the gas flow Qvc in the monitoring period, setting c=1, 2, and adjusting the analysis process of the welding quality according to the comparison result, wherein:
when qv is less than Qvc, the gas injection monitoring unit judges that the average gas flow is abnormal in the monitoring period, adjusts the power error value to be P1', and sets P1' =P1×cos [ (Qvc-qv)/Qvc ];
When qv=qvc, the gas injection monitoring unit determines that the average gas flow is normal in the monitoring period, and does not adjust;
When qv > Qvc, the gas injection monitoring unit determines that the average gas flow is abnormal in the monitoring period, and adjusts the power error value to P1", setting P1" =p1× {1+cos [ (Qvc-qv)/Qvc ] }/2.
6. The electric welding construction data monitoring system according to claim 1, wherein the image monitoring module is provided with a position monitoring unit for analyzing welding positions according to a top view of a welding area in a monitoring period;
the position monitoring unit performs cluster analysis on the top view of the welding area according to pixel gray values, and divides the top view pixels after the cluster analysis into welding pixels and non-welding pixels;
The position monitoring unit takes a pixel starting point of a top view of a welding area as a coordinate origin, takes a transverse positive arrangement direction of pixels as an x axis, takes a longitudinal positive arrangement direction of pixels as a y axis, and takes a pixel length r as a unit length to establish a plane rectangular coordinate system; the position monitoring unit projects the welding pixel points after cluster analysis into a plane rectangular coordinate system, calculates sample point coordinates (a, b), and sets:
The position monitoring unit calculates an offset vector (X, Y) according to the sample point coordinates (a, B) and preset welding sample point coordinates (A, B), and is set with X=A-a and Y=B-B;
wherein i=1, 2..n, N is the number of welding pixels, X (i) is the abscissa of the ith welding pixel, Y (i) is the ordinate of the ith welding pixel, X is the lateral amount of the offset vector, Y is the longitudinal amount of the offset vector;
The position monitoring unit calculates a module D of the offset vector, sets d=x 2+Y2, compares the module D of the offset vector with a preset offset vector module D, and analyzes the welding position state according to the comparison result, wherein:
when D is smaller than D, the position monitoring unit judges that the welding position state is normal;
and when D is more than or equal to D, the position monitoring unit judges that the welding position state is abnormal.
7. The electric welding construction data monitoring system according to claim 6, wherein the image monitoring unit is further provided with a quality optimizing unit, the quality optimizing unit is configured to obtain an actual welding seam penetration sh in a monitoring period according to a welding view of the welding area, and calculate a welding abnormality index β according to the actual welding seam penetration sh in the monitoring period and the number N of welding pixels in a top view of the welding area, and a calculation formula of the welding abnormality index β is as follows:
β=exp{S-SY/SY+sh-h/h}；
S=r2×N；
wherein S is the welding area, SY is the welding seam coverage area;
The quality optimization unit is used for comparing the welding abnormality index beta with a preset abnormality index G, analyzing the welding process according to the comparison result, and optimizing the welding quality analysis process according to the welding process analysis result, wherein:
When beta is more than or equal to G, the quality optimization unit judges that the welding process is abnormal and optimizes the analysis process of welding quality, the quality optimization unit optimizes the power error value to be P1', and P1' =P1×exp [ (G-beta)/G ];
And when beta is smaller than G, the quality optimization unit judges that the welding process is normal and does not perform optimization.
8. The system of claim 1, wherein the welding analysis module determines a welding state based on a welding quality index αj and a welding position analysis result, and sets j=1, 2,3, wherein:
When alpha j is more than F or the welding position state is abnormal, the welding analysis module judges that the welding state in the monitoring period is unqualified;
When alpha j is smaller than F and the welding position state is normal, the welding analysis module judges that the welding state in the monitoring period is qualified;
wherein F is a welding quality index threshold value, and F is more than or equal to 1.2 and less than or equal to 1.6.
9. The electric welding construction data monitoring system according to claim 8, wherein the welding management unit is provided with an alarm unit for counting the number of monitoring cycles M in which the continuous welding state is failed according to the stored judgment result of the welding state;
The alarm unit compares the continuous monitoring period number M with the unqualified number of each preset, and alarms the user according to the comparison result, wherein the continuous monitoring period number M is unqualified in the welding state, and the alarm unit comprises the following steps:
when M is less than M1, the alarm unit does not alarm to the user;
when M1 is more than or equal to M2, the alarm unit alarms the user with low risk;
when M is more than M2, the alarm unit gives a high-risk alarm to a user;
Wherein M1 is a first preset number of failures, M2 is a second preset number of failures, and M1 is more than 0 and less than M2.
10. The electric welding construction data monitoring system according to claim 9, wherein the welding management unit is further provided with a welding management unit for adjusting an analysis process of welding parameter information of a next monitoring period and a welding position of a welding gun of the next monitoring period according to an alarm result, wherein:
When the alarm result is that the alarm is not given, the welding management unit does not adjust the analysis process of the welding parameter information of the next monitoring period; the welding management unit adjusts the welding position (X Original source ,Y Original source ) of a welding gun in the next monitoring period according to the offset vector (X, Y) of the current monitoring period, adjusts (X Original source ,Y Original source ) to be (X1 Original source ,Y1 Original source ), and sets X Original source =X Original source +X,Y1 Original source =Y Original source +Y; the welding management unit outputs a welding position (X1 Original source ,Y1 Original source ) of a welding gun in the next monitoring period to a user;
When the alarm result is low risk alarm, the welding management unit adjusts the welding power of the next monitoring period to P 'and sets P' =Px [1+ln (alpha j) ]forthe analysis process of the welding parameter information of the next monitoring period; the welding management unit adjusts the welding position (X Original source ,Y Original source ) of the welding gun in the next monitoring period according to the offset vector (Xz, yz) of the monitoring period of unqualified continuous welding process, setting z=1, 2..m, (X Original source ,Y Original source ) is adjusted to (X2 Original source ,Y2 Original source ), and x2 Original source =X Original source +（X1+X2+...+XM）/M,Y2 Original source =Y Original source + (y1+y2+, +ym)/M; the welding management unit outputs a welding position (X2 Original source ,Y2 Original source ) of a welding gun in the next monitoring period to a user;
When the alarm result is high risk alarm, the welding management unit adjusts the welding power of the next monitoring period to P 'in the analysis process of the welding parameter information of the next monitoring period, sets P' = P multiplied by alpha j, and recommends a user to overhaul the welding position of the welding gun;
Wherein X1 is the lateral amount of the offset vector of the first monitoring period in the monitoring period of failed continuous welding process, X2 is the lateral amount of the offset vector of the second monitoring period in the monitoring period of failed continuous welding process, XM is the lateral amount of the offset vector of the third monitoring period in the monitoring period of failed continuous welding process, Y1 is the longitudinal amount of the offset vector of the first monitoring period in the monitoring period of failed continuous welding process, Y2 is the longitudinal amount of the offset vector of the second monitoring period in the monitoring period of failed continuous welding process, YM is the longitudinal amount of the offset vector of the third monitoring period in the monitoring period of failed continuous welding process.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118674323A (en) * | 2024-08-09 | 2024-09-20 | 深圳市艾讯智能硬件有限公司 | Parameter management system for welding table based on AI |
| CN119187775A (en) * | 2024-11-26 | 2024-12-27 | 潍坊学院 | Welding monitoring system based on artificial intelligence |
| CN119197645A (en) * | 2024-09-29 | 2024-12-27 | 中铁四局集团有限公司 | A double-row immersed tube connection quality monitoring and management system |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118674323A (en) * | 2024-08-09 | 2024-09-20 | 深圳市艾讯智能硬件有限公司 | Parameter management system for welding table based on AI |
| CN119197645A (en) * | 2024-09-29 | 2024-12-27 | 中铁四局集团有限公司 | A double-row immersed tube connection quality monitoring and management system |
| CN119187775A (en) * | 2024-11-26 | 2024-12-27 | 潍坊学院 | Welding monitoring system based on artificial intelligence |
| CN119187775B (en) * | 2024-11-26 | 2025-02-11 | 潍坊学院 | Welding monitoring system based on artificial intelligence |
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