JPS63104074A - Spark training apparatus for welder - Google Patents

Abstract

(57) [Abstract] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention is directed to tool handling.
It relates to equipment for training welders, especially welders.
Regarding the spark trainer for r).

The invention can be used as a technical equipment for teaching manual and semi-automatic welding skills.

Welding electrode featuring a conventional burn-off simulation drive
e) a welder train equipped with a simulator, a high-frequency generator simulating the welding arc, and a workpiece model with special paper attached;
r) is known in the art. This trainer can mimic several phenomena associated with the welding process such as light, noise, smoke, and also simulates electrode motion relative to the workpiece, arcing, and electrode vibration [e.g. East German (GDR) Patent No. 109.278, IPCG 09
8 9100.1975, patentee: Gunther Schütt, G.
Guarido Vencell (Siegfriecl W)
ensel)].

A disadvantage of this welder trainer is that the welder training characteristics are inadequate because they do not fully encompass the physical factors of the welding process. Furthermore, no side effects on the parameters of the welding process are quaternary.

Trainers for welders are also known in the art, comprising a welding electrode simulator with an electric spark generator and a holder and motor drive for simulating the electrode melting during welding.

The training device also includes a device for fixing a sheet of regular or electrographic paper to simulate a workpiece. A spark discharge simulating a welding arc is used to trace the path between the workpiece simulation device and the tip of the welding electrode simulator. The training device also includes a pulse counter, the readings of which are
ngρrocess ) and to record how many times the arc gap between the electrode and the workpiece is interrupted or exceeded for a particular length. The control device is connected to the welding electrode simulator via an electric spark generator. Welder's operation (manipu)
Headphones are also connected to the control device for producing an acoustic signal representative of (I) of (lation).

This technical solution [e.g. gay. B, Lugin, V, A, Kuzmiche 7, Abaletas 7 O Training
Wildas, Svarotyunoe Broizvodostovwo, Moscow (v, p.

Lugin, V., A., Kuzmicbev.
, Apparatc+s for Traini
nB Welders, 5varochnoe
ProizvodsLvo, Moscow
), No. 9, pp. 50-51] was adopted as the prior art device of the present invention.

This prior art training device is deficient in that it can only be used to train welders in a limited number of welding operations. This device cannot be used for training in welding 3-D workpieces. Furthermore, this device is not equipped with any hand 13 for monitoring the arc gap length, electrode tilt angle and welding speed.

Therefore, training efficiency is not high. Furthermore, there is no single optical feedback presented to the alII building recipient, and such feedback allows the trainee to evaluate his or her own behavior in the welding process. This also affects the efficiency of the training process.

PROBLEM TO BE SOLVED The main object of the present invention is to provide a spark trainer for welders, which makes the training of welders much more efficient.

Another object of the invention is to make the simulation of welding processes more appropriate.

Yet another object of the invention is to provide training for welders in a wide variety of welding techniques.

Yet another object of the present invention is to provide comprehensive control of a simulated welding process.

Yet another object of the invention is to provide more objective monitoring of the training process.

A solution to the problem is a welding electrode simulator, an electric spark generator with an output simulating the welding arc and connected to the welding electrode simulator, a simulator of the welding object! The device, a spark discharge generated between the welding object simulation device and the welding electrode simulator chip, is connected to the welding electrode simulator and the electric spark generator to simulate the welding arc. According to the present invention, a spark training device for a welder comprising a training process control device and a helmet with earphones for connecting to the control device and producing acoustic signals representing the actions of the training device is provided. This is achieved in that the apparatus comprises a device for monitoring the position of the tip of the welding electrode simulator with respect to the welding object being drawn, the output of which is connected to the input of the control device.

This provides total control of welder operations and substantially improves the efficiency of welder training.

Suitably, the device for monitoring the position of the tip of the welding electrode simulator with respect to the simulated welding object comprises: a welding speed monitoring device connected to an input of the control device; a spark control device connected to an input of the control device; Gap current length monitoring device (spark gap current length monitoring device)
length + aonitoriB unit),
A circuit that generates a signal responsive to the simulated welding process (this is the input of the control device) (1nput) and the output of the spark gap current length monitoring device) (
a device for monitoring the angle between the welding electrode simulator and the plane normal to the surface of the simulated welding object (which is connected to the input of the control device); ing)
and a circuit for generating a signal corresponding to the time at which the welding electrode simulator welds on the surface of the simulated welding object (which is connected to the spark gap current length monitoring device and the welding electrode simulator). should be equipped with the following.

This arrangement allows a better simulation of the actual welding process.

Suitably, the welding object simulation device comprises a set of metal spokes arranged parallel to the surface of the simulated welding object and rigidly fixed on this surface perpendicular to the welding direction. Operational welding feed equipment made as (op
erational u+eldingfield
The number of these metal spokes is chosen based on the dimensions of the simulated welding surface and the desired accuracy for monitoring the position of the contact electrode simulator tip. .

In this way, welding speed is monitored, which is one welding parameter that was never monitored in prior art welder trainers.

The welding speed monitoring device uses a timing pulse oscillator (timi
B puts oscillator), a register connected to the output of the timing pulse oscillator;
and a plurality of matching circuits, each matching circuit having a first input connected to a respective actupt of the resistor and electrically connected via a matching element to a respective metal counter of the operational welding field equipment. a matching circuit having a second input and an input connected to all outputs of the matching circuit and an output that is the output of the welding speed monitoring device) It is also desirable to have one.

A device for monitoring the current rc of a spark gap comprises a detector having an input connected to the output of an electric spark generator and a spark gap length error signal generating circuit (this is a circuit for generating a spark gap length error signal) (connected to output)
It is also advantageous to have.

This device and its circuit vIJ& make it possible to monitor another new parameter not previously monitored, namely the length of the spark gap.

Conveniently, the circuit generating the signal representative of the simulated welding process should be a comparator connected to the output of the device monitoring the current length of the spark gap, and also connected to the ring of the welding electrode simulator and the simulated The device for monitoring the angle between the surface of the welding target and the normal plane includes an angle sensor located on the welding electrode simulator and an angular error signal generating circuit that is a comparator connected to the output of the electrode angle sensor. should be provided.

The electrode angle control device makes it possible to monitor another previously uncontrolled welding parameter, namely the angle of the 'IL pole simulator.

Advantageously, the electric spark generator comprises a series connection of a master pulse oscillator and an amplifier having an output connected to an input of a detector of a spark gap 'K current length monitoring device. You should stay there.

Preferably, the control device includes a pulse oscillator, and a spark gap length channel connected thereto and connected to the output of the spark gap current length monitoring device, a welding electrode simulator angle channel connected to the electrode angle monitoring device, and a welding electrode simulator angle channel connected to the electrode angle monitoring device. A channel for the thermal conditions of the welding method to be simulated, connected to the welding speed monitoring device, a simulated welding method speed channel, a simulated welding time channel, a circuit controlling the welding electrode melting simulation drive device ( This is connected to the output of a circuit that generates a signal representative of the welding process to be simulated (connected to the welding electrode simulator), a generator of an audible alarm signal and a welding noise simulation signal (this is connected to the spark gap current length monitoring equipment, angle monitoring equipment, welding speed monitoring equipment and helmet connection).

This control device allows for a more objective evaluation of the trainee's behavior.

Preferably, a simulated welding process (simula
The input of the thermal conditions channel of the ted weldiB process should be connected to the output of a circuit that generates an error signal representing the thermal conditions of the simulated welding process, and this circuit 7 of the length monitoring device and the output of the circuit for generating a signal representative of the simulated welding process, and a transducer for the signal representative of the length of the arc ear, a transducer for the signal representative of the arc current. , a multiplier, an adder, a switch, an integrator, and a comparator connected in series are connected to the outputs of the above two converters, and the second input of the adder is connected to the welding speed setting circuit by 4I. The control input of the switch is connected to the output of a circuit that generates a signal representative of the simulated welding process.

The above circuit for generating an error signal representative of the thermal conditions of a simulated welding process offers the advantage of a better simulation of the actual welding process.

In order to generate a circular fJ number representing the welder's behavior in the training process (which occurs based on the length of the spark gap, the inclination angle of the welding electrode simulator and the thermal conditions of the simulated welding method) a) a light source in which the capacitive electrode simulator has a luminous flux directed to the surface of the simulated welding object and is electrically connected to the output of the integrator of the thermal condition error signal generation circuit; It is desirable to be equipped with the following.

This is the first time that a spark trainer for welders is equipped with optical feedback.

Preferably, the circuit generating the signal representative of the welding time of the welding electrode simulator comprises a series connected comparator and a switch circuit w1, the output of which is connected to the winding of an electromagnet attached to the tip of the welding electrode simulator. It should be equipped with te (・ru).

The invention will now be described in more detail with reference to specific embodiments of the invention and the accompanying drawings.

(Left space below) Example Figure 1 shows a block diagram of a spark training device for welders according to the present invention: Figure Pt52 shows a block diagram of an electrode simulator tip position monitoring device according to the present invention: Figure PIS3 shows a block diagram of a spark training device for welders according to the present invention. FIG. 4 shows a welding object simulation device according to the present invention in which the welding object is a flat welded joint; FIG. 4 shows a welding object simulation device in which the welding object is a potted joint according to the present invention; ,
FIG. 6 shows a functional block diagram of a welding speed monitoring device according to the invention; FIG. , shows a functional block diagram of a spark gap current length monitoring device according to the invention; FIG. 8 shows a block diagram of an electrode angle monitoring device according to the invention; FIG. 9 shows a functional block diagram of an electric spark generator according to the invention. FIG. 10 shows a block diagram of a control device according to the invention; FIG. 11 shows a block diagram of a circuit for generating a temperature condition error signal according to the invention; FIG. FIG. 13 shows an enlarged view of the device A of the welding electrode simulator according to the invention; FIG. 14 shows a circuit for generating a signal representing the welding time of the electrode simulator according to the invention; FIG. The block diagram is shown below.

A spark trainer for welders is disclosed, the indicative features of which are the simulation of the welding arc by spark discharge and the welding path by optical means.

According to the invention, the spark trainer comprises a welding electrode simulator 1 (FIG. 1), an electric spark generator which simulates a welding arc by means of a spark discharge and has an output connected to an input 3 of the welding electrode simulator 1. It is equipped with a generator 2.

The spark trainer is a welding object simulator mechanically connected to a device 5 for monitoring the position of the tip of the welding electrode simulator 1 with respect to the simulated welding object.
ration unit) 4.

The device (U old) 5 includes a training method control device (Lrain) which is connected to the input 8 of the welding electrode simulator 1.
iB process control uni
t) connected to input 6 of 7. Control device 7
is connected to the input 9 of the helmet 10, which is equipped with earphones, to produce an audio signal characterizing the work performed by the welder during training.

The output of the electric spark generator 2 is connected to the input 11 of the device 5, and the output of the device 5 is connected to the input 12 of the welding electrode simulator 1.

A device 5 for monitoring the position of the tip of the welding electrode simulator 1 includes a welding speed monitoring wave rf 113 (FIG. 2), a spark gap current length monitoring device 14, and a signal representing the simulated welding process. a device 16 for monitoring the angle between the axis of the welding electrode simulator 1 and the normal plane to the surface of the simulated welding object, as well as a welding electrode simulator to the surface of the simulated welding object. A circuit 17 is provided for generating a signal representative of the welding time of 1.

The output of spark gap current length monitoring wave rf 114 is connected to inputs 18 and 19 of circuits 15 and 17, respectively. Input 11 of device 5 is device 1
This is input number 4. The outputs of the devices 13, 14, 16 and the circuit 15 are connected to the input 6 of the training method control device 7.

According to the present invention, the welding object simulation device 4
comprises a foundation made of dielectric material and operational welding field equipment resting on the foundation [3]
, 4 and 5). The operational welding field device is a set of metal spokes 21. These spokes are placed on a flat foundation 20 (FIG. 3) parallel to the surface 22 of the simulated welding object and rigidly fixed perpendicular to the welding direction indicated by arrow C.

In the case of square joint welding, the foundation 23 (FIG. 4) is a square joint with spokes 21 on both sides.

For pipe joint welding, the foundation is branch pipes 24”, 241 and 24
Dielectric multi-stage tube with II+ in each stage 24. Two spherical ground joints (bal I-and -5ockedj
oints) 25 and 26. Consists of two clamps 27 and 28 and two stands 27 and 28.

The multistage pipe 24 is installed on stands 29 and 30 using spherical sliding joints 25 and 26 and clamps 27 and 28 so that its posture can be adjusted.

The metal spokes 21 in each stage of the tube 24 are arranged v1 parallel to the tube axis and are interlocked.

The number of metal spokes 21 for any type of foundation is chosen based on the dimensions of the simulated surface and the desired accuracy of monitoring the tip position of the welding electrode simulator 1 (FIG. 1), e.g. At least 1000 spokes per meter of welded seams.

A replaceable number of regular or heat-sensitive paper (not shown) welding field equipment.
ld unit).

Referring to FIG. 6, a functional block diagram is designed to monitor how the trainee maintains a desired welding speed during the training process and to generate a welding speed error signal. A welding speed monitoring device 13 is shown.

The device 13 includes a timing pulse oscillator 31 and a switch 3
3 is provided with a resistor 32 connected to the output of an oscillator 31 via 3. Each output of the register 32 is connected to a match circuit 34, and another input of each minus number circuit 34 is connected to each spoke 2 via an interface 35.
It is electrically connected to 1. - all seven tops of the number circuit 34 are connected to each input of the OR gate 36;
The output of this gate 36 is the welding speed monitoring device 13.
and is connected to the input of the control device 7 (FIG. 1).

The matching circuit 34 comprises two NOT gates 37 and 38 and two AND gates 3 and 40,
The respective inputs of ND gates 39 and 40 are NO.
It is connected to the outputs of T-gates 37 and 38.

The other inputs of the three AND gates and 40 are the outputs of their respective interfaces 35 and registers 3.
It is connected to each output of 2. The -number circuit 34 also comprises an OR gate 41 whose inputs are connected to the outputs of AND gates 39 and 40. To isolate the high voltage welding field device with the spokes 21 from the low voltage input of the matching circuit 34, each interface 35 has an input circuit consisting of a capacitor 42 and a resistor 43, a diode 44 with a capacitor 45. i
4: @L.

ing. Each interface 35 also includes a light-emitting diode (light-emiLLinHdiode).
It also has an optoelectronic coupler comprising a 47.7 ottodiode 48 and a resistor 49. The timing pulse oscillator 31 has a frequency of 0.1 to 10Hz.
1 oscillator 31 intended to generate a continuous sequence of pulses (which may be adjusted without notice) at a frequency of
The specific welding speed is adjusted depending on the frequency of occurrence of the welding.

Register 32 is a logical zero.
is available in only one position and is logical 1 in other positions.
5hift r+4ister). Initially, a logical zero enters the first position of the register.

The spark current length monitoring device 14 includes an amplitude detector 50
(FIG. 7), a circuit 51 for generating an error signal representing the length of the spark gap is connected to the 7 output of a detector 50 whose input is connected to the electric spark generator 2 (Q%1 (connected to the output of Figure)).

amplitude detector
50 is intended to produce a signal representative of the length of the spark gap and comprises a diode 52, a resistor 53 and a capacitor 54.

Circuit 51 is an analog comparator (colIparator)
It is.

One of the outputs of the amplitude detector 50 is connected to an input 18 of a circuit 15 which generates a signal representative of the simulated welding process, the circuit 15 being designed to generate a signal of the initiation and extinction of the spark discharge. This is a comparator.

A device 16 (FIG. 8) for monitoring the angle between the sleeve of the welding electrode simulator and the plane normal to the surface of the simulated welding object is connected to an angle sensor 55 and a circuit 56 for generating an angular error signal. (a comparator electrically connected to the output of the angle sensor 55).

An electric spark generator 2, the circuit of which is shown in Figure ip9, generates, amplifies and controls a high voltage oscillation that is supplied to a welding electrode simulator 1 (Figure 1), and also controls the length of the spark gap and the spark discharge. The six-electric spark generator 2, which is intended to generate a signal representative of the start of the signal, comprises a mask pulse oscillator 57 and an amplifier 58 connected in series with the oscillator 57. The output of the amplifier 58 is connected to the input 11 of the device 5 (FIG. 2 and MS7), in particular to the detector 5.
Connected to input 0.

The pulse oscillator 57 generates a continuous oscillation sequence at a frequency of 10 to 15 kHz.
llation 5equence).

Amplifier 58 is designed to amplify the voltage of the output signal of oscillator 57 to a level sufficient for electrical spark discharge between the tip of welding electrode simulator 1 (FIG. 1) and device 4. , the gap represents the distance between the electrode and the workpiece and ranges from 0.5 to 10 m. The amplifier 58 includes transistors 59 and 60, diodes 61, 62 and 63, and a transformer.
mers) 64 and 65, capacitors 66, 67 and 68, resistor 69 and switch 70.
Stage transformer amplifier (transform+ner a+
It is built around the circuit of nplifier).

The control device 7 (FIG. 10) includes a pulse oscillator 71, a switch 72 connected to the output of the pulse oscillator 71, a spark gap length channel 73 connected to the output of a VC device (FIG. 1412), and a welding electrode simulator. 1 angle channel 74 (Fig. 10) [Apparatus 1G (
fjS2 (Fig.)], device 13 (f:tS
A simulated welding method speed channel 75 (FIG. 10), a simulated welding method thermal conditions channel 76 (FIG. 10) and a simulated welding method duration connected to the outputs of FIG. 2). It is provided with several types of channels, such as channel 77 (FIG. 10). The control device 7 also has a circuit 78 (Fig. PtS10) for controlling a simulation drive device for welding electrode melting [this is connected to the output of the circuit 15 (Fig. 2) and the input 8 of the welding electrode simulator 1 (Fig. 1). ] and a sound generator 79 that generates an alarm signal and a simulation signal of welding noise.
(ptSl 0 diagram) is also provided. sound generator 79
Its input is connected to device 14 (FIG. 2), device 16 and device 13, and its output is connected to input 9 of helmet 10 (FIG. 1).

Channels 73, 74, 75 and 76 (FIG. 10) are of identical design, each channel having the following series connected components: electronic switch circuit 80° 81.82 or 83;
Error counter 84, 85° 86 or 87, error number decoder 88, 89° 90 or 91, and error number indicator 92
, 93.

94 or 95.

Channel 77 includes the following series-connected members: welding time counter 96, welding time decoder 97, and welding time indicator 98 J14.

Pulse oscillator 71 is designed to generate pulses every second and can use any of the prior art circuits of continuous wave oscillators.

A circuit 78 for controlling the welding electrode melting simulation drive device includes a cut-in relay of the drive device.
an electronic comparator (electronic relay) with an output (not shown) that is serially connected to
c cosparaLor).

The input of channel 76 is connected to circuit 99 which generates an error signal indicative of the thermal conditions of the simulated welding process.
(FIG. 1), this circuit is intended to realize the solution of the heat balance equation. Since the simulation of the welding process in the training device does not require knowledge of the temperature distribution over the volume of the workpiece, the parabolic partial differential equation can be ignored, and the normal differential equation can be used to calculate the thermal The total type of heat transfer such as conduction, convection, radiation, etc. is taken into account to define the balance of heat input and output within a given volume. Mathematically, a simplified heat balance can be given by the following equation:

U ” a + b −j2゜τ =
v (U) (in the above formula, h - enthalpy of welding bath; ■ - welding speed; U - arc voltage; τ - arc current; l - arc gap length; a, b, D, R, k and coo welding constant depending on the type and conditions of the welding, the geometrical dimensions and thermal properties of the electrode and workpiece: δ - signal indicating irregular welding conditions, δ = 0 if the welding conditions are irregular; In the regular case, δ=1.) Circuit 99 is connected by inputs 100 and 101 to the output of device 14 (FIG. 2) and to the output of circuit 15! has been done. The output of circuit 99 is connected to a welding electrode simulator 111 (FIG. 111) and to an implant 102 (FIG. 110) of channel 76. circuit 99
is connected to a converter 103 (FIG. 11) for a signal representing the spark gap length, a converter 104 for a signal representing the arc current, and to the outputs of the converters 103 and 104;
: A multiplier 105, an adder 106, a switch 107, an integrator 108, and a comparator 109 are connected in series. The second input of adder 106 is potentiometer 110
is connected to the welding speed adjustment circuit. switch 1
Control implant F of 07 is the input of 9 circuits,
It is connected to the output of circuit 15 (FIG. 2).

Comparator 109 is intended to produce a signal indicative of irregular thermal conditions.

Switch 107 is intended to turn off the signals simulating the last two components of the heat balance equation, welding speed and arc current, when a signal indicating irregular welding conditions occurs.

optical signals that display the welder's actions during the training process.
In particular, the welding electrode simulator 1 allows the light beam to pass through the light pipe 112 to generate the welding process being simulated based on the spark gap length, the angle of the welding electrode simulator 1 and the temperature conditions of the simulated welding process. The light r directed towards the surface 113 of the object, i.e. the second workpiece.
j, equipped with 111 (Fig. 12).

The welding electrode simulator 1 operated as a rod-shaped electrode includes a holder 114 for an electrode 115 and a frame 116 (FIG. 13).
, angle sensor 55112), melting of electrode 115 (1+
Drive unit 1 simulating urn -of f )
17 (Fig. ptS12 and Fig. tJS13), with a metal tip 118 on the end face of the frame 116, which is connected by a high voltage cable 119 to one of the outputs of the electric spark generator 2 (Fig. 1). The welding electrode simulator 1 also includes a dielectric ring 120. The metal tip 118 is hollow and serves as a light pipe.
One end of the conduit 112 is fixed therein. The other end of the light conduit is optically connected to a light source 111, which together with the light source 111 is rigidly fixed inside the hollow holder 114 of the electrode 115.

9 circuit outputs)? The output of one integrator 108 is connected to a light source 111. The light source 111 is fixed within the dielectric ring 121, while the end of the light conduit 112 is fixed within the dielectric ring 122.

Referring to FIG. 14, a circuit 17 for generating a signal representing welding time includes a comparator 123 and a one-switch circuit 124 connected in series. The output of the switch circuit 124 is connected to a winding 125 of an electromagnet attached to the chip of the welding electrode simulator 1. The electromagnet is
In addition to the winding, there are 7 frames 1 of F 126 and winding 125.
27! 4: I am @I.

(Hereinafter in the margin) Operation According to the present invention, the spark training device for welders operates as follows.

Before operation, set all devices and circuits of the spark trainer to the initial state.

The trainee takes the welding electrode simulator 1 in his right hand, puts on the helmet 1σ, and begins the simulated welding process. A thin piece of ordinary paper or electrographic paper is previously placed on a predetermined area of the welding field of the simulation device 4 of the welding object. The weld seam was drawn on a paper sheet, which was then recorded by a skilled welder using the tip path 128 of the electrode simulator 1 (
Figure 5). Also, before the start of the training process, welding conditions are set in the control device 7, device 5, and circuit 99.

These conditions include the maximum duration of the training period, the tolerance of the spark gap length, the welding speed, the angle of the electrode simulator 1,
The temperature of the welding bath and the melting rate of the electrode simulator 1 are included. Check that all equipment and circuits are in initial condition.

The trainee must burn the path of the simulator tip onto the paper sheet by moving the tip of the electrode simulator 1 along the seam.
), simultaneously simulating the melting of the electrode. The trainee must maintain basic welding parameters such as arc gap length, electrode simulator 1 angle, welding speed and welding bath temperature within certain set limits.

The trainee takes the electrode simulator 1 to the point where the simulated welding process is to begin, maintains the required arc gap & angle, maintains the required angle of the electrode simulator 1, and switches 33.70. and 72 pushbuttons 129 (obtained within holder 114) (12th
Press ).

The supply voltage is applied to the final stage of amplifier 58 built around transistor 60. A high voltage is generated at the metal tip 118 of the electrode simulator 1.

If the spark gap is less than 10W, the metal tip 11
8 and the metal spokes of the welding field device (Figs. 3, 4, 5), a spark discharge occurs and the paper is burnt at that particular point.
rough), the voltage at the output of the detector 50 (tjS7 diagram) is indicative of the length of the spark gap.

The current length of the spark ear is determined by measuring the current consumed by the final stage of amplifier 58, built around transistor 60 (FIG. 9). This current consumption is a function of the spark gap length; the smaller the spark gap, the greater the current consumption. The spark gap maintained by the trainee is short.
The shorter the time, the greater the output voltage of the detector 50, which corresponds to a greater heat input to the simulated welding. When a spark discharge begins, some voltage fluctuation occurs at the output of detector 50. This causes comparator 15 (FIG. 7) to respond and indicate the start of the simulated welding process. Comparator 15 controls the operation of circuit 78 (FIG. 10) which controls the electrode melt simulation driver, and circuit 9 is activated. The welding electrode simulator 1 begins to shorten at a rate corresponding to the preselected welding conditions.

The output signal of detector 50, which contains information regarding the current length of the spark gap, is also applied to input 100 of circuit 99. This signal causes converter 103
will generate a signal representing the arc voltage of the actual welding process. This output signal causes the converter 104
now generates the arc current signal of the actual welding method. The power generator 105 uses the arc current and voltage signals to calculate the arc power signal. Adder 106 adjusts the heat content of the simulated welding bath according to the speed of the simulated welding process.

Switch 107 cuts off the simulated weld bath heat content signal when the spark discharge is interrupted. Integrator 1
08 calculates a signal representing the content of the weld bath based on the thermal parameters of the simulated workpiece. Output No. 43 of the integrator 108 is supplied to the light source 111,
Controls the size of the luminous flux. The spot of light thereby generated simulates a circular welding bath on the surface of the welding field device within the area of the spark discharge.

Comparator 109 (FIG. 11) generates an error signal indicative of the heat content of the simulated weld bath.

The optical "welding bath" is actually an optical feedback signal to the trainee; this signal is
The trainee is told how to achieve and maintain the following welding parameters: temperature of the welding bath, length of the spark gap and angle of the electrode simulator 1 at optimum levels. The brightness of the 'welding bath' spot is a visible feedback signal that indicates the degree of heating of the welding bath.The light conduit 112 has a conical beam and the size of the optical 'welding bath' is the length of the light guiding gap. This gives the trainee a feedback signal indicating the correct length of the spark gap.

When the electrode simulator 1 lights up the welding field device and deviates from its correct position, the optical "welding bath" changes its shape from a circle to an ellipse, and the major axis of the ellipse is the same as the electrode simulator 1.
shows a plane that is out of its correct position. This is also a kind of optical feedback so that the trainee can maintain the correct angle of the electrode simulator 1.

When the pushbutton 120 is pressed down, a signal at the frequency of IH7, simultaneously with the above process, is transmitted to the generator 71 (10th
) to the counter 96 of the welding time channel 77 and to the information inputs of the switch circuits 80, 82 and 83. When the trainee maintains the set length of the spark gap, the selected angle of the electrode simulator 1, the selected welding speed and the selected temperature of the welding bath, a noise signal simulating a normal welding process is output from the generator 79 to the helmet. 1
Sent to 0's earphone.

The trainee moves the tip of the electrode simulator 1 along the simulated weld and marks the path of the spark discharge. The burnt path on the paper is a recorded evidence of the trainee's skill in the process of the simulated welding process, which allows the trainee's behavior to be professional and correct or vice versa. It is possible to evaluate whether

According to the invention, the spark trainer is also equipped with means for monitoring the speed of welding, which is a welding speed monitoring device 13 (FIG. 6). For this purpose, the simulated welding method was applied to the first metal spoke 2 of the welding field equipment.
Starting at spoke 11 and ending at spoke 21n. A high voltage spark is caused on the first spoke 211 and the pushbutton 1
29, the output signal of circuit 351 and the first dinot of register 32 occur simultaneously for the first time. Therefore, circuit 34. and no signal occurs at the output of OR gate 36. At the next instant, the shift pulse (sbiftpulse) is activated by the oscillator 3.
1 to register 32, and a logical zero is shifted from the first position of register 32 to its second position. In order to prevent signals representing irregular welding speeds from occurring at the output of the circuit 342, the trainee must connect the tip of the electrode simulator 1 to the normally metal spoke 21.
212, thus causing a high voltage spark on the second varnish board 212. The process is then repeated as described above.

It can be said that a certain balance exists between the welding process speed and the shift frequency, ie the frequency of the oscillator 31. If this equilibrium is disrupted, a signal is generated at the output of circuit 34 and the output of circuit 36, respectively. This signal means that the preselected welding speed is not observed.6 Therefore, this welding speed is
By varying the frequency of the oscillator 31, it can be varied within a wide range to suit the particular conditions of the simulated welding process.

According to the invention, the spark controller also provides for monitoring the angle of the electrode simulator 1. If the angle of the electrode simulator 1 exceeds a preselected value, the angle sensor 55 is triggered into the activated state and the circuit 56
generates a control signal that is applied to the input of ν
- generates an error signal power C to be sent to the input of the switch circuit 81;

If the trainee fails to maintain one or more welding parameters within selected limits during the training process, an error signal indicating the basic parameters of the welding process is transmitted to circuit 51,
56 and 99 and device No. 13, and the respective sui-nochi circuits 80, 81 and 83.
(Figure 10) is applied to the control input. These signals allow the pulses from the oscillator 71 to pass to the coefficient inputs of the error number counters 84, 85, 86 and 87. Indicators (1ndicators)
92.

93, 94 and 95 are visual displays of the number of errors made.

If the period of the error signal for any welding parameter is less than seconds, this error is ignored and the counter 84~
If the duration of the 0° error signal not recorded by 87 is even longer, counters 84-871! each? It takes one pulse per l' and records the welding parameters that are incorrect for a certain period of time.

In this way, the training technique and the quality of the simulated welding process can be monitored on the indicators 92-95 and the welding time indicator 98.
can be evaluated based on the reading.

Irregularities in the simulated welding process also cause a set of tones (t
an audio generator (audio gen) that produces a signal
erator) 79, the tone signals are audio alar@signals of the main parameters of the simulated welding process applied to the earphones of the helmet 10. These signals provide audible feedback to help the trainee understand how they are performing in maintaining basic welding parameters.
edback signals).

If the spark gap is too short (in a true situation this means the electrode is welded to the workpiece)
, a comparator 123 of the circuit 17 (FIG. 14), which generates a signal representative of the welding time of the electrode simulator 1, produces a signal that is sent to a switch circuit 124. When the signal is received,
The circuit 124 sends control signals to a winding 125 located at the end of the electrode simulator 1 (FIG. 13). The metal tip 118 is a welding field device (weldiB f
It is strongly (pulled) by the metal spokes 21 of the ieldunit.

The person receiving the training must use the electrode simulator 1 on the spoke 21.
Considerable effort must be made to separate from

When the electrode simulator 1 is separated from the spoke 21, the winding 125 is de-energized.

In summary, the evaluation of the training includes the readings of the indicators 92, 93, 94 and 95, the number of errors in maintaining the length of the spark gap, the angle of the electrode simulator 1, the speed of welding, the temperature of the welding bath and It is based on the marked paths of the tip of the electrode simulator 1 (these are examined against a reference path recorded by an expert welder).

Effects of the Invention According to the present invention, the spark trainer for welders has the following effects in all basic parameters of the simulated welding process:
It offers the advantage of total control compared to trained person operation. The trainer offers a wide range of types of welding that can be taught. And the last and most important feature is that the trainer provides audio and light signals for the welder being trained, which greatly contributes to the efficiency and quality of training. It is something to do. Training periods can be substantially reduced.

(Margin below)

[Brief explanation of the drawing]

1 shows a block diagram of a spark trainer for welders according to the invention; FIG. 2 shows a block diagram of an electrode simulator tip position monitoring device according to the invention; FIG. FIG. 4 shows a welding object simulation device in which the welding object is a flat welded joint; FIG. 4 shows a welding object simulation device in which the welding object is a heel joint according to the invention; FIG. Fig. 16 shows a functional block diagram of a welding speed monitoring device according to the invention: Fig. 7 shows a welding object simulation device in which the welding objects are branch joints of pipes with different diameters; FIG. 8 shows a functional block diagram of a spark gap current length monitoring device; FIG. 8 shows a functional block diagram of an electrode angle monitoring device according to the invention; FIG. 9 shows a functional block diagram of an electric spark generator according to the invention. Figure 10 shows a block diagram of a control device according to the invention: Figure 11 shows a block diagram of a circuit for generating a temperature condition error signal according to the invention: Figure 12 shows a light source according to the invention. Fig. 13 shows an enlarged view of the device of the welding electrode simulator according to the invention: Fig. 14 shows a block diagram of a circuit for generating a signal representing the welding time of the electrode simulator according to the invention. shows. [Explanation of reference numbers in the drawings] 1 - Welding electrode simulator 2 - Electric spark generator 3 - Input of electrode simulator 1 4 - Welding object simulation? 11 Place 5 - Device for monitoring the position of the tip of the welding electrode simulator with respect to the simulated welding object 6 - Input 7 - Training process control device 8 - Input 9 of the electrode simulator 1 - Input 10 of the helmet 10 - a helmet 11 with earphones - an input 12 of the device 5 - an input 13 of the simulator 1 - a welding speed monitoring device 14 - a spark gap current length monitoring device 15 - a circuit 16 for generating a signal representative of the simulated welding process. Device 17 for monitoring the angle between the sleeve of the electrode simulator 1 and the plane normal to the surface of the simulated welding object - the welding time of the electrode simulator 1 to the surface of the simulated welding object; A circuit 18 generating a representative signal - an input 19 of the circuit 15 - an input 20 of the circuit 17 - the basics 21, . 212. ...2in - Metal spork 22 - Simulated welding surface 23 - Foundation 24 - Multi-stage pipe 241.24" and 241 - Branch pipes 25 and 26 of pipe 24
- Spherical ground joints 27 and 28 - Two clamps and 30 - Stand 31 - Timing pulse oscillator 32 - Resistor 33 - Switches 34 and 341 - Matching circuits 35 and 351 - Matching element 36 - OR gate 37 and 3B - NOT gate 39 and 1. r40 - AND gate 4l - OR gate 42 - Capacitor 43 - Resistor 44 - Diode 45 - Capacitor 46 - Resistor 47 - Light emitting diode 48 - 7 Otodiode 49 - Resistor 50 - Amplitude detector 51 - Spark gap length circuit 52 for generating an error signal indicative of the electrode angle - diode 53 - resistor 54 - capacitor 55 - electrode simulator angle sensor 56 - circuit 57 for generating an error signal indicative of the electrode angle - mask pulse oscillator 58 - amplifiers 59 and 60 - transistors 61, 62 and 63 - diodes 64 and 65 - transformers 66, 67 and 68 - capacitor 69 - resistor 70 - switch 71 - pulse oscillator 72 - switch 73 - channel of spark gap length 74 - electrode simulator angle Channel 75 - Speed of the simulated welding method Channel 7 Low Channel of the temperature conditions of the simulated welding method Channel 7 of the welding period of the simulated welding method Channel 78 - Drive to simulate welding electrode melting Circuit for controlling the device 79 - Sound generator 80.81.82 and 83 of alarm signal and welding noise simulation signal - Electronic switch circuit 84.8
5.86 and 87 - Counter of error numbers 88.89,90
and 91 - error number decoder 92.93.94 and 95
- error number indicator 96 - welding open cutter 97 - welding time decoder 98 - welding time indicator 99 - circuits 100 and 101 for generating error signals indicating the temperature conditions of the simulated welding process - circuits 100 and 101 of circuit 99. Input 102 - Input 103 and V 104 of channel 76 - Signal converter 105 - Multiplier 106 - Adder 107 - Switch 108 - Integrator 109 - Comparator 110 - Potentiometer 111 - Light source 112 - Light conduit 113 - Simulated processing Object surface 114 - holder 115 - electrode 116 - 7 frame 117 - electrode melting simulation drive device 118 - 11 metal chips - high voltage cable 120 - dielectric rings 121 and 122 - dielectric washer 123 - comparator] 24 - Switch circuit 125 - Electromagnet winding 126 - Electromagnet core 127 - Frame 128 of winding 125 - Chip path 129 of electrode simulator 1 - Push button agent

Claims (12)

[Claims] (1) a welding electrode simulator, an electric spark generator simulating a welding arc and having an output connected to the welding electrode simulator, a welding object simulation device, and between the welding object simulation device and the welding electrode simulator chip; a training process control device connected to the welding electrode simulator and the spark generator to simulate the welding arc generated in the welding process, and connected to the control device to supply the welder's audio signals characterizing the welder's actions. A spark trainer for welders, comprising a helmet with earphones, comprising a device for monitoring the position of the tip of a welding electrode simulator with respect to a simulated welding object, said monitoring device A spark trainer for a welder, characterized in that the output of the is connected to the input of a control device. (2) a welding speed monitoring device (13), in which a device (5) for monitoring the position of the tip of the welding electrode simulator (1) with respect to the simulated welding object is connected to an input of the control device (7); , a spark gap current length monitoring device (14) connected to the input of the control device (7).
a circuit (15) connected to the input (6) of the control device (7) and the output of the spark gap current length monitoring device (14) and generating a signal representative of the simulated welding process; , is connected to the input (6) of the control device (7) and the welding electrode simulator (1)
device (16) for monitoring the angle between the axis of connected welding electrode simulator (
Claim (1) characterized in that it comprises a circuit (17) that generates a signal representing the welding time of (1).
Spark trainer for welders as described in section. (3) The welding object simulation device (4) includes a set of metal spokes (4) arranged parallel to the simulated welding object surface and rigidly fixed on the surface perpendicular to the welding direction. 21), the metal spokes (21_1, 21
_2...21_n) is selected on the basis of the dimensions of the surface of the simulated welding object and the desired accuracy of monitoring the position of the tip of the welding electrode simulator (1). A spark training device for welders according to paragraph (1) or paragraph (2). (4) The welding speed monitoring device (13) has a timing pulse oscillator (34) and a register (32) connected to the output of the timing pulse oscillator (31). a plurality of matching circuits having a first input connected to the welding field unit and having a second input electrically coupled to a respective metal spoke (21) of the welding field unit via a matching element (35); (34) and an OR gate (36) whose inputs are connected to all outputs of the matching circuit (34) and whose output is the output of the welding speed monitoring device (13). A spark training device for a welder according to claim (3), characterized in that: (5) a spark gap current length monitoring device (14) is connected to the detector (50) and the output of the detector (50), the input of which is connected to the output of the electric spark generator (2); Claims (2), (3) and (4), characterized in that the invention comprises a circuit (51) for generating an error signal indicating the length of the spark gap.
A spark trainer for a welder according to any one of paragraphs. (6) The circuit (15) for generating a signal representative of the simulated welding process is a comparator connected to the output of the spark gap current length monitoring device (14). ) to (5), the spark training device for a welder according to any one of items (5) to 5). (7) a device (16) for monitoring the angle between the axis of the welding electrode simulator (1) and a plane normal to the surface of the simulated welding object is placed in the welding electrode simulator (1); Claims (2) to (6), comprising: an angle sensor (55); and an angle error signal generation circuit (56) electrically connected to the output of the angle sensor (55). ) A spark training device for welders as described in any one of paragraphs 1 and 2. (8) The electric spark generator (2) comprises a master pulse oscillator (57) and an amplifier (58) connected in series, the output of the amplifier (58) being connected to the spark gap current length monitoring device ( 14) Spark training device for a welder according to claim 5, characterized in that it is connected to the input of the detector (50) of item 14). (9) a spark gap length channel (73) in which the control device (7) is connected to the pulse oscillator (71) and to the output of the spark gap current length monitoring device (14); , a welding electrode simulator (16) connected to an electrode simulator angle monitoring device (16);
1) angle channel (74), a simulated welding method thermal conditions channel (76), a simulated welding method speed channel (75) connected to a welding speed monitoring device (13); The channel (77) of the channel welding period is connected to the output of the circuit (15) for generating a signal representative of the simulated welding process and to the welding electrode simulator (1), providing a drive device for simulating the melting of the welding electrode. A circuit for controlling (78), a sound generator (79) for alarm signals and welding noise simulation signals connected to a spark gap current length monitoring device (14), an angle monitoring device (16), a welding speed monitoring device (
13) and a helmet with earphones (10), the spark training device for a welder according to any one of claims (2) to (8). . (10) The input of the simulated welding process thermal conditions channel (76) is connected to a circuit (99) that generates an error signal indicating the simulated welding process temperature conditions.
The circuit (99) is connected to the output of
a spark gap current length monitoring device (14) and a circuit (15) for generating a signal representative of the simulated welding process, and a converter for the signal representative of the spark gap length; (103), a converter (104) for a signal representing arc current, a converter (1
03 and 104) connected to the outputs of the multipliers (
105), an adder (106), a switch (107), an integrator (108) and a comparator (109), and the second input of the adder (106) is welded. a circuit (15) connected to the speed setting circuit (110) and whose control input of the switch (107) generates a signal representative of the simulated welding process;
A spark training device for a welder according to claim 9, characterized in that the spark training device is connected to an output of a welder. (11) Spark gap length, welding electrode simulator (
A welding electrode simulator (1) is used to generate optical signals characterizing the welder's behavior in the training process regarding the inclination angle and temperature conditions of the simulated welding process.
) is provided with a light source (111) whose luminous flux is directed onto the surface of the simulated welding object, which light source is connected to a circuit that generates a signal indicative of the temperature conditions of the simulated welding process. A spark training device for a welder according to claim 10, characterized in that the spark training device is electrically connected to the output of the integrator (108) of claim 99. (12) The circuit (17) for generating a signal representing the welding time of the welding electrode simulator (1) includes a comparator (123) and a switch circuit (124) connected in series, and the switch circuit ( 124) is connected to the winding (125) of an electromagnet attached to the tip of the welding electrode simulator (1). Spark trainer for.