JPH059192B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is related to welding construction management, and relates to measurement, recording, and welding construction management in high-grade material welding that requires temperature control between preheating passes, heat input amount management, etc. This invention relates to an automatic welding condition measurement and recording device that can be applied to, etc.

[Conventional technology] Conventionally, the measurement and recording work associated with the above management in welding high-quality steel materials such as high-strength steel, which requires control of the temperature between preheating passes and the amount of welding heat input, is performed by a measurement recorder using a clamp meter, etc. during welding. Measurements of current and voltage were carried out with a stopwatch, and arc time was measured with a stopwatch.

[Problems to be Solved by the Invention] The above-mentioned conventional measurements have low measurement accuracy and require a long measurement time, which delays the measurement recorder's calculation and judgment of the amount of heat input per unit welding length, which cannot be reflected in the next construction. There was a problem. In addition, many man-hours were required because a large number of welding recorders were required.

The present invention was proposed to solve the above problems, and includes a sensor section that can automatically identify the start and end of welding, and calculates and records welding condition values, heat input, etc. for each bead. It is an object of the present invention to provide an automatic welding condition measurement and recording device in which a recording unit can be freely placed in a welding power source and a welder can perform highly accurate and highly efficient measurement and recording work by himself.

[Means for Solving the Problems] An automatic welding condition measurement and recording device according to the present invention includes a welder terminal 1, a controller 100, and a sensor/acquisition cell unit 101. The sensor unit 7 is composed of a sensor unit 7 and an acquisition cell unit 9. The sensor unit 7 is composed of an A/D converter 101a and a welding condition counter 101b, and the acquisition cell unit 9 is composed of a calculation/comparison/judgment section 101c and a storage section 101.
The controller 100 is made up of a system controller 102 and a peripheral device 103, and the system controller 102 is made up of a communication control section 100a, an arithmetic/comparison/determination section 100b, and a storage section 100c. The device 103 includes an input section 100d, a display section 100e, a storage section 100f, and an output section 100g. The welder terminal 1 consists of an input section 111a, a display section 111b, and a communication control section 111c. The D converter 101a inputs the signal from the welding electrode 8, and the welding condition counter 1
01b detects the start and end of welding based on the signal input from the A/D converter 101a, and measures the welding current, voltage, and arc time. The calculation/comparison/judgment section 101c of the acquisition unit inputs signals from the welding condition counting section 101b and the storage section 101d, and also connects to the welder's terminal via the communication control section 101e. 1 and the controller 100, compare and judge the welding condition value with the standard value of the temperature between preheating passes, calculate and judge the amount of heat input, and output it to the storage section 101d, as well as via the communication control section 101e. welder terminal 1
and is output to the controller 100, and the calculation/comparison/judgment section 100b of the controller receives the signals from the storage section 100c and the input section 100d and the welder's terminal 1 inputted via the communication control section 100a.
Based on the signals from the sensor/acquisition cell unit 101, the controller calculates and records the temperature between preheating passes and the average heat input for each bead, and again compares and judges the standard values, and automatically displays the comparison and judgment results. The display unit 1 of the welder terminal via the display unit 100e and the communication control unit 100a.
11b and the storage unit 100c, and the display unit 100e of the controller displays the signals input from the calculation/comparison/judgment unit 100b and the storage unit 100f to perform alarm and verification functions, and also outputs the signals to the storage unit 100f and the output. The input section 111a of the welder's terminal outputs various data to the display section 111b, and the communication control section 1
11c to the sensor/acquisition unit 101 and the controller 100, and the display section 111b displays the signal from the input section 111a. It is characterized by displaying the signal, performing alarm and verification functions, and allowing the welder with the terminal device and the person monitoring the controller to check and manage various data such as the temperature between preheating passes and the amount of heat input in parallel with the welding status. do.

[Function] According to the present invention, there is provided a sensor section 7 that automatically detects welding phenomena and measures the average welding current/voltage and welding time, and further calculates the amount of heat input from these measured values and attribute values from the terminal device. The acquisition cell 9, which can calculate and record data such as In the event of an occurrence, an interrupt is automatically displayed on the CRT of the controller, and an alarm lamp is also displayed on the terminal unit 1, so that the welder and the person monitoring the controller can monitor the preheating pass temperature, heat input, etc. in parallel with welding. Since various data can be checked and an alarm is automatically issued to both parties in the event of an abnormal value, it is possible to reliably manage the amount of heat input, etc., thereby solving the above-mentioned conventional problems. It is.

[Examples] Examples of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a diagram showing the configuration of a first embodiment of the present invention,
FIG. 2 is an elemental block diagram of the first embodiment, and FIG. 8 is a functional block diagram of the first embodiment.

When the element block diagram shown in FIG. 2 is viewed from the functional point of view, it becomes as shown in FIG. 8.

The A/D converter 101a of the sensor/acquisition cell unit 101 in FIG. 8 corresponds to 7c in FIG.
The welding condition counting section 101b corresponds to 7b and 7e in FIG. 2, and the calculation/comparison/judgment section 101c corresponds to 8 in FIG.
The storage unit 101d corresponds to 8 in FIG.
Corresponding to b, the communication control unit 101e is 8 in FIG.
Corresponds to d and 8e.

Communication control section 10 of controller 100 in FIG.
0a corresponds to 11a and 11b in FIG.
The comparison/determination section 100b corresponds to 22 in FIG. 2, the storage section 100c corresponds to the second 19 and 20, the input section 100d corresponds to 14 in FIG.
0e corresponds to 13 in FIG. 2, the storage section 100f corresponds to 17 in FIG. 2, and the output section 100g corresponds to 15 and 16 in FIG.

The input section 111a of the welder terminal 1 in FIG. 8 corresponds to 1a and 1d in FIG. 2, the display section 111b corresponds to 1b in FIG. 2, and the communication control section 111c corresponds to the second
This corresponds to 1c in the figure.

1, 2, and 8, welders 2 who perform welding work on welding workpieces 4 connect their terminal devices 1 to the welding power source 8 of their welding torch 3.
An optical fiber cable 5 is connected to a sensor unit 7 for measuring welding conditions arranged on a welding cable 6 at an output terminal of the sensor unit 9 and an acquisition cell 9 integrated therewith. Further, the plurality of acquisition cells 9 are connected in serial form to a controller section 100 that controls them by a cable 10. The data transmitted from the acquisition cell 9 is sent to the multiplexer panel 11
a, 11b to the system CPU 22, and necessary data processing is performed using the system RφM 19 and RAM memory 20. At this time, the content is displayed on the monitor terminal (or CRT) 13,
Input via the keyboard 14 and various necessary outputs via the printer 15 and floppy disk 16 are performed by a single operator 12.

To explain the details of the system shown in FIG. 1 with reference to FIG. 2, welding current 7b and welding voltage 7a are applied to A/D converter 7c in sensor unit 7 and sampled at a predetermined period.
and RφM, and digital conversion calculation processing is performed by the action of timer 7e. On the other hand, the terminal device 1 has a keyboard interface 1d for direct input by the welder.
and various keyboards 1a are provided, and data including various measurement data is displayed on an LED display device 1b.
It is configured to be displayed on the welder's side at any time.

RAM8b of sensor/acquisition cell unit 101
The data recorded in is sent to the system controller 102 via the communication cable 10 through the multiplexer panel 11a and the multiplexer 11b upon completion of measurement or upon a request from the system controller 102. The system controller 102 is configured to be able to simultaneously manage a large number of sensor/acquisition cell units 101 having such a configuration.

Next, the functions of each numbered part will be explained based on FIG.

The system controller 102 is a welding supervisor 1
The RAM 8b searches and collects attribute data and welding measurement data in the plurality of sensor/acquisition cell units 101 through the multiplexer 11b and the multiplexer panel 11a. This search and collection depends on each system.
The programs stored in the ROM 19 and ROM 8c are executed by the actions of the CPU 22 and CPU 8a, respectively.

These data are stored in the system controller
It is stored in the RAM memory 20, displayed on the monitor terminal 13 through the terminal I/F, externally recorded on the hard disk 17 through various I/Fs, and printed out to the printer 15 through the GP-IB interface (I/F). Or externally recorded on the floppy disk 16.

Terminal 1 is a CPU/serial I/φ that controls initial value data setting and data transmission/reception to the acquisition cell.
1c and a keyboard 1a for inputting measurement attribute values.
and its interface 1d, and an LED display device 1b that displays inquiry data including alarms.
It is composed of, etc.

An example of the panel configuration of this terminal device 1 is shown in FIG.

The sensor/acquisition cell unit 101 performs bidirectional (talker/listener) communication with the aforementioned terminal device 1 and system controller through serial interfaces 8d and 8e and the CPU 8a, and also communicates with the welding current and voltage from the sensor unit 7. Based on the arc time information, the program in the ROM 8c calculates the amount of heat input, automatically evaluates and determines the temperature between preheating passes and the amount of heat input by the action of the CPU 8a, and temporarily records the results in the RAM 8b.

Furthermore, this sensor/acquisition cell unit 101
are distributed in the vicinity of the welding power source 8, and the sensor unit 7 takes in the voltage and current values during welding through terminals 7a and 7b, and processes the effects of the sub-CPU 7d.
Automatic sampling measurement using A/D converter 7c
Perform according to the program in ROM/timer 7e.
The same program also automatically determines and detects the start and end of welding by comparing it with threshold values and time.

The arc time is counted by a built-in timer 7e. Abnormal values such as the temperature between preheating paths and the amount of heat input determined mainly by the sensor/acquisition cell unit 101 are transmitted and received by the action of each CPU and output to each display device.

The system controller 102 automatically compares and compares the initial setting values of the A card such as the joint number input from the terminal 1 with the initial setting values input from the controller 100.

Further, calculations and comparisons of the temperature between preheating passes and the amount of heat input are mainly performed by the data acquisition cell 9, but the calculations can also be checked by the controller 102 based on the average voltage, current value, and arc time from the sensor unit 7.

Furthermore, the controller 100 searches for, displays, and displays attribute data and measurement collected data in each acquisition cell 9.
Corrections can also be made.

Further, FIGS. 3 and 4 show a sensor/acquisition cell unit 101 and a system controller 10.
2 and a plurality of sensor/acquisition cell units 10
The system controller 10 is connected to the system controller 10 through the serial I/φ interface 11 using a format converter 18 that controls and controls the transmission between the
Another embodiment (second embodiment) in which signals are transmitted with 2 is shown. The configuration of the second embodiment is similar to that shown in FIGS. 1 and 2 above, except for the format converter 18.
Similar to that shown in the figure.

FIG. 5 shows an example of the configuration of the panel of the terminal device 1. The panel includes input keys 1a such as initial setting keys, welding rod brand keys, and measurement input keys, and an LED display device 1 for displaying attribute data such as initial setting values and measured values.
b, and is further equipped with display lamps such as automatic alarm lamps (61 and 62, respectively) in case of abnormal preheating pass temperature and abnormal heat input, and various system abnormality lamps 63 for communication and the like. The welding work instruction card A60 is inserted and stored in a slot at the upper end of the terminal panel to enable comparison with set values at any time.

FIG. 6 shows functional details of the main devices of the above embodiment. That is, FIG. 6A shows the functions necessary to realize the "actions" of the system controller 102 and peripheral devices (monitor terminal 13, keyboard 14, hard disk 17, printer 15, and floppy disk drive 16) in FIG. FIG. 6B shows the CPU 8a and ROM of the data acquisition cell 9 of the sensor/acquisition cell unit 101.
8c and RAM 8b, and FIG. FIG. 6D shows the functions to be performed by the sensor unit 7.

Next, the operation of this apparatus system will be explained with reference to the main operation flow shown in FIG. Before starting work, the supervisor 12 in the control room stores basic attribute values such as initial settings in advance in the controller RAM 20.
and allocates welding work instruction card A to each accumulation cell (29) at approximately the same time as welding operator 2 confirms the construction joint (30). Further, at the same time as confirmation input of the contents of the welding work instruction card A from the welder's terminal keyboard 1a (31), these setting values are automatically verified (32) by the controller CPU 22. If the set values are different between the two, an instruction is given to stop the measurement operation. These initial settings include standard values for the following judgments, and if these are appropriate, the welder can input initial attribute values such as welder number, number of layers, and rod lot number (33). . Next, the welder inputs the pre-welding preheating temperature or interpass temperature (34). The input temperature data is immediately sent to the acquisition cell 9, where it is automatically compared with the standard value, and in the event of an abnormality, it is immediately sent to the terminal device 1.
and a warning is displayed (41) on the monitor terminal 13. While the welding work (35) is being carried out, the sensor unit 7 automatically identifies and counts the condition values such as current, voltage and arc time for each bead.
At this time, any number of welds can be continuously measured by the sensor unit. When you input the bead length corresponding to each bead (36), the average heat input for that bead is automatically calculated, and in the same way as the temperature, automatic comparison with the standard value is performed, and abnormalities such as exceeding the standard value are detected. In this case, an alarm is automatically displayed (42) on the terminal and controller.

Furthermore, the bead length is automatically tabulated by layer and compared with the planned weld length. If the difference is larger than the specified width, both the welding operator and the supervisor are requested to review the bead length input value ( 43) Do.

In addition to displaying alarms based on these automatic judgments, reference values such as all the data of the work done so far and the average heat input can be called up and displayed (37) by the welder and supervisor at any time. These welding operations (35) and bead length input (36) can be performed by combining any number of beads for construction. Furthermore, the supervisor 12 can output part or all of this data at any time while doing other work such as output work.

Next, for each work step shown in FIG. 7, the relationship with the apparatus shown in FIGS. 2 and 5 will be explained.

(Work 29): The supervisor 12 allocates welding joints, the sensor/acquisition cell unit 101 to be used, and the welder terminal 1 to a plurality of welders using the welding work instruction card A.

(Work 30): Welder 2 checks the constructed joint.

(Work 31): Set initial value data such as joint number using terminal device 1. For this purpose, the initial setting key 1a shown in FIG. 5 is used.

(Work 32): When the supervisor inputs the initial values for each terminal using the controller 102, the system CPU in the system controller 102
22, etc., and the results are displayed on the controller monitor terminal 13 and the LED display device 1b of the terminal device.

(Work 33): Welder 2 prepares for welding and
Confirm and input the welder number, number of layers, and rod lot using the terminal 1. This work is necessary because depending on the joint, the welder may change, or work may be stopped and restarted during construction.

(Work 34): Furthermore, the welder 2 inputs the preheating pass temperature using the terminal device 1. These data are
It is sent to the sensor/aggregated cell unit 101 through interfaces 1c and 8d, and the CPU
By the action of 8a, the preheating standard value is compared with the preheating standard value recorded in advance in the ROM 8c. In case of abnormality,
An alarm is displayed (41) on the terminal display section 1b and the controller monitor terminal 13. These details are recorded on the hard disk 17, floppy disk 16, etc. of the controller.

(Operation 50): In case of abnormality, the supervisor checks the preheating/interpass temperature improvement process.

(Work 35): Welder 2 performs welding work. The start and end of welding and the arc time are controlled by the sub-CPU 7d of the sensor unit in the sensor/acquisition cell unit 101.
Detection and counting are performed using the voltage/current reference values stored in the ROM/timer 7e and a judgment algorithm. This welding operation can be repeated an arbitrary number of times if the interpass temperature becomes abnormal.
(Work 33-34-35-33) (Work 36): Input the corresponding bead length from the terminal device 1 according to the welded permutation. Simultaneously with the input, the sensor/collected cell unit 101 automatically performs calculation comparison of the heat input amount and bead length matching comparison, and if there is an abnormality in each, the controller 101
and is displayed and output to the terminal device 1. This calculation/comparison is performed by the CPU of the system controller 102.
22 can also be executed. These results also apply to RAM8 of the sensor/acquisition cell unit.
When a certain capacity is reached, the data is sequentially transmitted and recorded to the hard disk 17 of the controller through the multiplexer panel 11a, the multiplexer 11b, and various interfaces.

(Work 51): In the case of heat input abnormality, the supervisor checks the abnormality improvement process and cancels the alarm including the terminal device 1.

(Work 37): The welder confirms the heat input amount of each bead and the average heat input amount using the terminal device 1, and reflects it in the next construction.

Terminals 7a and 7b that enter the sensor unit in Fig. 2
are connected to the welding machine's voltmeter and ammeter, respectively. Regarding the relationship between various characteristic values and the limitations of characteristic values, (1) Relationship between characteristic values The data input from the welding terminal includes the preheating temperature and interpass temperature set by the welder. , weld length, etc., which are necessary for comparing the target preheating pass temperature with the standard value and calculating the heat input amount.

In addition, the data detected by the sensor is the automatically measured welding current, welding voltage, and welding time, which are the basis of welding calculations, and is essential for real-time heat input display in parallel with welding work. refers to data. Note that calculation and evaluation of heat input per unit length of welding are well known.

(2) Limitation of characteristic values It is necessary to limit the role of characteristic values as described above until the target welding heat input is calculated and measured, and these are as described in the examples.

[Effects of the Invention] Since the present invention is configured as described above, it has the following excellent effects.

(1) Since the sensor and acquisition cell are integrated into a portable unit, it can be installed freely and effectively even with scattered welding power sources. Furthermore, since the optical fiber cable of the terminal device can be wired integrally with the welded conduit cable, preparation for installation can be easily carried out, which is highly practical.

(2) The sensor/acquisition cell unit can automatically determine the start and end of welding.

(3) The acquisition cell also has a CPU that can calculate, judge, and record the preheating pass temperature, heat input, etc. based on the welding condition values based on the input from the terminal, and the sensor/acquisition cell unit is distributed. have

Therefore, a large number of terminal devices can be controlled by one controller. (Example: 15 terminals/controller) (4) It is possible to compare and record the temperature between preheating passes input from the terminal with the standard value, and in the event of an abnormality, an alarm is automatically displayed on the terminal and controller. can be done.

In addition, in parallel with the work, confirmation by the welder himself and by the supervisor using the monitor terminal can be made at the same time.

(5) Various measurement attribute values such as welder number, rod lot number, and joint number, as well as various measurement values such as preheating temperature and bead length, can be input from the terminal, and preheating by the welder itself can be performed in parallel with the work. It is possible to check the interpass temperature and heat input, and the supervisor can check it on the monitor terminal.

(6) It is possible to continuously weld any number of welds (up to about 30 welds) due to the distributed arrangement of sensor/acquisition cell units with calculation and comparison/judgment functions. Therefore, work efficiency can be dramatically increased.

(7) Bead length management can also be performed to match weld length input.

(8) Therefore, for many welders with terminal equipment,
A single supervisor can perform high-density monitoring of parallel welding conditions (abnormal value alarms, etc.). In addition, it is possible to reduce the number of man-hours required for measurement and recording, and to reflect the information in a timely manner in construction, thereby improving welding quality.

[Brief explanation of drawings]

FIG. 1 is a diagram showing the configuration of a first embodiment of the present invention,
FIG. 2 is an elemental block diagram of the first embodiment, FIG. 3 is a diagram showing the configuration of the second embodiment of the present invention, FIG. 4 is an elemental block diagram of the second embodiment, and FIG. 5 is the same as that of the first embodiment. FIG. 3 is a diagram showing an example of the configuration of the terminal panel, FIG. 6 is a diagram for explaining the functions of the first to second embodiments of the present invention, and FIG. 7 is a diagram showing the functions of the first to second embodiments of the present invention. 2
FIG. 8, which is a diagram showing the operation flow of the embodiment, is a functional block diagram of the first embodiment. 1...Terminal device, 3...Welding torch, 5...Optical fiber cable, 7...Sensor unit, 8...
Welding power source, 9... Acquisition cell, 10... Cable,
11a...Multiplexer panel, 11b...Multiplexer, 13...Monitor terminal, 14
...Keyboard, 15...Printer, 16...
Floppy disk, 60...Welding work instruction card A, 100...Controller section, 101...Sensor/acquisition cell unit, 102...System controller, 103...Peripheral equipment.

Claims (1)

[Scope of Claims] 1. In an automatic welding measurement and recording device consisting of a welder terminal 1, a controller 100, and a sensor/acquisition cell unit 101, the sensor/acquisition cell unit 101 is composed of a sensor unit 7 and an acquisition cell unit 9, and the sensor unit 7 consists of an A/D converter 101a and a welding condition counting section 101b, and the acquisition cell unit 9 includes an arithmetic/comparison/judgment section 101c and a storage section 101.
The controller 100 is made up of a system controller 102 and a peripheral device 103, and the system controller 102 is made up of a communication control section 100a, an arithmetic/comparison/determination section 100b, and a storage section 100c. The device 103 includes an input section 100d, a display section 100e, a storage section 100f, and an output section 100g. The welder terminal 1 consists of an input section 111a, a display section 111b, and a communication control section 111c. The D converter 101a inputs the signal from the welding power source 8, and inputs the signal from the welding condition counter 1.
01b detects the start and end of welding based on the signal input from the A/D converter 101a, and measures the welding current, voltage, and arc time. The calculation/comparison/judgment section 101c of the acquisition cell unit can be freely arranged in the welding power sources scattered in various
inputs signals from the welding condition counting section 101b and the storage section 101d, and also inputs signals from the communication control section 101e.
Welder terminal 1 and controller 10 via
A signal from 0 is input, and the welding condition value is compared and determined with the standard value of the temperature between preheating passes, and the heat input is calculated and determined, and is output to the storage unit 101d, and is sent to the welder via the communication control unit 101e. The calculation/comparison/judgment section 100b of the controller outputs the signals from the storage section 100c and the input section 100d to the welder's terminal 1 which is input via the communication control section 100a.
Based on the signals from the sensor/acquisition cell unit 101, the inter-preheating pass temperature and average heat input are calculated and recorded for each bead, compared again with the standard values, and the comparison and judgment results are automatically displayed. The display section 100e of the controller is output to the display section 111b of the welder's terminal via the display section 100e and the communication control section 100a of the controller, and is also output to the storage section 100c. The input section 111a of the welder's terminal outputs various data to the display section 111b, and the communication control section. 1
11c to the sensor/acquisition unit 101 and the controller 100, and the display section 111b displays the signal from the input section 111a. It is characterized by displaying the signal, performing alarm and verification functions, and allowing the welder with the terminal device and the person monitoring the controller to check and manage various data such as the temperature between preheating passes and the amount of heat input in parallel with the welding status. Automatic measurement and recording device for welding conditions.