CN108544148B - Suspension spot welding spot leakage-proof monitoring device - Google Patents
Suspension spot welding spot leakage-proof monitoring device Download PDFInfo
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- CN108544148B CN108544148B CN201810523912.5A CN201810523912A CN108544148B CN 108544148 B CN108544148 B CN 108544148B CN 201810523912 A CN201810523912 A CN 201810523912A CN 108544148 B CN108544148 B CN 108544148B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
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- Engineering & Computer Science (AREA)
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Abstract
The invention discloses a suspension spot welding spot leakage-proof monitoring device, which is characterized in that a power supply sampling module is used for sampling power supply signals of a monitored welding machine through a sampling circuit; the sampling conversion module is provided with a sampling conversion circuit, the sampling conversion circuit is provided with a counter, an electromagnet and a Hall switch sensor, the counter and the electromagnet establish a connection relationship, and the electromagnet and the Hall switch sensor establish a connection relationship; the cylinder operation monitoring module is used for introducing an operation power supply signal of the cylinder into the monitoring device to form welding spot leakage-proof monitoring auxiliary control; the welding machine control module is used for performing operation control on the welding machine to be monitored; the gun handle remote resetting module is used for resetting the gun handle working state of the welding machine to be monitored; the alarm prompt module is used for carrying out alarm prompt after the welding machine to be detected completes welding work. The invention solves the problem of welding spot leakage in the existing production process, realizes real-time monitoring of the welding spot number of the workpiece, prevents quality accidents caused by less or no welding spot number of workers, and improves production benefits.
Description
Technical Field
The invention relates to the technical field of suspension spot welding, in particular to a suspension spot welding spot leakage-proof monitoring device.
Background
The suspension welding is also called suspension welding, and is a machining mode in which a workpiece is fixed and a welding tongs moves, and is mainly used for welding low-carbon steel, low-alloy steel, stainless steel, plating steel, plates and round steel which cannot be or are inconvenient to weld by a general fixed welding machine. It is widely used in the industries of automobiles, rolling stock, burglary-resisting doors, cabinets, household appliances, buildings, silk screen spot welding, etc. When the suspension type spot welder is used for welding, a workpiece is firstly positioned between welding tongs electrodes, then a welding switch is pressed down, a 'pressurizing' program section is started, an electromagnetic air valve acts, compressed air enters a welding machine cylinder to enable the welding tongs electrodes to act, the workpiece is pressed tightly, a 'welding' program section is started after proper time delay, at the moment, a primary coil of a welding transformer is connected with a power supply through control of a silicon controlled rectifier, a secondary coil generates welding current, the workpiece is welded, after the 'welding' program section is finished, the primary coil of the transformer is powered off, the welding machine enters a 'maintaining' program, after the pressure is maintained for a period of time, the electromagnetic air valve is disconnected, the welding tongs release the workpiece, and the welding machine enters a 'rest' program. At this point a welding cycle has been completed.
With the development of modern society, more people purchase automobiles and the requirements on the quality of the automobiles are higher, so that manufacturers try to control the operation of each link with increased force, and strive to improve the quality of products. In the actual situation, some workpieces have two or thirty welding spots or more, workers can miss the workpieces by a little negligence, and the quality of the products is affected to a certain extent, so that certain economic losses are caused for companies and production workers, and high-risk marks are often hung in assembly factories. No matter how careful the workers are, a series of quality accidents such as welding spot leakage, nut loss and the like are avoided.
For many years, improvement and gradual perfection are continuously carried out, and various welding machine manufacturers are also tried to develop, and the requirements of the process can not be met whether the welding machine is in a machine or out of the machine, whether discrete components or integrated circuits are arranged, quality accidents of low welding rate occur when welding is omitted, and whether the welding machine is an assembly general plant or a fitting supplier, the quality accidents are very troublesome, so that a technical scheme is needed to solve the problems faced by the prior art.
Disclosure of Invention
The invention aims to provide a suspension spot welding spot leakage-proof monitoring device, which aims to solve the problem of spot welding leakage in the existing production process, realize real-time monitoring of the number of welding spots of workpieces, prevent quality accidents caused by few or missed welding spots of workers, improve the welding technology, reduce the trouble of dead counting of the workers, namely lighten the mental labor of the workers, and further improve the production benefit.
In order to achieve the above purpose, the technical scheme of the invention is as follows: the monitoring device comprises a box body, wherein a central processing unit is arranged in the box body, and the monitoring device further comprises a power supply sampling module, a sampling conversion module, a cylinder operation monitoring module, a welding machine control module, a gun handle remote reset module and an alarm prompting module; the power supply sampling module is used for sampling power supply signals of the monitored welding machine through the sampling circuit; the sampling conversion module is provided with a sampling conversion circuit, the sampling conversion circuit is provided with a counter, an electromagnet and a Hall switch sensor, the counter and the electromagnet are connected, and the electromagnet and the Hall switch sensor are connected; the cylinder operation monitoring module establishes a connection relation with the central processing unit, and is used for introducing an operation power supply signal of the cylinder into the monitoring device to form welding spot leakage-proof monitoring auxiliary control; the welding machine control module establishes a connection relationship with the central processing unit and the alarm prompting module, and is used for controlling the operation of the welding machine to be monitored; the gun handle remote resetting module is used for resetting the gun handle working state of the welding machine to be monitored; the alarm prompting module is used for prompting an alarm after the welding machine to be detected finishes the welding work.
The monitoring device for the leakage prevention of the suspension spot welding spots further comprises a flow indication module, wherein the flow indication module is connected with the central processing unit, is provided with a flow indication lamp, and is used for indicating the welding flow of the welding machine to be monitored.
The monitoring device for the leakage prevention of the suspension spot welding spots further comprises a display module, wherein the display module is connected with the central processing unit, the display module is used for displaying welding counts of the welding machine to be monitored, the display module is provided with a display, and the display is connected to the outer side of the box body.
The monitoring device for the leakage prevention of the suspension spot welding spots further comprises a preset module, wherein the preset module is used for establishing a connection relation with the central processing unit, and the preset module is used for setting the number of the welding points of the suspension spot welding monitoring spots. Before the device is used, the number of the beating points of the welded workpiece is preset, and as the alarm prompt module is designed, after the welding of the workpiece is finished, a stop signal is sent out by the monitoring counter, so that the welding machine stops working, and the alarm lamp flashes and sends out alarm sound to prompt that the welding of the workpiece is finished. If the worker has finished beating but has no alarm prompt, the worker needs to check the missing welding spot, and the missing welding spot workpiece is prevented from flowing into the next working procedure, so that the welding quality of the product can be completely ensured.
According to the suspension spot welding spot leakage-proof monitoring device, the power supply sampling module, the sampling conversion module, the air cylinder operation monitoring module and the welding machine control module are connected with the welding machine controller of the welding machine to be monitored. The welder controller and the central processing unit are positioned in the suspension welding spot leakage-proof monitoring device.
The monitoring device is provided with 10 pin connectors for connecting control wires.
According to the suspension welding spot leakage-proof monitoring device, the electromagnet comprises the iron core, the iron core comprises the core body and the magnetic loop shell, and the core body is inserted into the center of the magnetic loop shell.
According to the suspension spot welding spot leakage-proof monitoring device, the periphery of the electromagnet is covered with the enameled wire, and the enameled wire is wound in the hollow I-shaped wire die framework.
According to the suspension spot welding spot leakage-proof monitoring device, the electromagnet is connected with the supporting seat, and the upper end of the supporting seat is connected with the Hall switch sensor.
According to the suspension spot welding spot leakage-proof monitoring device, the sampling circuit is connected to a power supply of the welding machine and is provided with the transformer and the rectifier bridge, and the rectifier bridge is connected with the electromagnet.
The invention has the following advantages: the power supply is sampled at the single-phase 380v alternating voltage of the inlet power supply, the welding signal is sourced from the sampling circuit, the welding transformer power supply of the welding machine is subjected to voltage reduction rectification, and then the Hall switch sensor is operated in a switch state through a strong magnetic field generated by an electromagnet, so that a counting signal is input to the counter, repeated counting caused by vibration of a relay contact due to instantaneous drop of the power supply voltage when the welding transformer works and counting distortion (inaccuracy) caused by reaction lag of the relay when a welding spot is emphasized are effectively prevented, the empty counting of equipment when an electrode is wrongly repaired or when the welding spot is debugged (only a cylinder works and a silicon controlled rectifier is not conducted) is completely avoided, the aim of accurate counting is fulfilled, quality accidents caused by few or missed welding points are prevented, the trouble of dead point counting of workers is reduced, the mental labor of workers is reduced, and the production benefit is improved.
Drawings
FIG. 1 is a diagram of a box structure and a panel of a suspension spot welding spot leakage-proof monitoring device;
FIG. 2 is a schematic diagram of a suspension spot weld leakage monitoring device;
FIG. 3 is a schematic circuit diagram of a suspension spot weld leakage monitoring device;
FIG. 4 is a diagram of the number of the faucet wire of the suspension spot weld leakage monitoring device;
FIG. 5 is a schematic diagram of an electromagnet core of a suspension spot weld leakage monitoring device;
FIG. 6 is a schematic illustration of an electromagnet enameled wire of a suspension spot weld leakage monitoring device;
FIG. 7 is a schematic illustration of an electromagnet assembly of a suspension spot weld leakage monitoring device.
Detailed Description
The following examples are illustrative of the invention and are not intended to limit the scope of the invention.
Referring to fig. 1, 2 and 3, the monitoring device for preventing leakage of a suspension spot welding spot comprises a box body 1, wherein a central processing unit 2 is arranged in the box body 1, and the monitoring device further comprises a power supply sampling module 3, a sampling conversion module 4, a cylinder operation monitoring module 5, a welding machine control module 6, a gun handle remote reset module 7 and an alarm prompting module 8; the power supply sampling module 3 establishes a connection relation with the central processing unit 2, and the power supply sampling module 3 is used for sampling power supply signals of the monitored welding machine through a sampling circuit; the sampling conversion module 4 establishes a connection relation with the central processing unit 2, the sampling conversion module 4 is provided with a sampling conversion circuit, the sampling conversion circuit is provided with a counter, an electromagnet 11 and a Hall switch sensor 15, the counter establishes a connection relation with the electromagnet 11, and the electromagnet 11 establishes a connection relation with the Hall switch sensor 15; the cylinder operation monitoring module 5 establishes a connection relation with the central processing unit 2, and the cylinder operation monitoring module 5 is used for introducing an operation power supply signal of a cylinder into a monitoring device to form welding spot leakage-proof monitoring auxiliary control; the welding machine control module 6 establishes a connection relationship with the central processing unit 2 and the alarm prompting module 8, and the welding machine control module 6 is used for controlling the operation of the welding machine to be monitored; the gun handle remote resetting module 7 establishes a connection relation with the central processing unit 2, and the gun handle remote resetting module 7 is used for resetting the gun handle working state of the welding machine to be monitored; the alarm prompting module 8 is used for prompting an alarm after the welding machine to be detected completes the welding work.
In one embodiment of the suspension spot welding spot leakage-proof monitoring device, the monitoring device further comprises a flow indication module 9, the flow indication module 9 establishes a connection relationship with the central processing unit 2, the flow indication module 9 is configured with a flow indication lamp, and the flow indication module 9 is used for performing welding flow indication on the welding machine to be monitored. The monitoring device further comprises a display module 10, the display module 10 and the central processing unit 2 are connected, the display module 10 is used for displaying welding counts of the welding machine to be monitored, the display module 10 is provided with a display, and the display is connected to the outer side of the box body 1.
In one embodiment of the suspension spot welding spot leakage-proof monitoring device, the monitoring device further comprises a preset module 17, the preset module 17 establishes a connection relationship with the central processing unit 2, and the preset module 17 is used for setting the number of the welding points of the suspension spot welding spot. Before the device is used, the number of the beating points of the welded workpiece is preset, and as the alarm prompt module 8 is designed, after the welding of the workpiece is finished, a stop signal is sent out by the monitoring counter, so that the welding machine stops working, and the alarm lamp flashes and sends out alarm sounds to prompt that the welding of the workpiece is finished. If the worker has finished beating but has no alarm prompt, the worker needs to check the missing welding spot, and the missing welding spot workpiece is prevented from flowing into the next working procedure, so that the welding quality of the product can be completely ensured.
In one embodiment of the suspension spot welding spot leakage-proof monitoring device, the power supply sampling module 3, the sampling conversion module 4, the cylinder operation monitoring module 5 and the welding machine control module 6 are connected with a welding machine controller of the welding machine to be monitored. The monitoring device is provided with a 10-pin socket which is used for connecting a control wire.
In one embodiment of the suspension spot weld leakage monitoring device, the electromagnet 11 comprises a core comprising a core 12 and a magnetic circuit housing 13, wherein the core 12 is inserted into the center of the magnetic circuit housing 13. The periphery of the electromagnet 11 is covered with an enameled wire 16, and the enameled wire 16 is wound in a hollow I-shaped wire die skeleton. The electromagnet 11 is connected with a supporting seat 14, and the upper end of the supporting seat 14 is connected with the Hall switch sensor 15.
In one embodiment of the suspension spot weld leakage monitoring device, the sampling circuit is connected to the power supply of the welder, the sampling circuit is provided with a transformer and a rectifier bridge, and the rectifier bridge is connected with the electromagnet 11.
Referring to the following table selection materials, the assembly description is carried out on the suspension spot welding spot leakage-proof monitoring device:
| name of the name | Specification of specification | Unit (B) | Quantity of |
| Technical relay | JDM1-9L-N/AC380V | Bench | 1 |
| Hall switchSensor for detecting a position of a body | NJK-8002C | Personal (S) | 1 |
| Small relay | MY2NJ/DC24V | Personal (S) | 1 |
| Small relay | MY2NJ/AC24V | Personal (S) | 1 |
| Small relay | MY2NJ/AC380V | Personal (S) | 1 |
| Rectifying full bridge | RS201(202) | Personal (S) | 1 |
| Ship type switch | KCD4-202N | Personal (S) | 1 |
| Aviation plug | YD32-10/2P | Personal (S) | 2 |
| Indicating lamp | JR-M8/AV24V | Personal (S) | 3 |
| Alarm indicator lamp | AD16-22SM/Y(AC24V) | Personal (S) | 1 |
| Reset button | JSFSAN/Φ16 | Personal (S) | 1 |
| Cable with improved cable characteristics | RVV1X10/AC500V | M | 1.2 |
| Mode track | MM | 90 | |
| Self-made control box | 350×200×100 | Personal (S) | 1 |
Referring to the panel design of fig. 1, the box (350×200×100) is manufactured, and the back cover can be detached;
a disc core is welded in the box body and used for fixing the transformer and the relay track, and the paint spraying or baking can be performed after the mounting holes are reserved;
an electromagnet core and a magnetic circuit shell are manufactured according to fig. 5;
an electromagnet coil was fabricated according to fig. 6;
the hall switch sensor is assembled according to fig. 7;
a switch, a counter, a flow indicator lamp, an alarm lamp and the like are arranged on the panel;
a transformer, a relay, a rectifier bridge, a Hall switch sensor assembly and the like are arranged in a box body;
making a socket according to the wire number welding of fig. 4;
connecting the control lines according to the schematic diagram of fig. 3;
after confirming the error, the welding machine is arranged beside a welding machine control box;
accessing each control line into a welder control box according to the schematic diagram of fig. 3;
the remote reset switch is arranged on an operating handle of the welding machine, and a control wire is connected;
after confirming no error, electrifying the machine for testing, and putting into use after the debugging is qualified.
The sampling circuit samples the single-phase voltage of the inlet power supply, the sampling conversion circuit of the welding current is that after the welding machine transformer power supply is reduced and rectified, the Hall switch sensor 15 is operated in a switch state by the strong magnetic field generated by the electromagnet 11 to input a counting signal to the counter, thereby effectively preventing repeated counting caused by vibration of a relay contact caused by instantaneous drop of the power supply voltage when the welding machine transformer works and counting distortion (inaccuracy) caused by delay of the relay response when the welding spot is emphasized.
The cylinder operation monitoring module 5 introduces the monitoring device through the operation power supply of the cylinder to form auxiliary control conditions, and the flow indicator module 9 displays the working flow of the monitor by the panel light. After the welding of the workpiece is finished, a stop signal is sent out by the monitoring counter, so that the welding machine stops working, and the alarm prompt module 8 flashes through the alarm lamp and sends out an alarm sound prompt: the workpiece is welded. If the worker has finished beating but has no alarm prompt, the missing welding spots of the workpiece are indicated, the worker checks, the missing welding spot workpiece is prevented from flowing into the next process, and therefore the welding quality of the product is completely guaranteed.
While the invention has been described in detail in the foregoing general description and specific examples, it will be apparent to those skilled in the art that modifications and improvements can be made thereto. Accordingly, such modifications or improvements may be made without departing from the spirit of the invention and are intended to be within the scope of the invention as claimed.
Claims (10)
1. The utility model provides a suspension spot welding spot leak protection monitoring devices, monitoring devices includes the box, the inside central processing unit that is equipped with of box, its characterized in that: the monitoring device also comprises a power supply sampling module, a sampling conversion module, a cylinder operation monitoring module, a welding machine control module, a gun handle remote resetting module and an alarm prompting module; the power supply sampling module is used for sampling power supply signals of the monitored welding machine through the sampling circuit; the sampling conversion module is provided with a sampling conversion circuit, the sampling conversion circuit is provided with a counter, an electromagnet and a Hall switch sensor, the counter and the electromagnet are connected, and the electromagnet and the Hall switch sensor are connected; the cylinder operation monitoring module establishes a connection relation with the central processing unit, and is used for introducing an operation power supply signal of the cylinder into the monitoring device to form welding spot leakage-proof monitoring auxiliary control; the welding machine control module establishes a connection relationship with the central processing unit and the alarm prompting module, and is used for controlling the operation of the welding machine to be monitored; the gun handle remote resetting module is used for resetting the gun handle working state of the welding machine to be monitored; the alarm prompting module is used for prompting an alarm after the welding machine to be detected finishes the welding work;
the sampling circuit samples the single-phase voltage of the inlet power supply, the sampling conversion circuit of the welding current inputs the counting signal to the counter by the magnetic field generated by the electromagnet after the welding transformer power supply is reduced and rectified, and the Hall switch sensor works in the switch state.
2. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the monitoring device further comprises a flow indication module, wherein the flow indication module establishes a connection relationship with the central processing unit, the flow indication module is provided with a flow indication lamp, and the flow indication module is used for carrying out welding flow indication on the welding machine to be monitored.
3. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the monitoring device further comprises a display module, the display module establishes a connection relationship with the central processing unit, the display module is used for displaying welding counts of the welding machine to be monitored, the display module is provided with a display, and the display is connected to the outer side of the box body.
4. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the monitoring device further comprises a preset module, wherein the preset module establishes a connection relation with the central processing unit, and the preset module is used for setting the number of the beating points of the suspension spot welding monitoring welding spots.
5. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the power supply sampling module, the sampling conversion module, the cylinder operation monitoring module and the welding machine control module are connected with a welding machine controller of the welding machine to be monitored, and the welding machine controller is located in the box body.
6. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the monitoring device is provided with a 10-needle socket which is used for connecting a control wire.
7. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the electromagnet comprises an iron core, wherein the iron core comprises a core body and a magnetic circuit shell, and the core body is inserted into the center of the magnetic circuit shell.
8. The suspension spot weld leakage prevention monitoring device as defined in claim 7 wherein: the periphery of the electromagnet is covered with an enameled wire, and the enameled wire is wound in a hollow I-shaped wire mould framework.
9. The suspension spot weld leakage prevention monitoring device as defined in claim 7 wherein: the electromagnet is connected with a supporting seat, and the upper end of the supporting seat is connected with the Hall switch sensor.
10. The suspension spot weld leakage prevention monitoring device according to claim 1, wherein: the sampling circuit is connected to a power supply of the welding machine and is provided with a transformer and a rectifier bridge, and the rectifier bridge is connected with the electromagnet.
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| CN201810523912.5A CN108544148B (en) | 2018-05-28 | 2018-05-28 | Suspension spot welding spot leakage-proof monitoring device |
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| CN110681969A (en) * | 2019-09-25 | 2020-01-14 | 广州潮创自动化科技有限公司 | Intelligent control device with welding stroke detection function for fixed welding machine and control method thereof |
| CN110614466A (en) * | 2019-10-28 | 2019-12-27 | 格力电器（芜湖）有限公司 | Spot welder monitoring system and spot welding equipment |
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