CN104379291B - For monitoring the system and method for welding quality - Google Patents

Abstract

A kind of arc welding system and method.System can according to the variable during waveform condition monitoring welding procedure the weight correspondingly determining described variable, the defect of detection weld seam, the possible reason of diagnosis defect, quantify weld seam total quality, obtain and use represents the data of good weld seam, the yield improving automatic soldering technique and quality control, solder technology that teaching is correct, the cost savings of welding procedure and obtaining of differentiating are used as difference welding procedures or application pre-set most preferably weld setting.

Description

For monitoring the system and method for welding quality

Related application:It is submitted that the application continues (CIP) patent application as part, and described continuation in part patent application is wanted Ask the U.S. Patent application No.12/775 that on May 7th, 2010 submits to, the priority of 729 and rights and interests, described U.S. Patent application No.12/775,729 require on November 13rd, 2009 submit to U.S. Provisional Patent Application No.61/261,079 priority and Rights and interests, the complete disclosure of described patent application is incorporated herein by quoting.

Technical field

Present general inventive concept relates to electric arc welding, more specifically, relates to the system of following purpose, method and dress Put: monitoring welding procedure during variable and correspondingly determine variable weight, quantify welding quality, obtain and use expression The data of good welds, improve the yield of automatic Welding Process and just improve the quality control of automatic Welding Process, teaching True solder technology, the cost savings of (identify) welding procedure and obtaining of differentiating are used as different welding procedures or application Pre-set most preferably welds setting.

Background technology

Many different conditions and parameter have contribution to the total quality of final welding.Therefore, the manufacturer of arc welder is Attempt monitoring welding machine operation, with determine welding quality and welding machine operate in production equipment during efficiency.Authorizing United States Patent (USP) No.6 of Vaidya, illustrates a kind of trial of monitoring arc welder in 051,805 (calling " Vaidya " in the following text), its In, use computer or other programmable instruments to come average current and the efficiency of monitoring weld operation, the efficiency quilt of welding operation It is expressed as the ratio of the time performing welding and the total time of work shift.According to standard technique, this disclosed monitoring system Including first control circuit, this first control circuit uses the CPU with standard accessory (such as RAM and EPROM) Form.Second control circuit is connected to the first circuit, to input during monitoring process and output information.Watch-dog is being disclosed For gather information in the time period of continuity a few hours or up to 999 hours.Watch-dog determines welding efficiency and monitors for really Determine the time of average current and for accumulative electric arc weld interval of whole efficiency.

Vaidya discloses monitor current and feed rate of welding wire and the ability of air-flow during welding process.All this The information of kind is stored in applicable storage device, for the operating characteristic recovering welding machine during welding procedure subsequently.With this Mode, can measure the productivity of welding machine, to calculate cost efficiency and other parameters.As advised in Vaidya, other manufacture Business has attempted measuring the average current during welding procedure by monitoring arc welder.But, during measuring welding procedure Average current, voltage, feed rate of welding wire or other parameters and use such data to record the performance of welding operation also Unsatisfactory.In the past, just monitored parameter understood the most in advance by supervising device.

Therefore, even if using the technology illustrated in Vaidya to monitor such as electric current, voltage even welding wire in the past and sending Enter the parameter of speed, response has caused confusion and the practical stability of electric arc cannot have been determined or weldering cannot be judged Connect technique and be above or below desired parameters value.The most such information must be known: refusal accepts (reject) weld cycle and/or determine the quality of the welding carried out during this weld cycle with required precision.In a word, prison Control is for the operation of arc welder of various welding procedures unsatisfactory, because it is real not may be used for evaluating welding procedure Execute the existing knowledge of the welding procedure of period.

In order to overcome these shortcomings, authorizing United States Patent (USP) No.6 of Hsu, 441,342 (calling " Hsu " in the following text) disclose and work as welding machine The Arc Welding Process performing to be selected monitors watch-dog and the method for arc welder when creating the information about welding machine operation.Cause This, the application of the high power computer technology of standard can make based on the intelligent data that identical precision and watch-dog produce With.The watch-dog of Hsu and monitoring system use the Given information during welding procedure.This information is fixing, does not change.Prison The particular aspects paying close attention to welding procedure concentrated by control device, to use the priori suitable with actual performance.Therefore, in welding procedure Particular aspects during, determine the stability of selected parameter and qualified size or level.Before monitoring, with known required Welding procedure is divided into multiple regular time section by parameter.It is then possible to process this data by known computer technology, to comment The each side of valency weld cycle.

Hsu discloses and performs welding procedure by the arc welder of a series of quick repetitive patterns of generation.Each waveform Constitute the weld cycle with a circulation time.Each weldering is created by the known waveform generator operated for controlling welding machine Connect circulation (that is, waveform).These waveforms are divided into multiple state, such as the multiple states being divided in pulse welding technique, i.e. background (background) electric current, acclivity, peak point current, decline slope and the state subsequently back into background current.By inciting somebody to action Known drive waveforms is divided into multiple states of the time period being defined as produced arc characteristic, can monitor these shapes Any one state selected in state.It is in fact possible to the many states of multiplexing.Such as, in pulse welding technique, Ke Yijian Control the state relevant to peak point current.Hsu discloses by monitoring so that the two-forty of preferably more than 1.0kHz is read out The state of welding procedure.During each peak current condition of the waveform used in pulse welding technique, each reality of repeated detection Welding parameter, e.g., electric current, voltage or even feed rate of welding wire.In this way, in the monitoring process phase of peak current condition Between, have ignored acclivity, decline slope and background current.

Therefore, by this peak point current compared with known peak point current.The function that can use peak point current detects Change from the true peak electric current of arc welder output.In Hsu, use order (command) peak point current downside and The minimum level of high side and maximum horizontal, repeatedly to determine peak point current during each peak current condition of pulse welding waveform Level.No matter when electric current exceedes maximum or less than minima, counts this event during each waveform.Butt welding Connect total deviation or the event of time (that is, performing welding procedure or its certain pith duration) to count.As Really this count value exceedes each waveform or the setting number during weld interval, then can send alarm, alerts this specific weld work Skill experienced by less desirable welding situation.If it is true that count value exceedes maximum horizontal, then refusal (reject) this welding. This ability program poor with statistical standard is used together, and repeatedly reads peak electricity during each peak current condition of waveform Stream, to sense standard extent.Calculate it practice, this standard deviation is root-mean-square (RMS) difference carried out by computer program. In Hsu, calculate average peak current and record this peak point current and Realize and stability features.Also determine that just by The RMS of the curtage of each state (such as, the peak current condition of impulse waveform) of monitoring.In monitoring peak current level Or during standard increment, the background current stage can be monitored by levels of current and persistent period.

Hsu discloses the state in selection waveform and by needed for this state and known command signal and monitored shape During state, the actual parameter of welding procedure compares.This selection priori based on waveform generator.Such as, in specific weldering Under silk feed rate WFS1, waveform generator is programmed, to regulate peak point current to control arc length.Then, when with When this feed rate of welding wire WFS1 is welded, " being notified " watch-dog selects peak point current section as monitored state. But, under another feed rate of welding wire WFS2, waveform generator is programmed, to regulate background time (background time) controls arc length (rather than peak point current).Then, when entering with this feed rate of welding wire WFS2 During row welding, " being notified " watch-dog selects background time as monitored state and parameter.By contrast, posteriority (posteriori) watch-dog is not aware that under different feeds rate of welding wire, it should the different aspect of monitoring waveform detects Arc stability.In this example, under the first feed rate of welding wire WFS1, monitor background time or be sent into speed at welding wire Monitor peak point current under degree WFS2 and would is that unusual poor efficiency.Therefore, Hsu discloses the priori waveform utilizing desirable value Time period monitor this section of waveform.Thus can actual monitored Arc Welding Process and be more than total waveform is averaging.

Compared with the normal processes only reading the output parameter experienced during welding procedure, in Hsu, the spy of this watch-dog Levy and be to employ priori.Therefore, become in time during the normal behaviour of welding machine is in terms of the only one of welding procedure Change and different time, by monitoring, enormously simplify detect this normal behaviour task.The teaching of Hsu may not apply to Monitoring voltage in constant voltage technique, because during whole weld cycle, required voltage level is known feature.But, In other welding procedures, when during the different sections of waveform, voltage and current is both varied from, the method for Hsu exists Before actual parameter monitored during accurately reading selected waveform segment, provide stability, RMS, standard deviation, meansigma methods, Low lower limit and the pin-point reading of maximum.

According to Hsu, overall output information need not be read with accurate precision to monitor time-varying welding process, such as impulse welding Connect and short circuit welding.As the seclected time in the selected state of waveform or each waveform of section, start watch-dog.Monitoring Device compares actual parameter and desired parameters with the form guiding the command signal of welding machine electric power.In Hsu, can be only at waveform It is monitored during some particular segments；But, in anomalous event, such as, when the arc is extinguished or when a short circuit occurs, logical Overvoltage sensing or current sense realize the subprogram of computer operation, to restart electric arc and/or to correct short circuit.These events Subprogram and monitoring programme parallel running.Therefore, these abnormal integrated operations not interfering with watch-dog.These subprogram quilts It is configured to abnormal state or time period.By in the way of as mentioned above similar, monitor the parameter in the state of these exceptions or Signal.

In Hsu, for operation or the purpose of efficiency of evaluation welding machine, can add up about calendar time, changing shifts even It it is the manufacturing information of operator.Particular segment or state by monitoring waveform monitor each weld cycle, it is possible to add up at any time Between passage and the undesirably event that experiences.So can also carry out trend analysis so that defective in the actual generation of welding procedure Production weld seam (production welds) before, operator can take error correction.Divided by trend analysis, defect Analysis, accumulative defect, the monitoring in real time of charging to and arc welder is correlated with of all these project, it is possible to directly enter with immediate mode Row interference, to take the preventive measure relative with error correction.

Summary of the invention

Total inventive concept be susceptible to the variable during monitoring welding procedure the weight correspondingly determining described variable, Quantify welding quality, obtain and use the data of expression good welds, detection weld defect and the possibility of diagnosis weld defect The system of reason, method and apparatus.Welding quality data consider output increased and the automatic welding of automatic Welding Process The quality control of technique, instruct correct solder technology, differentiate the cost savings of welding procedure and obtain being used as difference welding Technique or application pre-set most preferably weld setting.Illustrate by way of example and present general inventive concept disclosed herein Various aspects, multiple example system, method.

According to an exemplary, disclosing a kind of method monitoring arc welder, described method is by creating Actual welding parameter between the welding wire and the workpiece that advance thus the monitoring when arc welder performs selected Arc Welding Process Described arc welder, described selected technique is controlled by the command signal of the power supply of described welding machine.Described method includes: (a) produces The waveform of raw a series of quick repetitions, each waveform constitutes the weld cycle with a circulation time；B described waveform is divided by () Become multiple state；(c) within the time period, to inquire the selected welding ginseng that speed measurement occurs in a described waveform state Number, to obtain the data acquisition system of the welding parameter selected；D (), for each time period, calculates described choosing from described data acquisition system The stability value of fixed welding parameter；(e) by each stability value with expection stability value compared with, to judge described stability Whether the difference of value and described expection stability value exceedes predetermined threshold；And if (f) described difference exceedes described threshold value, then based on Described difference, determines the weight of described stability value with size weight (magnitude weight), and based on waveform state phase Time for its waveform contributes (contribution), determines the weight of described stability value with time contribution weight.With this Mode, described method can assign multiple power to the parameter (that is, the item in data acquisition system) that records constituting isolated point (outlier) Weight (such as, deviation based on its state and the degree/size of time contribution).In an exemplary embodiment, will be isolated The measured value of the welding parameter outside the limit value of three (3) the individual standard deviations that point is defined as the meansigma methods in deviation welding parameter. It is contemplated that for the watch-dog integrated with arc welder performing this illustrative methods.

According to an exemplary, disclosing a kind of method quantifying welding quality, described method is by creating Actual welding parameter between the welding wire and the workpiece that advance thus the monitoring when arc welder performs selected Arc Welding Process Described arc welder quantifies welding quality, and described selected technique is controlled by the command signal of the power supply of described welding machine.Described Method includes: (a) produces the waveform of a series of quick repetition, and each waveform constitutes the weld cycle with a circulation time；(b) Described waveform is divided into multiple state；In c time period that () repeated during weld interval, to inquire that speed measurement is at one Or the multiple selected welding parameter occurred in more described state；And (d) based on during the time period to described selected The described measurement of welding parameter, calculates multiple mass parameters of each described state, and wherein, described mass parameter characterizes described weldering The total quality connect is measured.It is contemplated that for the watch-dog integrated with arc welder performing this illustrative methods.

In an exemplary embodiment, described method also includes: (e) is each by calculate for each time period The value of described mass parameter is compared with corresponding prospective quality parameter value, with the quality parameter value calculated described in judgement and institute Whether the difference stating prospective quality parameter value exceedes predetermined threshold；And if (f) described difference exceedes described threshold value, then based on described Difference, with size weight determine described in the weight of quality parameter value that calculates, and based on its state relative to including described shape The time contribution of the waveform of state, with time contribution weight determine described in the weight of quality parameter value that calculates.It is contemplated that use In the watch-dog integrated with arc welder performing this illustrative methods.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, institute State time period substantially 250ms.

In an exemplary embodiment, when described selected welding parameter includes for each described state described Between in section to the counting of the described measurement that each described selected welding parameter is taked, average voltage in the described time period Voltage, the rms voltage RMSV in the described time period, voltage variance V in the described time period_var, in the described time period Average current current, the rms current RMSI in the described time period and electric current variance I in the described time period_var, its In, the described counting of the voltage sum/voltage measurement recorded in the time period described in voltage=, wherein

$\mathrm{RMSV}=\sqrt{\frac{{\mathrm{\Σ}}_{i=1}^N{\left({\mathrm{voltage}}_i\right)}^2}{N}}$

Wherein, V_var=RMSV-voltage, wherein, the electric current sum/electric current recorded in the time period described in current= The described counting measured, wherein

$\mathrm{RMSI}=\sqrt{\frac{{\mathrm{\Σ}}_{i=1}^N{\left({\mathrm{current}}_i\right)}^2}{N}}$

And wherein, I_var=RMSI-current.

In an exemplary embodiment, described mass parameter includes quantity count meansigma methods QCA of each state, institute State quantity count meansigma methods QCA to be calculated as:

$\mathrm{QCA}=\frac{{\mathrm{\Σ}}_{i=1}^N{\mathrm{count}}_i}{N}$

Wherein, N is the sum of weld cycle in the described time period, and wherein, count_iRefer to pin in the described time period Counting to the described measurement of specific one weld cycle.

In an exemplary embodiment, described mass parameter includes quantity count standard deviation QCSD of each state, Described quantity count standard deviation QCSD is calculated as:

$\mathrm{QCSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{count}}_i-\mathrm{QCA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter includes quantity count standard deviation QCSD of each state, Described quantity count standard deviation QCSD is calculated as:

$\mathrm{QCSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{count}}_i-\mathrm{QCA})}^2}{N}$

In an exemplary embodiment, described mass parameter includes quality voltage meansigma methods QVA of each state, institute State quality voltage meansigma methods QVA to be calculated as:

$\mathrm{QVA}=\frac{{\mathrm{\Σ}}_{i=1}^N{\mathrm{voltage}}_i}{N}$

Wherein, N is the sum of weld cycle in the described time period, and wherein, voltage_iIn referring to the described time period Voltage measurement for specific one weld cycle.

In an exemplary embodiment, described mass parameter includes quality voltage standard deviation QVSD of each state, Described quality voltage standard deviation QVSD is calculated as:

$\mathrm{QVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{voltage}}_i-\mathrm{QVA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter includes quality voltage standard deviation QVSD of each state, Described quality voltage standard deviation QVSD is calculated as:

$\mathrm{QVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{voltage}}_i-\mathrm{QVA})}^2}{N}$

In an exemplary embodiment, described mass parameter includes the quality current average QIA of each state, institute State quality current average QIA to be calculated as:

$\mathrm{QIA}=\frac{{\mathrm{\Σ}}_{i=1}^N{\mathrm{current}}_i}{N}$

Wherein, N is the sum of weld cycle in the described time period, and wherein, current_iIn referring to the described time period Current measurement for specific one weld cycle.

In an exemplary embodiment, described mass parameter includes quality current standard deviation QISD of each state, Described quality current standard deviation QISD is calculated as:

$\mathrm{QISD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{current}}_i-\mathrm{QIA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter includes quality current standard deviation QISD of each state, Described quality current standard deviation QISD is calculated as:

$\mathrm{QISD}=\frac{{\mathrm{\Σ}}_{i=1}^N{({\mathrm{current}}_i-\mathrm{QIA})}^2}{N}$

In an exemplary embodiment, described mass parameter includes the quality voltage mean of variance of each state QVVA, described quality voltage mean of variance QVVA are calculated as:

$\mathrm{QVVA}=\frac{{\mathrm{\Σ}}_{i=1}^N{V}_{{\mathrm{var}}_i}}{N}$

Wherein, the sum of weld cycle in N is the described time period.

In an exemplary embodiment, described mass parameter includes that the quality voltage variance criterion of each state is poor QVVSD, described quality voltage variance criterion difference QVVSD is calculated as:

$\mathrm{QVVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(V_{\mathrm{vari}}-\mathrm{QVVA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter includes that the quality voltage variance criterion of each state is poor QVVSD, described quality voltage variance criterion difference QVVSD is calculated as:

$\mathrm{QVVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(V_{\mathrm{vari}}-\mathrm{QVVA})}^2}{N}$

In an exemplary embodiment, described mass parameter includes the quality electric current mean of variance of each state QIVA, described quality electric current mean of variance QIVA are calculated as:

$\mathrm{QIVA}=\frac{{\mathrm{\Σ}}_{i=1}^N{V}_{{\mathrm{var}}_i}}{N}$

Wherein, the sum of weld cycle in N is the described time period.

In an exemplary embodiment, described mass parameter includes that the quality electric current variance criterion of each state is poor QIVSD, described quality electric current variance criterion difference QIVSD is calculated as:

$\mathrm{QIVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(I_{\mathrm{vari}}-\mathrm{QIVA})}^2}{N-1}$

In an exemplary embodiment, described mass parameter includes that the quality electric current variance criterion of each state is poor QIVSD, described quality electric current variance criterion difference QIVSD is calculated as:

$\mathrm{QIVSD}=\frac{{\mathrm{\Σ}}_{i=1}^N{(I_{\mathrm{vari}}-\mathrm{QIVA})}^2}{N}$

Similar mass parameter (e.g., such as quality feed rate of welding wire based on monitored feed rate of welding wire (WFS) Meansigma methods (QWA), quality feed rate of welding wire standard deviation (QWSD), quality feed rate of welding wire mean of variance (QWVA) and Quality feed rate of welding wire variance criterion poor (QWVSD)) mode that can also be similar to calculated.

In an exemplary embodiment, described method also includes: (e) uses the described quality represented with module Parameter evaluation welding subsequently.It is contemplated that for the watch-dog integrated with arc welder performing this illustrative methods.

According to an exemplary, disclosing a kind of method evaluating multiple welding, described method is by creating Advance welding wire and workpiece between actual welding parameter thus arc welder according to Arc Welding Process perform welding time prison Control described arc welder to evaluate according to essentially identical Arc Welding Process, multiple welderings of performing under substantially the same conditions Connecing, described selected technique is controlled by the command signal of the power supply of described welding machine.During described method is included in each welding: A () produces the waveform of a series of quick repetition, each waveform constitutes the weld cycle with a circulation time；B () is by described ripple Shape is divided into multiple state；(c) within the time period, to inquire the selected welding that speed measurement occurs in a described state Parameter, obtains the data acquisition system of described selected welding parameter；D (), for each time period, calculates from described data acquisition system The mass value of described selected welding parameter；(e) by each mass value compared with prospective quality value, to judge described mass value Whether predetermined threshold is exceeded with the difference of described prospective quality value；If f () described difference exceedes described threshold value, then based on described difference, Determine the weight of described mass value with size weight, and contribute, with the time relative to the time of its waveform based on described state Contribution weight determines the weight of described mass value；And (g) uses all described mass value obtained during described weld interval, Including the mass value of any weighting, determine the quality score of described welding.

In an exemplary embodiment, described method also includes: if the quality score of (h) described welding is in quality In first preset range of score, then refusal accepts described welding；And if the quality score of (i) described welding obtains in quality In the second preset range divided, then accept described welding.

In an exemplary embodiment, described method also includes: (h) makes the quality score that each welding is corresponding For good and all it is associated.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, institute Stating the time period is about 250ms.

In an exemplary embodiment, described selected welding parameter is arc current.An exemplary enforcement In scheme, described selected welding parameter is arc voltage.

According to an exemplary, disclose and a kind of include that the arc welder of integrated monitoring device is manually held to use The individuality (that is, operator) of row Arc Welding Process provides the method for instruction, welding wire that described welding machine is advanced by establishment and work Actual welding parameter between part performs Arc Welding Process, and described watch-dog can monitor actual welding parameter, and electric arc Welding procedure is controlled by the command signal of welding machine electric power.Described method includes: (a) produces the waveform of a series of quick repetition, often Individual waveform constitutes the weld cycle with a circulation time；B described waveform is divided into multiple state by ()；(c) within the time period, The selected welding parameter occurred in a described state with inquiry speed measurement, to obtain described selected welding parameter Data acquisition system；D (), for each time period, calculates the mass value of described selected welding parameter from described data acquisition system；E () will Each mass value is compared with prospective quality value, to judge whether the difference of described mass value and described prospective quality value exceedes predetermined Threshold value；If f () described difference exceedes described threshold value, then based on described difference, determine the weight of described mass value with size weight, and And contribute relative to the time of its waveform based on described state, the weight of described mass value is determined with time contribution weight；G () makes The current gross mass score of welding is updated with the mass value including any weight；H () judges that whether current gross mass score exists In the preset range of the acceptable quality score during welding procedure；And if (i) current gross mass score obtains in acceptable quality Outside the preset range divided, then provide the information about corrective action to operator.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, institute Stating the time period is about 250ms.

In an exemplary embodiment, information is visually provided.In an exemplary embodiment, in audition Upper offer information.

In an exemplary embodiment, described information includes the welding wire change in location relative to workpiece of prompting.? In one exemplary, described information includes the welding wire change relative to the rate travel of workpiece of prompting.

In an exemplary embodiment, information is provided with predetermined reporting rates to operator.An exemplary reality Executing in scheme, described reporting rates is less than 30 seconds.In an exemplary embodiment, described reporting rates is more than or equal to 30 Second.

In an exemplary embodiment, if the change recently in current gross mass score indicates current gross mass to obtain Point likely fall outside the preset range of acceptable quality score, then described information is provided.

In an exemplary embodiment, described method also includes: if (j) current gross mass score is in acceptable quality Within the preset range of score, then provide about the confirmation that need not carry out corrective action to operator.

A kind of method disclosing multiple operators evaluating and performing Arc Welding Process, described method is advanced by establishment Welding wire and workpiece between actual welding parameter thus each arc welder by its corresponding operating person be used for perform described electricity The described arc welder that during arc welding technique, monitoring is associated with each operator is evaluated and is performed described Arc Welding Process Multiple operators, described Arc Welding Process is controlled by the command signal of the power supply of described welding machine.Described method includes: for often Individual operator, (a) produces numeric score, described numeric score instruction welding according to described electric arc relative to predetermined base weld The mass measurement of the welding that technique is formed；B () is measured described operator and is performed the time quantum that described Arc Welding Process spends；With And (c) makes described numeric score and described weld interval be associated with described operator.

In an exemplary embodiment, described numeric score is produced by following steps: (a1) produce a series of soon The waveform that speed repeats, each waveform constitutes the weld cycle with a circulation time；(a2) described waveform is divided into multiple shape State；(a3) within the time period, to inquire the selected welding parameter that speed measurement occurs in a described state, to obtain State the data acquisition system of selected welding parameter；(a4) for each time period, described selected weldering is calculated from described data acquisition system Connect the mass value of parameter；(a5) by each mass value compared with prospective quality value, to judge described mass value and described expection Whether the difference of mass value exceedes predetermined threshold；(a6) if described difference exceedes described threshold value, then based on described difference, with size weight Determine the weight of described mass value, and contribute relative to the time of its waveform based on described state, true with time contribution weight The weight of fixed described mass value；And (a7) uses all described mass value obtained during described Arc Welding Process, including The mass value of any weighting, to determine described numeric score.

According to an exemplary, disclose and a kind of selected Arc Welding Process is carried out cost effectiveness analysis Method, wherein, the actual welding parameter between welding wire and workpiece that arc welder is advanced by establishment perform electric arc welding Technique, described selected technique is controlled by the command signal of the power supply of described welding machine.Described method includes: (a) confirms can shadow Ring multiple welding conditions of integral solder quality；B () is for one of multiple welding change welding conditions and for being welded and fixed Remaining welding conditions all；C () is for each welding: (i) produces the waveform of a series of quick repetition, and each waveform constitutes tool There is the weld cycle of a circulation time；(ii) described waveform is divided into multiple state；(iii) within the time period, to inquire speed Rate measures the selected welding parameter occurred in a described state, to obtain the data set of described selected welding parameter Close；(iv) for each time period, the stability value of described selected welding parameter is calculated from described data acquisition system；V () will be every Individual stability value is compared with expection stability value, to judge whether the difference of described stability value and described expection stability value surpasses Cross predetermined threshold；(vi) if described difference exceedes described threshold value, then based on described difference, described stability value is determined with size weight Weight, and based on waveform state relative to its waveform time contribute, with the time contribution weight determine described stability value Weight；(vii) use includes that the stability value obtained during the weld interval of any weighting stability value is to calculate welding Total quality score；(viii) cost of welding is determined；And (ix) makes quality score and cost be associated with welding.

In an exemplary embodiment, welding condition includes welding wire characteristic, characteristic, protective gas flow velocity, guarantor Protect gas composition and workpiece preheating temperature in one or more.

In an exemplary embodiment, cost includes the dollar spending relevant to generating welding.Exemplary at one In embodiment, cost has included welding required total time.

In an exemplary embodiment, described stability value is the canonical statistics deviation of selected welding parameter.

In an exemplary embodiment, described inquiry speed is 120kHz.In an exemplary embodiment, institute Stating the time period is about 250ms.

In an exemplary embodiment, described method also includes: the quality that (d) output is associated with each welding obtains Divide and cost (or its corresponding meansigma methods).

According to an exemplary, disclose the welding parameter that a kind of use pre-sets and obtain that there is required quality The method of welding, the actual welding parameter between the welding wire advanced by establishment and workpiece is by performing the electric arc welder selected The arc welder of skill produces welding, and described welding procedure is controlled by the command signal of the power supply of described welding machine.Described method includes: A () presents multiple set of selected welding parameter together with the quality score corresponding to each set to user, wherein, and described quality The total quality of the welding that the set of selected welding parameter obtains is used before Score quantifies；B () receives about making from user The input collecting incompatible execution welding procedure by which selected welding parameter；And (c) use corresponding to input selected The collection incompatible execution welding procedure of welding parameter.

In an exemplary embodiment, each set presenting the welding parameter selected with use to user performs to weld The cost that technique is associated.

In an exemplary embodiment, described method also includes: (d) receives the minimum acceptable quality of confirmation from user and obtain The input divided；And (e) filters out and the welding selected corresponding less than the associated quantity score of minimum acceptable quality score All set of parameter.

In an exemplary embodiment, described method also includes: (d) receives confirmation acceptable quality score model from user The input enclosed；And (e) filters out corresponding with the associated quantity score outside qualified welding quality score range selected All set of welding parameter.

In an exemplary embodiment, a kind of method diagnosing Arc Welding Process is disclosed, and described method is passed through Create being used between welding wire and the workpiece advanced and create the actual welding parameter of weld seam thus at arc welder execution electric arc Described arc welder is monitored during welding procedure.Described welding procedure is controlled by the command signal of the power supply of described welding machine.Described side Method includes the waveform producing a series of quick repetition, and each waveform constitutes the weld cycle with a circulation time, and by institute State waveform and be divided into multiple state.Described method further includes in the time period repeated during described welding procedure, to ask Ask multiple welding parameters that speed measurement occurs in state one or more described.Described method also includes based on described weldering Described measurement to described welding parameter during connecing technique, calculates multiple quality ginseng of each one or more state Number.Described method farther includes to analyze at least one in the plurality of mass parameter and the plurality of welding parameter, with logical Cross judge described weld seam one or more local (localized) or one of continuous print (continuous) defect or More possible reasons diagnose described Arc Welding Process.

Described method may further include by the value of each described mass parameter that calculates for each time period with Corresponding prospective quality parameter value compares, with the quality parameter value calculated described in judging and described prospective quality parameter value it Whether difference exceedes predetermined threshold.If described difference exceedes described threshold value, described method also includes based on described difference, with size weight The weight of the quality parameter value calculated described in determining, and based on its state relative to the described waveform including described state Time contributes, with time contribution weight determine described in the weight of quality parameter value that calculates.

In an exemplary embodiment, a kind of system for diagnosing Arc Welding Process is disclosed, described system By creating performing for creating the actual welding parameter of weld seam between welding wire and the workpiece advanced at arc welder Described arc welder is monitored during Arc Welding Process.Described welding procedure is limited by the waveform of a series of quick repetitions, described The waveform of a series of quick repetitions is controlled by the command signal of the power supply of described welding machine.Described system includes logic state control Device, described logic state controller for becoming a series of time slice state by described waveform segments, and is used for selecting specific The circuit of waveform state.System farther includes supervising device, and described supervising device is for monitoring during described welding procedure In the time period repeated, to inquire multiple welding parameters that speed measurement occurs in state one or more described, to obtain The data that must arrange for the plurality of welding parameter.Described system also includes for based on described monitored multiple welding ginsengs Number calculates the circuit of the multiple mass parameters for each described state.Described system farther includes diagnostic logic circuit, institute State diagnostic logic circuit for analyzing at least one in the plurality of mass parameter and the plurality of welding parameter, with by sentencing One or more local of fixed described weld seam or one or more possible reason of continuous print defect diagnose described Arc Welding Process.

Described system may further include each described mass parameter for calculating for each time period Value compared with corresponding prospective quality parameter value with the quality parameter value that calculates and described prospective quality parameter described in judging Whether the difference of value exceedes the circuit of predetermined threshold.If described system could be included for described difference exceedes described threshold value, base In described difference with size weight determine described in the weight of quality parameter value that calculates and based on its state relative to including State state described waveform time contribution with time contribution weight determine described in the electricity of the weight of quality parameter value that calculates Road.

According to the following detailed description to exemplary, claims and accompanying drawing, present general inventive concept Many aspects and other embodiments will easily be made apparent from.

Brief Description Of Drawings

Hereinafter, referring to the drawings, present general inventive concept and embodiment thereof and advantage it are more fully described by way of example, In the accompanying drawings:

Fig. 1 is combination block diagram and the calculating of the watch-dog illustrating the arc welder according to an exemplary Machine flow chart or program；

Fig. 2 is the current order curve chart from waveform generator, and this curve chart illustrates according to an exemplary embodiment party The command waveform being divided into time period or the state with both fixed duration and variable duration of case；

Fig. 3 is the actual command signal of the arc current according to an exemplary and the reality added with dotted line The current curve diagram of arc current parameter；

Fig. 4 be according to an exemplary for monitoring the internal signal of welding machine rather than such as Fig. 2 and Fig. 3 institute The block diagram of the one aspect of the present invention of the welding parameter illustrated；

Fig. 5 is to illustrate such as the waveform of experience, wire feeder order letter in the exemplary shown in Fig. 4 Number and the time base curves figure of actual wire feeder command signal；

Fig. 6 is a part for the parameter curve illustrating the level monitoring feature according to an exemplary；

Fig. 7 be illustrate according to an exemplary during the selected state of waveform shown in Fig. 2 and Fig. 3 The block diagram of disposal of stability and computer flow chart or program；

Fig. 8 be for process from the exemplary shown in Fig. 1 horizontal monitor stages information block diagram and Computer flow chart or program；

Fig. 9 is the method for weighting of the welding data parameter illustrating the weighted sampling according to an exemplary Flow chart；

Figure 10 is the diagram of the conceptual production line according to an exemplary；

Figure 11 is the flow chart illustrating the guidance method according to an exemplary；

Figure 12 is the block diagram illustrating the system for monitoring student according to an exemplary.

Figure 13 is the flow chart of the method illustrating the monitoring student according to an exemplary.

Figure 14 A and Figure 14 B is to illustrate in the cost analysis for welding procedure according to an exemplary The form of example data；

Figure 15 is illustrate according to an exemplary pre-with what welding condition, welding machine and welding procedure were associated If the form of data；

Figure 16 illustrates the schematic block diagram of the embodiment of the system for diagnosing Arc Welding Process；And

Figure 17 is the flow chart of the method for the system diagnostics Arc Welding Process using Figure 16, and described method is by creating Being used between the welding wire and the workpiece that advance creates the actual welding parameter of weld seam thus performs electric arc welder at arc welder Arc welder is monitored during skill.

Describe in detail

Although present general inventive concept allows the embodiment that there are many multi-forms, but these designs are shown in the accompanying drawings Go out and will be described in its specific embodiments herein, being now appreciated that the disclosure will be considered only as overall sending out The citing of the principle of bright design.Therefore, present general inventive concept is not limited to specific embodiments illustrated herein.This Outward, United States Patent (USP) No.5,278,390 and No.6, the disclosure of 441,342 is incorporated by herein, because this A little disclosures can be provided with and help be best understood from the specific aspect of present general inventive concept and/or progressive background.

The following is the definition of the exemplary term used in entire disclosure.The singulative of all terms and plural number shape Formula both falls within each implication:

Include, but is not limited to for performing function (a kind of or many as used in this article with " logic " of " circuit " synonym Kind) or hardware, firmware, software and/or a combination thereof of action (one or more).Such as, based on required application or needs, patrol Volume can include microprocessor under software control, discrete logic (e.g., special IC (ASIC)) or other able to programme patrol Collect device.In some cases, logic can also be fully embodied as software.

As used in this article " software " or " computer program " include, but is not limited to one or more computer can Read and/or executable instruction, these instruction cause computer or other electronic installations perform in a desired manner function, action and/ Or behavior.These instructions can be implemented as various forms, e.g., including deriving from the single utility program of dynamic link library or code Subprogram, algorithm, module or program.Software is also implemented as various forms, e.g., and stand-alone program, function call, little service journey Sequence (servlet), applet (applet), the instruction being stored in the part of memorizer, operating system or other classes The executable instruction of type.It will be understood by those skilled in the art that the form of software depends on that (such as) is to required application Requirement, to the requirement of running environment of software and/or needing of designer/programmer.

" computer " or " processing unit " includes, but is not limited to any to store, fetch as used in this article (retrieve) and process data programmed or programmable electronics device.

Now, referring to the drawings, these accompanying drawings illustrate various exemplary and the employing of present general inventive concept The application of this present general inventive concept, Fig. 1 illustrate block diagram and flow chart that Standard Machine borne computer in arc welder 10 realizes or Program.Such as, welding machine 10 can be Lincoln Electric company (Cleveland city, Ohio) sell based on inversion The arc welder Power Wave of device (inverter).According to standard technique, welding machine 10 includes the three of conduct current power supply 12 Electricity input L1, L2, L3 mutually.The controller of airborne computer operation operates power supply based on inverter, to create at terminal 14 Positive potential and create negative potential at terminal 16.

By the Arc Welding Process performing to select by the selected waveform determined before guiding actual welding circuit, this is real Border welding circuit is shown having the smooth inductor 18 of standard.Welding machine 10 performs arc welding to the welding wire 20 advanced from reel 22 Connecing technique, this reel 22 is driven with desired rate by feeder 24, and this feeder 24 runs with the speed of motor 26.The heat of electric arc The melted welding wire 20 of amount and workpiece 30, to deposit to the motlten metal deriving from welding wire on workpiece.In order to monitor the reality of welding procedure Border parameter, diverter 32 (supervising device) provides output signal I from block 34 on circuit 34a_a.This signal represent any to The actual arc electric current fixed time.In a similar fashion, with the electricity between block 36 (supervising device) sensing welding wire 20 and workpiece 30 Pressure, so the output V on circuit 36a_aIt it is the transient arc voltage constituting the second welding parameter.The welding of the illustrated explanation of Fig. 1 Parameter is actual arc electric current I_aWith actual arc voltage V_a。

Another parameter of the controlled present invention of practice is a feed rate (WFS), and this speed is by the rotation of motor 26 Cause.Therefore, as illustrated by after a while, three readable welding parameters in outside of welding procedure are the electric arc electricity in circuit 34a Stream I_a, arc voltage V in circuit 36a_aWith feed rate of welding wire WFS readable in circuit 46b.By tachometer or encoder 46c (supervising device) reads the WFS in circuit 46b, and this tachometer or encoder 46c are connected to the driving roller 24 of feeder gear-box Or alternatively it is connected on the follower attached by welding wire.In fig. 1 it is illustrated that driven tachometer by push rolls.Such as, Tachometer can also be driven by the output shaft of motor 26.

Power Wave arc welder includes the waveform generator for creating a series of quick repetitive pattern, each waveform (such as, the voltage/current waveform of simple sequence) constitutes the weld cycle with a circulation time.This is repeated during welding procedure A little weld cycle, to limit weld interval.Authorizing shown in United States Patent (USP) No.5,278,390 of Blankenship One embodiment of PowerWave welding machine 10, wherein, welding machine controls, by order circuit 42, each ripple that power supply 12 is to be exported Shape and controlled the speed of motor 26 by order circuit 44.Order circuit 44 has by the welding wire driving control 46 of motor 26 The signal of microprocessor identification, drive pwm pulse exporting motor voltage in circuit 46a.It practice, the letter on circuit 44 Breath be numeral and circuit 46a on command signal be simulation.Waveform generator 40 creates numeral letter in circuit 42,44 Number, the required welding procedure to be performed to control welding machine 10.External parameter I can be read by the supervising device being suitable for_a、V_aWith WFS。

Each output waveform is divided into or is segmented into a series of time slice part or state by waveform generator 40.? In one exemplary, watch-dog M is the program being loaded in the computer of welding machine 10, (except other purpose it Outward), it is for reading the parameter during a selected section of waveform.In the spirit and scope without departing from present general inventive concept In the case of, it is possible to use software, hardware and combinations thereof realize watch-dog M.Determined that waveform is the most monitored by waveform generator 40 Part.It is true that the various time periods of the waveform of watch-dog M monitoring generator 40 output or state.It practice, waveform generator 40 select to form multiple time periods of waveform and by various State-outputs to command interface 70.Therefore, command interface 70 causes Parameter during the selected time period of each waveform measuring generator output.Information or data on command interface 70 just include Monitored one or more states and various parameter I_a、V_aAnd/or the particular value of WFS or level.

The interface 70 of watch-dog M comprises the data of the particular state that identification is just processing together with the welding parameter just read Value.Data in level segment 81 analysis interface 70, to determine the relation of parameter based on level.By actual parameter with derive from generation The parameter practised during the selected state of the waveform of device 40 or record compares.During the particular segment or state of waveform, water Flat monitor stages 81 reads the actual parameter in circuit 34a, 36a and 46b.The instantaneous value of these actual parameter is stored in inside In memorizer (regarding as report logic 82).As represented by agitator 84, quickly carry out the reading of actual parameter.Show at one In example embodiment, carry out the reading of actual parameter with the speed of the 120kHz of pulse welding.This speed can be regulated；So And, speed is the highest, and the sensitivity of horizontal survey is the highest.Level monitoring 81 also determines that actual welding parameter and minimum level or maximum The deviation of level.In this way, be possible not only to store actual value, also store the actual read number of the parameter representing given state with The data of the deviation that little level or maximum horizontal are compared.Reporting memory or logic 82 record during the given state of waveform with The deviation of setting level and the practical level during the selected state of waveform.For whole weld cycle, to these readings Carry out adding up, counting process in other words conj.or perhaps, to determine welding quality and any trend trending towards weld defect.

In an exemplary embodiment, these readings (such as, the most accumulative reading is determined based on multiple standards Set) weight.For example, it is possible to every 250ms adds up reading.In an exemplary embodiment, the weight determining set is Based on its with desired value (such as, predetermined threshold, meansigma methods) extent and its time period partially relative to the time of corresponding waveform Contribution.For example, it is possible to realize such weighting in horizontal monitor stages 81 or any similar or relevant data processing stage Method (such as, shown in Fig. 9 and method of weighting described below 900).

The fast velocity that stability monitor stages 91 determines with agitator 94 reads the reality on circuit 34a, 36a and 46b Welding parameter.In an exemplary embodiment, the reading of actual parameter is carried out with the speed of the 120kHz of pulse welding.Surely The standard deviation of actual welding parameter or absolute deviation during the state of the waveform that qualitative monitor stages 91 analyzes positive output.Report This deviation during the given state of memorizer or logic 92 wave recording and the actual value during the selected stage of waveform.Right In whole weld cycle, these readings are added up, counts and process in other words conj.or perhaps, to determine welding quality and any to trend towards The trend of weld defect.

In an exemplary embodiment, these readings (such as, the most accumulative reading is determined based on multiple standards Set) weight.For example, it is possible to every 250ms adds up reading.In an exemplary embodiment, the weight determining set is Based on its with desired value (such as, predetermined threshold, meansigma methods) extent and its time period partially relative to the time of corresponding waveform Contribution.For example, it is possible to realize such adding in stability monitor stages 91 or any similar or relevant data processing stage Power method (such as, shown in Fig. 9 and method of weighting described below 900).

When using monitor stages 81 or monitor stages 91, (skip) several waveform can be skipped over.An exemplary enforcement In scheme, after homing sequence, monitor all waveforms, the actual welding ginseng during the various selected states of analysis waveform Number.Multiple states of given waveform in monitoring welding procedure, and individually for each state recording result, for analysis level one Cause property, trend and stability.When measuring stability, watch-dog M uses standard deviation algorithm, to evaluate I_a、V_aAnd/or WFS.It is each that this information can be used in analyzing various sections of waveform that form the whole weld cycle with given circulation time Section.It practice, monitor some state (e.g., the peak point current during impulse waveform), to determine the stability of pulse welding technique And horizontal departure.In STT welding procedure, watch-dog M records the short circuit duration of each waveform, because these sections are according to Welder The external condition of skill changes in time.The change notification welding engineer of short circuit duration realizes regulation.

As shown in Figures 2 and 3, when a series of quick repetitive pattern that the waveform generator 40 of standard produces is divided into Between state.Output current order waveform is the impulse waveform 100 with peak point current 102 and background current 104, peak point current 102 fixed durations with the time period A shown in Fig. 3, background current 104 has the variable of time period B shown in Fig. 3 and holds The continuous time.Waveform is at moment t₁-t₄It is divided into the time period so that command interface 70 receives generator 40 at any given time The particular state just processed.As shown in Fig. 3 by a dotted line 110, the actual arc electric current deriving from the diverter 33 in Fig. 1 deviates The command current signal of waveform 100.

In selected functional status (e.g., state A or state B) period, the speed determined with agitator 84 or agitator 94 Read actual arc electric current I_a.It practice, this is single software agitator.Horizontal monitor stages 81 records actual parameter 110 He Along the deviation of coordinate direction between the command level of waveform 100.During selected state, stability monitor stages 91 reads The statistical standard of actual parameter is poor.Generally, state A and the B of pulse welding process are monitored.However, it is possible to monitoring t₁-t₂Between Propradation and/or t₃-t₄The decline state of period, with the actual parameter during these states of controlling or at least read waveform Activity.As described in illustrated in scheming, background time section B has variable time, as used moment t₁Variable time position illustrate 's.Therefore, the most monitored state can have fixing persistent period or variable duration.When being in variable duration Time, monitor this state, until the persistent period terminates.Report logic 82 senses it as from moment (that is a, t₄) to time subsequently Carve (that is, t₁) level.As moment t₁Relative to moment t₄During change, this time of each waveform is recorded as and known time The level compared, by selecting the bond pattern of generator 40 to obtain described known time from interface 70.

Actual welding parameter during the specific selected state of watch-dog M monitoring waveform；But, watch-dog is also compiled Journey, to operate the computer to determine stability and/or the water of internal signal (e.g., actually entering motor 26 on circuit 46a) Flat characteristic.Utilize the signal shown in Fig. 5, illustrate in the flow chart shown in Fig. 4 such inside of signal on circuit 46a Monitoring.

Microprocessor in wire feeder includes subprogram, and this subprogram is analogous to the PID of error amplifier and compares Network.In the diagram, it is block 152 that this PID comparator is schematically illustrated explanation, and it has the first input 46b, and (that is, welding wire send Enter speed WFS) and circuit 44 on command signal.The actual WFS on circuit 46b is read, to read by tachometer or encoder WFS, this tachometer or encoder are connected to the driving roller 24 of feeder gear-box or are alternatively connected to appended by welding wire On the follower connect.The output 156 of PID is the voltage level of the input of pulse width modulator 158, and it is in micro-process of feeder By digitized in device.The output of pulse width modulator is the command signal on circuit 46 for motor 26, is used for controlling feeder 24 Feed rate of welding wire.

According to an exemplary, watch-dog M includes the processing routine as described in be schematically illustrated in Fig. 4, Wherein, by process block 160 read the signal on circuit 156 and read before result exports such as on circuit 162 relative to Horizontal monitor stages 81 that embodiment shown in Fig. 1 is discussed and/or the input of stability monitor stages 91.Therefore, quickly (super Cross 1kHz) read the internal signal on circuit 156, the stability of level and/or this signal to check this internal signal.

Illustrating as illustrated in fig. 5, the waveform 100 of pulse welding extends into the continuing of waveform deriving from generator 40 Continuous.As for feed rate of welding wire, the command signal that circuit 44 derives from generator 40 uses the form shown in Fig. 5.It has included Beginning rising part 170 and last sloping portion 172.These two parts cause the command signal on circuit 44 to rise sharply or rapid drawdown.Online On road 44 between these aberrant commands parts of signal, there is average feed rate of welding wire order, use this order The stability of this internal signal on measurement circuit 156 and/or horizontal departure.In Figure 5, welding wire accelerating part it is always maintained at 170, until speed is stabilized.Also this time is monitored.The design identical with shown in Fig. 4 and Fig. 5 can be used to monitor Other internal signals.Horizontal monitor stages judges that the signal on circuit 156 exceedes minima or maximum the most for a long time.For For wire feeder, this generally represents occur blocking in feeder system.

Fig. 6 illustrates the design of horizontal monitor stages, and wherein, threshold value 180 is maximum parameter level and threshold value 182 is minimum Parameter level.When the parameter being illustrated as arc current exceedes threshold value 180 (as represented by transient state 184), recorded Current occurrences.In a similar manner, when electric current is less than minimum level 182 (as represented by transient state 186), low current thing is recorded Part.Furthermore it is possible to determine the weight of these events based on multiple standards.In an exemplary embodiment, each thing is determined The weight of part is to deviate the size of desired value (such as, predetermined threshold, meansigma methods) with its time period relative to corresponding ripple based on it The time contribution of shape.For example, it is possible in horizontal monitor stages 81, stability monitor stages 91 or any similar or relevant data Processing stage, realize such method of weighting (such as, shown in Fig. 9 and method of weighting described below 900).

Periodically weighted events is counted or perhaps accumulative, to provide horizontal monitor stages 81 as shown in Figure 1 Output.For example, it is possible to every 250ms accumulated weights event.Therefore, the detection of horizontal monitor stages 81 is higher than the deviation of predetermined threshold value Value 184 and the deviation value 186 less than preset level.In interface 70, these levels are set by particular state.These of waveform State uses the horizontal monitor stages 81 with threshold value, and other states of same waveform can be with stability in use monitor stages 91.Preferably, and it practice, the two monitor stages is all used for selected one or many of the waveform that watch-dog M just inquiring Individual state.

As illustrated by according to the disclosure in Fig. 4 and Fig. 5, the embodiment monitoring shown in Fig. 1 derives from generator The level of the actual parameter of internal control signal and/or stability during the selected state of the waveform of 40 or during whole welding. As previously described, the watch-dog M in Fig. 1 provides the weld cycle for analyzing working time section internal welding machine or whole operation Weighted data.After having determined that and storing data, use various analysis program to process data.According to an exemplary reality Execute scheme, analyzed the weighting stability data deriving from monitor stages 91 by two programs as shown in Figure 7.This area Technical staff with record with various computer program analysis stability datas, can show and process interference or evaluate.

As shown in Figure 7, analysis program 200 uses result (that is, the weighting stability of the monitor stages 91 of watch-dog M Value).As embodiment, at monitoring moment t₂-t₃Between time state (the current peak portion of waveform i.e., as shown in Figures 2 and 3 Point) period, run program 200.Illustrating that analysis program 200 is computer process, this flow process illustrates for analyzing peak point current shape Two systems of the result in stability stage 91 during state, in this peak current condition, calculate the actual current in circuit 34a Statistical standard poor.It practice, before monitor stages 91 is calculated deviation, slightly postpone.In state t₂-t₃Period reads I_aBut ignore I in other cases_aSampling select feature to be illustrated as sampling selector or wave filter 90a.It is incorporated to filter Time period t in ripple device 90a₂-t₃This program delay during beginning makes watch-dog can ignore the fluctuation in electric current, these ripples Dynamic is experience during each level change in the various stages of output waveform.

In the programmed flow process shown in Fig. 7, the computer program being shown as block 210 read and derive from monitor stages 91 Stability exports, and presets this block when at moment t3 indicated in the logic on the circuit 210a at each waveform end determined 210.Therefore, block 210 stability of (capture) each waveform is captured.This is processed according to two single analysis programs The stability data of one capture.

First program includes exceeding analysis subroutine (pass analysis routine) 212.If given waveform is steady Qualitative exceed in block 212 arrange required threshold value, then on circuit 214, export this information.If the stability of specific waveforms is low In required threshold value, then in circuit 216, logical signal occurs.During each weld cycle, the logic on circuit 224 start Enumerator 220,222.Therefore, in enumerator 220 or enumerator 222, the stability of waveform each during weld cycle is surpassed Cross signal to count.Certainly, each state t is ignored₂-t₃Part I so that I_aStable.As read block 220a, 222a Represent respectively, read, store or perhaps keep the result of the two enumerator.In an exemplary embodiment, as Really the accumulative unstability of counter stage 222 exceedes expection number, then, as represented by block 226, refusal accepts this welding and follows Ring.

Second analysis implementation of the computer program 200 shown in Fig. 7 is illustrated as block 230.This is in welding The program started during circulation.Using total instability analysis of weld cycle accumulative during all waveforms as sum, wherein, 100 is most stable of electric arc.As represented by block 236, read, store or perhaps keep this stability integrating instrument and analysis The output in stage.If the stage of reading 234 is less than the stability set, then as represented by block 238, refusal accepts this welding and follows Ring.Those skilled in the art can design other programs and analyze to obtain the result of watch-dog M in autostability stage 91.Calculate Machine program 200 shows two kinds of implementations for analyzing obtained weighting stability data.It is constructed according to watch-dog For the character of arc stability or the problems of welded quality of detection, can optionally start both implementations and (start A kind of mode or another way or start both modes simultaneously).Advantageously, that only reads in the selected state of waveform is steady It is qualitative, because the stability in variable pulse is unavailable.

According to another exemplary, shown in Fig. 8, it is used for the knot of the horizontal monitor stages 81 of analysis monitoring device M The really computer program of (that is, weighting reading value).In this embodiment illustrated, horizontal analysis (level Analysis) program 250 processes the output from the monitoring level stage 81 with two single subprograms, and the two is single Subprogram is confirmed as utilizing the minimum monitor stages 81a of wave filter 80c and utilizing the maximum monitor stages 81b of wave filter 80d. Can be used alone any one in these stages, or it practice, combine these stages.Subdivision 81a relates to determining Fig. 6 institute The conversion 186 shown, i.e. actual parameter is less than the event of threshold value minima 182.As program step 252 choice phase 81a, make By the minimum level on the circuit 202a deriving from generator 40.As represented, block 254 these events to each weld cycle Count.During weld cycle, enumerator is started by the logic on circuit 254a.Enumerator 254 is directed to weld cycle The sum of the waveform of middle use.As represented by circuit 258, by the moment t to the output from generator 40₃Appearance enter Row counting, obtains the number of waveform.As previously indicated, generally ignore the Part I of state, to remove any specific shape Exception when state starts is inconsistent.Block 260 is computer program flow process subprogram, for deriving from the accumulative of monitor stages 81a Minimum event 186 is divided by the several N deriving from enumerator 256.Which providing the meansigma methods of minimum transition during weld cycle, this is put down Average is provided to subprogram 262.As represented by block 262a, read, store or perhaps export average minimum transition.If This meansigma methods is higher than the particular threshold number provided by waveform generator or program step 264, then program subprogram 266 judges welding Circulation is underproof.If qualified, then hold fire.But, if qualified subprogram 266 judges that this meansigma methods is only It is close to several 264, is then provided alarm signal by block 266a.Total defective property provides a welding refusal to connect by subprogram 266b By signal.Those skilled in the art it is contemplated that to implement the minimum current to actual parameter with other computer programs inclined The analysis (when this analysis relates to setting threshold value) of difference or conversion.

In fig. 8, maximum monitor stages 81b combines minimum stage 81a and operates.Maximum horizontal is in and is derived from generator 40 Circuit 202b on, and use this maximum horizontal as program 270 choice phase 81b.Similar data message and programming are protected Hold identical quantity.Enumerator 272 is to state t₂The quantity of the event 184 during-t3 counts.Subprogram 280 provides The meansigma methods of event 184 during the various waveforms formed during weld cycle.As represented by block 282a, read, store or Person says it is to use this meansigma methods in block 282.In block 286, process qualified subprogram, wherein, generator 40 is exported by The number realized by computer program in other words that block 284 represents compares with the meansigma methods deriving from block 282, to work as meansigma methods During close to the setting number represented by block 284, as block 286a represents, it is provided that alarm signal.As indicated by block 286, if Reach this number, then perform refusal and accept subprogram.

It practice, implementation phase 81a and stage 81b together, and derive from block 262 He by the ghreshold numbers analysis read The meansigma methods of the two conversion of 282, accepts one to give weld cycle sending alarm and/or refusal.Therefore, it practice, divide Analyse minimum level deviation, analyze maximum horizontal deviation and analyze aggregate level deviation.Such as schematic, pictorial illustration in Fig. 8, by Computer program realizes all these analysis.Level segment 81a, 81b output utilizes report logic 82 (as discussed) to store And/or the level conditions of display.As discussed herein, it may be determined that adding of the level conditions of level segment 81a, 81b output Power.

In view of the foregoing, size and time contribution weight is used can to measure parametric stability and then measurement more accurately Integral solder quality.In this way, it is possible to calculate the easness understanding numerical value or score, to quantify the total quality of welding.? In one exemplary, based on monitored welding condition or parameter (e.g., the exemplary prison shown in Fig. 1 Those conditions of control or parameter), calculate between the 0-100 of welding or the welding score of 0%-100%.For example, it is possible to supervise in level Control stage 81, stability monitor stages 91 or any similar or relevant data processing stage realize such method of weighting (such as, shown in Fig. 9 and method of weighting described below 900).

Figure 9 illustrates the method for weighting 900 according to an exemplary.For example, it is possible to it is real in watch-dog M Existing method of weighting.In the initial step 902 of method of weighting 90, the waveform of weld cycle is divided into a series of time slice portion Divide or state.Then, in step 904, with given speed, to welding parameter (such as, the electricity corresponding with at least one state Pressure, current intensity) it is sampled.In an exemplary embodiment, sampling rate is more than or equal to 120kHz.Show at one In example embodiment, it is possible to use sampling rate produces the interruption that interrupt service routine (ISR) processes.

The welding parameter using sampling calculates welding data.In exemplary method of weighting 900, welding data includes Perform counting, voltage and, voltage squared and, current intensity and and current intensity quadratic sum.Perform counting and start from 0 and every The individual sampling period, (such as, every 120kHz) increased by 1.Voltage and with current intensity and start from 0 and each sampling period respectively Increase sampling voltage and sampling current intensity.Similarly, voltage squared and start from 0 with current intensity quadratic sum and each take The sample cycle increase respectively sampling voltage square with sampling current intensity square.

After the predetermined sampling period, in step 906, transmission sampling welding data is (as follows for processing further Described), welding data value be reset as 0 and repeated sampling process (that is, step 904).An exemplary In, the sampling period is 250ms.Each set of sampling welding data forms analytical data bag.Analytical data bag is being entered After one step processes (such as, every 250ms), can obtain characterizing the extra soldered number of the current welding quality grade of corresponding states According to.These extra soldered data can be drawn and/or are averaging.These grades in weld length (that is, weld cycle) Meansigma methods is that welding provides total quality instruction.

By the welding data of each analytical data bag of appearance in step 906 being entered one for each sampling state Step processes, and causes calculating extra soldered data.Extra soldered data include performing counting, average voltage, voltage root-mean-square (RMS), voltage variance, current intensity meansigma methods, current intensity RMS and current intensity variance.From the execution meter of welding data The value of number replicates the value performing counting of extra soldered data.Average voltage is calculated as voltage and (deriving from welding data) removes To perform counting.Voltage RMS is calculated as the business by voltage squared and (deriving from welding data) being counted to get divided by execution Square root.Voltage variance is calculated as voltage RMS and deducts average voltage.Current intensity meansigma methods is calculated as current intensity (deriving from welding data) is divided by performing counting.Current intensity RMS is calculated as by (current intensity quadratic sum is derived from welding Data) divided by performing the square root of business that counts to get.Current intensity variance is calculated as current intensity RMS and deducts current intensity Meansigma methods.

After step 906, process subsequently is depended on currently welding is for determining that the exercise of welding quality parameter is welded Meet (training weld) and be also intended to the normal weld according to this welding quality parameter evaluation.Therefore, in step 908, sentence Before settled, welding is exercise welding or normal weld.In an exemplary embodiment, implied terms is unless additionally referred to Showing (such as, inputted by user), otherwise welding is normal weld.

If judging that current welding is exercise welding, then for major part (such as, the 20-of exercise welding in step 908 30 seconds) for, preserve following extra soldered data value: perform counting, average voltage, voltage variance, current intensity average Value and current intensity variance, and other welding data value and extra soldered data value can be ignored.The big portion of exercise welding Dividing is practice periods section.In an exemplary embodiment, practice periods section corresponds at least 80 continuous analytical data bags (that is, section sample time).

Hereafter, in step 910, the extra soldered data value preserved during using practice periods section calculates welding quality Parameter.Such as, the following welding quality parameter of each sampling state is calculated: quality performs weighted mean value, quality performs counting Standard deviation, quality voltage meansigma methods, quality voltage standard deviation, quality current intensity meansigma methods, quality current intensity standard deviation, matter Amount voltage mean of variance, quality voltage variance criterion is poor, quality current intensity mean of variance and quality current intensity side Difference standard deviation.

Quality performs the execution meter of all analytical data bags processed during weighted mean value is calculated as practice periods section The meansigma methods of number.Performing counting can be integer by rounding.During quality execution counting criteria difference is calculated as practice periods section The counting that performs of each analytical data bag processed performs the standard deviation of weighted mean value relative to quality.Quality voltage meansigma methods The meansigma methods of the average voltage of all analytical data bags processed during being calculated as practice periods section.Quality voltage standard deviation The average voltage of each analytical data bag processed during being calculated as practice periods section is relative to quality voltage meansigma methods Standard deviation.The current intensity of all analytical data bags that quality current intensity meansigma methods processes during being calculated as practice periods section The meansigma methods of meansigma methods.Each analytical data bag that quality current intensity standard deviation processes during being calculated as practice periods section Current intensity meansigma methods is relative to quality current intensity standard error of the mean.Quality voltage mean of variance is calculated as exercise The meansigma methods of the voltage variance of all analytical data bags processed during the time period.Quality voltage variance criterion difference is calculated as practicing Practise the voltage variance standard deviation relative to quality voltage variance of each analytical data bag processed during the time period.Quality electric current Current intensity variance average of all analytical data bags that intensity variance meansigma methods processes during being calculated as practice periods section Value.The current intensity of each analytical data bag that quality current intensity variance criterion difference processes during being calculated as practice periods section Variance is relative to the standard deviation of quality current intensity variance.As it has been described above, based on being identified the most qualified welding These mass parameters during transmission can serve as welding the benchmark measuring or perhaps defining the level subsequently.

If determining that current welding is to form the evaluation welding compareed (i.e., it is desirable to evaluate with exercise welding in step 908 The welding of its quality), then welding data or extra soldered data all need not preserve.The substitute is, obtain and preserve each Plant the result of Mass Calculation.These Mass Calculation are included in the existence of the various isolated point of initial detecting in step 914.Isolated point is Data point or value, it apart exceedes threshold distance with by this data point or the meansigma methods that is worth to.An exemplary enforcement In scheme, isolated point is the value outside the limit of three standard deviations of distance average that falls.

In method of weighting 900, the isolated point found in step 914 includes performing isolated point, voltage isolated point, voltage Variance isolated point, current intensity isolated point and current intensity variance isolated point.For each monitored state, evaluate each point Analysis packet, to detect the existence of any one in these isolated points.

If analytical data bag meets following relation, then it is considered as performing isolated point: (perform counting-quality execution counting flat Average) absolute value > (3 × quality perform counting criteria poor).If analytical data bag meets following relation, then it is considered as voltage lonely Vertical point: the absolute value of (average voltage-quality voltage meansigma methods) > (3 × quality voltage standard deviation).If analytical data bag is full Be enough to lower relation, be then considered as voltage variance isolated point: the absolute value of (voltage variance-quality voltage mean of variance) (3 × matter Amount voltage variance criterion is poor).If analytical data bag meets following relation, then it is considered as current intensity isolated point: (current intensity is put down Average-quality current intensity meansigma methods) absolute value > (3 × quality current intensity standard deviation).If analytical data bag meet with Lower relation, then be considered as current intensity variance isolated point: the absolute value of (current intensity variance-quality current intensity mean of variance) > (3 × quality current intensity variance criterion is poor).

After detecting these isolated points, use two step weighted sums of each isolated point (that is, in step 916 and 918 In) calculate correspondence analysis packet quality instruction.

The first step of weight is determined relative to this isolated point that is sized to of the three standard deviation limit by each isolated point Suddenly (that is, step 916).Generally, data point or value close to 0.3% can be fallen outside the three standard deviation limit, and then are considered lonely Vertical point.When the value of isolated point increases to the limit more than three standard deviations, the weight of this isolated point increases.Orphan under four standard deviations The full weight of vertical point is 100% and the weight limit of isolated point is 200% under five standard deviations.Generally, in normal data set In conjunction, the probability of the isolated point of full (that is, the 100%) weight of appearance is 15, has 1 in 787.

Therefore, in step 916, determine the weight of each isolated point according to such method.It is applied to each holding The weight of row isolated point is calculated as the absolute value of (performing counting criteria more than the amount of the three standard deviation limit/quality poor), and Weight limit value is 2.0.The weight being applied to each voltage isolated point is calculated as the (amount/matter more than the three standard deviation limit Amount voltage standard is poor) absolute value, and weight limit value is 2.0.It is applied to the weight quilt of each voltage variance isolated point It is calculated as the absolute value of (poor more than the amount of the three standard deviation limit/quality voltage variance criterion), and weight limit value is 2.0. The weight being applied to each current intensity isolated point is calculated as the (amount/quality current intensity mark more than the three standard deviation limit Accurate poor) absolute value, and weight limit value is 2.0.The weight being applied to each current intensity variance isolated point is calculated For the absolute value of (poor more than the amount of the three standard deviation limit/quality current intensity variance criterion), and weight limit value is 2.0.

It is defined as this isolated point by the execution counting of each isolated point state and determines second step (that is, the step of weight 918).Specifically, what the value of each isolated point was multiplied by this isolated point state performs counting, thus illustrate this state relative to The time contribution of overall waveform.In this way, there is the bigger state generation performing counting (that is, performing the time) to have the most relatively The isolated point of big weight.Therefore, along with the execution time of specific isolated point increases, the weight of this isolated point also will increase.

The weight of the isolated point in step 916 and 918 produces the final set weighting isolated point, including finally weighting execution Isolated point, final weighted voltage isolated point, final weighted voltage variance isolated point, final weighted current intensity isolated point and Whole weighted current intensity variance isolated point.These final weighting isolated points are sued for peace by step 920, to produce each point The final weighting isolated point of analysis packet and.Hereafter, in step 922, the determination quilt of the quality instruction of each analytical data bag Be calculated as by perfect mass value is deducted final weighting isolated point and, the business that obtains divided by perfect mass value again.This perfection matter Value is multiplied by the quantity (being i.e., in this case, 5) of isolated point kind equal to the counting that performs of analytical data bag.

Therefore, instant quality instruction (that is, for the most complete analytical data bag) can be by really during welding process Fixed and with welding machine communication or be otherwise utilized.In this way, during (i.e.) welding process, potential problems occur Time, these potential problems just can be detected, this with only carry out detecting after completing to weld, the most too late so that can not take The situation of any corrective action forms comparison.

Furthermore, it is possible to adding up to until the quality instruction meansigma methods of any time point during welding process is averaging, with Determine until the welding quality of this time point indicates.Such as, after completing welding process, each quality all can be indicated It is averaging, to obtain the total quality instruction of whole welding, score, grade, classification etc..Can be by the total quality instruction of welding Comparing with predetermined quality instruction (such as, be derived from exercise welding), the instruction of described predetermined quality reflects the minimum of qualified welding Quality indicated value.

In this way, it is possible in real time or near-real-time, accurately, effectively, consistent and/or automatically determine welding matter Amount.This is especially advantageous, because not being always to be enough to judge welding quality and because operator may not to the range estimation of welding Deviation or the other problems that can affect integral solder quality during recognizing welding process in other words can be detected.

In some example embodiments, the quality instruction (that is, welding score) of welding is to evaluate essentially identical Under the conditions of and repeat according to essentially identical Arc Welding Process (e.g., during (such as, robot) welding process automatically) The effective tool of the welding formed.By calculating instantaneous, periodicity and/or the welding score of entirety, the automatization of welding every time Quality control treatments may be adapted to electric arc welding process.Specifically, according to welding condition and electric arc welding process, start most by Minimum qualified welding score or qualified welding score range are defined as threshold value.Hereafter, will weld every time (instantaneous, periodically and/or Overall) welding score with threshold value compared with, rapidly and accurately to judge accept welding or refuse to accept welding. It addition, by the trend evaluating the welding score producing running or complete running, can be easier to determine asking in production process Topic, and/or can be easier to optimize production process.

Figure 10 illustrates conceptual production line 1000, wherein, the first welding score S1 1002, second welds score S2 1004 and the 3rd welding score S3 1006 the most right with the welding machine or welding bench 1014 including integrated monitoring device M 1016 The welding that first workpiece WP1 1008, second workpiece WP2 1010 and the 3rd workpiece WP3 1012 perform is associated.This area Ordinarily skilled artisan will understand that, same workpiece can be performed different welding.

Then, by welding score compared with predetermined qualified welding score threshold, to judge accept or refuse to connect Welded every time.Can be by welding machine/welding bench or by isolated system or in (such as, the appraisal of independent position Platform 1018) carry out this and compare.In an exemplary embodiment, the ratio between welding score and threshold value is manually performed Relatively.In an exemplary embodiment, perform automatization and manually compare.In an exemplary embodiment, weldering is used Connect score and judge whether the manual examination (check) of correspondence welding is guaranteed.In an exemplary embodiment, at least partly use Welding score determines the whole efficiency of production line.

In an exemplary embodiment, one or more appraisal platform 1018 is set along production line 1000, To measure the welding of the moment in production process.If appraisal platform 1018 judges that the welding score of welding meets or super Cross predetermined qualified welding score threshold, then appraisal platform 1018 accepts welding by sending acceptance welding order 1020.Ring Should be in accepting welding order 1020, it is allowed to include that the workpiece of qualified welding moves on along production line 1000, to carry out into one Step processes.

On the contrary, if appraisal platform 1018 judges that the welding score of welding is reduced to less than predetermined qualified welding score threshold Value, then appraisal platform 1018 is refused to accept welding by sending refusal acceptance welding order 1022.Accept in response to refusal Welding order 1022, leaves production line 1000 including the workpiece of defective welding and is removed (such as, from production line 1000 in other words Manually remove).Hereafter, the workpiece with the welding being rejected acceptance can be further processed, and such as, transforms or with it His mode is repaired and is rejected the welding of acceptance or reclaims this workpiece completely.

In an exemplary embodiment, registration stores each acceptance welding order 1020 in other words and/or refusal connects By welding order 1022, for consulting subsequently and analyzing.In this way, it is possible to be easier to determine about soldering and/or life The trend of product process, and then, so so that be easier to improve the whole efficiency of the production line utilizing welding process.

In some example embodiments, the welding quality instruction (that is, welding score) calculated can be used in innovation In method, it is used for providing instruction teaching operator in other words to manually perform Arc Welding Process.Specifically, just make as operator When generating welding with welding machine (such as, arc welder 10), welding machine (such as, by the watch-dog M of welding machine) determine welding Instantaneous and/or periodicity welds score, and this score is for providing the directly feedback about current welding quality to operator. As it has been described above, these welding scores are to measure based on the weighted statistical more accurately reflecting welding quality compared with only estimating welding. Specifically, by welding score compared with predetermined qualified welding score or qualified welding score range, with decision person's Whether any corrective action is necessary.It addition, evaluate the welding score of each time, to determine whether that existence deviates from qualified weldering Connect any trend (such as, showing as welding the continuous reduction of score) of score.

Figure 11 illustrates the guidance method 1100 according to an exemplary.The beginning of method 1100, behaviour Author starts to perform in step 1102 welding procedure.

During welding procedure, in step 1104, periodically calculate welding score (based on one or more sampling or Person says the parameter recorded), to reflect current welded condition.Welding score can be calculated as reflecting the instantaneous of current welded condition The repetitive measurement of the welded condition in certain period of time (corresponding to repetitive measurement) during measured value, or reflection welding procedure Meansigma methods.In an exemplary embodiment, by being averaging starting acquired all measured values from welding procedure Calculate welding score, which reflects the integrality of current welding.

Then, in a step 1106, by welding score compared with predetermined threshold welding score.Threshold value welding score is good The minimum welding score of the most qualified good welded condition.If welding score welds score greater than or equal to threshold value, then exist Step 1108 judging, current welded condition is as good.Otherwise, judge that current welded condition is as difference in step 1108.

If current welded condition is good, providing instruction to operator the most in step 1110, show that welding is good, this carries Show and be appropriately carried out welding procedure.Hereafter, step 1112 is registered current welded condition, for follow-up consulting, analyzing And/or other purposes.Then, guidance method 1100 proceeds, the weld just performed with policer operation person as described above Reason.

If current welded condition is poor, then providing instruction to operator in step 1114, show that welding is poor, this prompting is just Performing welding procedure improperly.Hereafter, step 1118 is registered current welded condition, for follow-up consult, analyze and/ Or other purposes.Then, guidance method 1100 proceeds, the soldering just performed with policer operation person as described above.

Above-mentioned instruction can be provided to operator by any mode that be enough to during welding procedure notify operator.One In individual exemplary, visually provide instruction to operator, as in or the display of next-door neighbour welding machine integrated with welding machine There is provided on device.In an exemplary embodiment, to regard on protectiveness face helmet (visor) that operator wears or the helmet Feel mode shows instruction.In an exemplary embodiment, provide instruction acoustically to operator, as by with welding machine collection Become or the speaker of next-door neighbour's welding machine provides.In an exemplary embodiment, in the protective headgear that operator wears With audible means display instruction.

In an exemplary embodiment, if current welded condition is poor, then in step 1116, operator receives pass In the instruction that should take which type of one or more corrective action.In an exemplary embodiment, in welding procedure Period, provide instruction in real time.Such as, this instruction can relate to the welding rod (that is, the welding wire) change in location relative to workpiece of suggestion Or the welding wire of suggestion changes relative to the rate travel of workpiece.

Various device and technology can be used to determine the corrective action that may take, and e.g., it is good for causing empirical tests During the welding procedure of good welding, operator and/or welding condition set up model, and use the model data of gained to evaluate Perform other operators of similar soldering under similar conditions.Artificial intelligence and relevant emulation can also be used to set up this Plant model.In addition it is possible to use this model set up by sensor.

In an exemplary embodiment, use one or more sensor to determine some sides of welding procedure Face, such as, the Current Temperatures of workpiece, the level of the protective gas just delivered and/or the composition of protection gas.An exemplary reality Execute in scheme, use one or more sensor to determine the environmental condition that may affect welding procedure, such as, wind condition And/or damp condition.In an exemplary embodiment, using one or more sensor to determine may impact welding Operator's condition of technique, such as, the angle that operator's hand is formed with workpiece from the distance of workpiece and/or operator's hand. By deriving from the data of these or other sensor compared with model data, to confirm which type of one operator should take Or the instruction of multiple corrective action.

In an exemplary embodiment, visually provide corrective action to indicate to operator, as with welding machine collection Become or provide in the display device of next-door neighbour's welding machine.In an exemplary embodiment, the protectiveness face worn operator With visual manner display instruction on helmet or the helmet.In an exemplary embodiment, provide instruction acoustically to operator, As provided by integrated with welding machine or next-door neighbour's welding machine speaker.In an exemplary embodiment, wear operator Protective headgear in audible means display instruction.

Therefore, guidance method 1100 provides Real-time Feedback to operator during welding procedure so that operator easily knows Road when weld from good condition turn to poor condition and when weld from difference condition turn to good condition.Additionally, guidance method 1100 can point out the corrective action being intended to improve current (and then overall) welding condition.Owing to the change of welding condition may often be such that Caused by the action of operator, feedback (including the corrective action of any prompting) the teaching behaviour that therefore guidance method 1100 provides The solder technology that author is good.Additionally, strengthen the good welds technology of operator by continuing the good welded condition of confirmation.

Guidance method 1100 or some of aspect can also be easily adapted to be applied in other words the welding procedure of emulation.One In individual exemplary, guidance method 1100 is applied to utilize the welding simulation device of virtual reality technology.

In some example embodiments, the quality instruction of the performed welding of the operator calculated (that is, is welded Point) can be used in innovative approach, for for specific welding machine, welding procedure or the welding process person that comes verification operation, this is similar to The situation of grade is used in general education.Such as, the welding score calculated according to guidance method 1100 or some of aspect (such as, integral solder score) is that verification operation person provides convenient platform.Operator must obtain exceeding for welding machine, weldering Connect technique or welding process is one or more welding scores that the predetermined threshold being verified welds score.If operator does not has Have by checking, then guidance method 1100 can indicate operator's area for improvement.As described herein, it is possible to use volume Other ginsengs of outer function (such as, welding machine interiorly or exteriorly run software provide) measurement may be used for verification operation person Number.For example, it is possible to amendment guidance method 1100 so that it is include following the trail of the actual weldering of operator during welding procedure or welding process Connect the spent time.As another embodiment, guidance method 1100 can be revised so that it is include following the trail of in welding procedure or The amount of the consumable goods (such as, welding wire) that operator uses during welding process.

In addition to for verification operation person, welding score (with other parameters) can be also used for distinguishing different operations Person.Such as, although two operators achieve by (passing) score and for specific welding machine, welding procedure or weldering Termination process is verified, but the score of the two operator may differ widely.Therefore, relatively low with score empirical tests operation Person compares, and can select another empirical tests operator that score is much higher.

In some example embodiments, the welding quality instruction (that is, welding score) calculated and other relevant ginsengs Number and information may be used for auxiliary direction, and person instructs multiple student's solder technology, technique, program, process etc..Welding course is usually Including theory part and put into practice part.Theory part is typically to carry out teaching, discuss or demonstrating in classroom or like environment Form teaching.Generally, course is instructed the welding school of student's practice part or other environment will include being similar to factory In each place (e.g., workplace) of welding bench.Each student is assigned to his or she workplace, to perform Course put into practice part.

Such as, by following the trail of each student about the class attendance rate during the discussion of theory part and/or participation, Director is easy to estimate how long each student takes in the theory part of course.But, it is every that director is difficult to gauge At course, individual student puts into practice how long part is actual takes, because during director can not stay between all working always. For example, it is possible to structure and/or layout workplace so that preceptorial sight line extends only to single workplace every time, i.e. director The most residing workplace.The student of other workplaces may do and some things of non-solder (such as, are eaten, slept Feel, say phone), and director is not aware that.Director is also difficult to be readily determined at any given time, and which student will It is most likely to benefit from preceptorial taking up personally.Therefore, director eventually spends the time with a student, although another Individual student takes up personally with greater need for preceptorial.

Figure 12 illustrates according to an exemplary for monitoring Students ' Learning solder technology, technique, journey The system 1200 of sequence, process etc. (e.g., Arc Welding Process).System 1200 includes instructing region 1202, such as classroom or workshop (shop), eight workplaces 1204,1206,1208,1210,1212,1214,1216 and is set in instructing region 1202 1218.Each workplace includes welding machine.Specifically, the first welding machine W1 1220 is positioned in the first workplace 1204, the second weldering Machine W2 1222 is positioned in the second workplace 1206, and the 3rd welding machine W3 1224 is positioned in the 3rd workplace 1208, the 4th welding machine W4 1226 are positioned in the 4th workplace 1210, and the 5th welding machine W5 1228 is positioned in the 5th workplace 1212, the 6th welding machine W6 1230 Being positioned in the 6th workplace 1214, the 7th welding machine W7 1232 is positioned in the 7th workplace 1216, and the 8th welding machine W8 1234 It is positioned in the 8th workplace 1218.Additionally, student to be assigned to each workplace.Specifically, by first student S1 1236 points It is fitted in the first workplace 1204 and works, be assigned to second student S2 1238 in the second workplace 1206 work, by the 3rd Individual student S3 1240 is assigned in the 3rd workplace 1208 work, and the 4th student S4 1242 is assigned to the 4th workplace Work in 1210, be assigned in the 5th workplace 1212 work by the 5th student S5 1244, by the 6th student S6 1246 It is assigned in the 6th workplace 1214 work, is assigned in the 7th workplace 1216 work by the 7th student S7 1248, and It is assigned in the 8th workplace 1218 work by the 8th student S8 1250.

Arrange and instruct region 1202 so that director 1252 freely can move to another work from a workplace Between interactive with student.

In an exemplary embodiment, each in welding machine W1, W2, W3, W4, W5, W6, W7 and W8 includes integrated Watch-dog M, as welding machine 10 as shown in Figure 1.When student is just using welding machine to generate welding, by welding machine (by watch-dog M) determine the instantaneous of welding and/or periodically weld score, and using welding score to provide about currently welding matter to student The directly feedback of amount.As described in this article, these welding scores are based on more accurately reflecting welding compared with only estimating welding The weighted statistical of quality is measured.Specifically, will welding score with make a reservation for qualified weld score or qualified welding score range (example As, determine according to base weld before) compare, to judge whether student must carry out any corrective action.It addition, Each Time evaluation welding score, deviates from any trend of qualified welding score (such as, show as welding to determine whether to exist The continuous reduction of score).

Each in welding machine W1, W2, W3, W4, W5, W6, W7 and W8 is by network 1256 and manufacturing monitoring system (PMS) 1254 communicate.Network 1256 can be wired or wireless network.In an exemplary embodiment, network 1256 be with Too net network.

In the case of without departing from the spirit and scope of present general inventive concept, it is possible to use software, hardware and combinations thereof come Realize PMS 1254.In an exemplary embodiment, PMS 1254 being embodied as has peripheral unit (e.g., display in connection Device 1258 and data storage 1260) the upper software run of general purpose computer (such as, PC).An exemplary embodiment party In case, PMS 1254 can include the logic integrated with each welding machine, as in the case of watch-dog M.As it has been described above, PMS 1254 carries out data communication by network 1256 with welding machine W1, W2, W3, W4, W5, W6, W7 and W8.

PMS 1254 is that welding data is collected and monitoring tools, and it operationally (such as) has remembered every time for collection Record the short-term of the statistical value of welding and weld record for a long time.PMS 1254 can also follow the trail of other and produce relevant parameter and condition, As, circuit consumption.In system 1200, the PMS 1254 each collection number from welding machine W1, W2, W3, W4, W5, W6, W7 and W8 According to, to determine the time quantum that each student S1, S2, S3, S4, S5, S6, S7 and S8 spends during generating welding.PMS The time quantum (that is, weld interval) that each student in student S1, S2, S3, S4, S5, S6, S7 and S8 spends can be protected by 1254 It is stored to data storage 1260, for subsequent retrieval (retrieval) and use.It addition, PMS 1254 by network 1256 from Each reception welding score in welding machine W1, W2, W3, W4, W5, W6, W7 and W8, then these can be welded by PMS 1254 Code insurance is stored to data storage 1260, for subsequent retrieval and use.Therefore, PMS 1254 can be in multiple evaluation time sections Producing and store weld interval and the record of welding score of multiple student, these records can be that director 1252 in teaching and comments Estimate affluent resources during student.

It addition, PMS 1254 can show student S1, S2, S3, S4, S5, S6, S7 and S8 in display device 1258 in real time In current weld interval of each student combine the current of each student in student S1, S2, S3, S4, S5, S6, S7 and S8 Welding score.In this way, by observing display device 1258, director 1252 can obtain each student and weld accordingly Instantaneous and the accurate assessment of the current state connect.This allows director 1252 preferably for those that the demand that shows is the highest Estranged join the his or her time.

In system 1200, can adopt in any way, by weld interval and welding score be shown as numeric data and/or Graph data.In an exemplary embodiment, PMS 1254 provides user interface based on webpage, and this user interface is supported By web browser access data, consult data, generation report etc..

System 1200 easily changes scale, to accommodate any amount of student and multiple director.

Figure 13 illustrates the monitoring Students ' Learning solder technology according to an exemplary, technique, program, mistake The method 1300 of journey etc. (e.g., Arc Welding Process).It is many that method 1300 relates to performing Arc Welding Process in step 1302 Individual student.In an exemplary embodiment, student under substantially the same conditions and performs base in the essentially identical time This identical Arc Welding Process.

During Arc Welding Process, in step 1304, periodically the welding score of each student is calculated (based on one Or the parameter that records in other words of more sampling), to reflect the welded condition of current student.Welding score can be calculated as instead During reflecting the transient measurement of the welded condition of current student, or reflection Arc Welding Process, certain period of time is (corresponding to repeatedly Measure) in the meansigma methods of repetitive measurement of welded condition of student.In an exemplary embodiment, by from electric arc Welding procedure starts acquired all measured values and is averaging the welding score calculating student, which reflects the whole of current student Body welded condition.

During the evaluation time section of method 1300, determine that each student performs Arc Welding Process in step 1306 The time quantum that (that is, actual welding) spends.The operable data collected from the welding machine of each student can be used to determine student Weld interval.

In step 1308, the student making each welding score corresponding is associated.Similarly, in step 1308, The student making each weld interval corresponding is associated.Identification information (the example of the welding machine distributing to each student can be used As, serial number) make the data (such as, welding score, weld interval) from welding machine collection and/or welding machine generation and corresponding student's phase Association.

Welding score and weld interval is once made to be associated with corresponding student, it is possible to the most by any way Export this information.For example, it is possible to all students and welding score and the report output of weld interval accordingly thereof are filled to display Put, e.g., monitor.As another embodiment, can be by about student and corresponding welding score thereof and the letter of weld interval Breath registration is also stored in data storage (e.g., disc driver or flash drive), for subsequent retrieval and use.One In individual exemplary embodiment, periodically export information.In an exemplary embodiment, defeated at the end of evaluation time section Go out information.

Welding score can also be used and/or produce the extra identification information of student weld interval.For example, it is possible to will learn Raw welding score and/or weld interval are compared with predetermined threshold.In this way, welding score based on student and/or weldering Connect the time, it is possible to determine that the welding of student is qualified or defective.

In some example embodiments, the welding score of the welding calculated may be used in innovative approach, with mirror The implicit costs of other welding procedure are saved.In an exemplary embodiment, a series of based on perform according to welding procedure Welding, carries out the cost analysis (such as, cost-benefit analysis cost effectiveness analysis, cost effectiveness analysis) of welding procedure.In Figure 14 A to Figure 14 B Shown in, it is possible to use the data 1400 corresponding to exemplary weld carry out executory cost analysis.

First, select to affect multiple welding conditions 1402 of integral solder quality.Such as, in Figure 14 A and Figure 14 B, weldering Connect condition 1402 and include welding wire characteristic (such as, welding wire composition 1404, gage of wire, coating), characteristic (such as, workpiece group Become (composition) 1406, thickness of workpiece), protective gas flow velocity 1408, protective gas composition 1410 and/or workpiece preheating Temperature 1412.Then, as represented by 1414, for a series of welding, a welding bar in these welding conditions 1402 Part changes, and simultaneously as represented by 1414, for a series of welding, remaining all welding conditions 1402 are fixing 's.

For each welding in a series of welding, it is additionally based upon current welding condition 1402,1414 and calculates welding score 1416.Welding score 1416 characterizes the measurement of the total quality of the welding generated under soldering conditions.As it has been described above, these welding Score is to measure based on the weighted statistical more accurately reflecting welding quality compared with only estimating welding.

It addition, for each welding in a series of welding, determine the cost generating welding.An exemplary embodiment party In case, cost includes the dollar spending relevant to generating welding, and this dollar spending is characterized as being the monetary cost 1418 of welding.? In one exemplary, cost has included welding required total time, and this cost is characterized as being the time one-tenth of welding These are 1420 years old.The corresponding welding score of each welding in a series of welding and cost is made to be associated.

Figure 14 A and Figure 14 B includes the data 1400 of two welding in a series of welding respectively, wherein, for a series of Welding, among welding condition 1402, as shown in 1414, welding wire composition 1404, workpiece composition 1406, protective gas composition 1410 and workpiece preheating temperature 1412 be fixing, simultaneously for a series of welding, as shown in 1414, protective gas flow velocity 1408 change (such as, increasing or decreasing).

For the welding corresponding to Figure 14 A, calculate and determine monetary cost 1418a, time cost 1420b and welding in other words Score 1416c.For the welding corresponding to Figure 14 B, calculate and determine monetary cost 1418d, time cost 1420e and weldering in other words Connect score 1416f.Therefore, if it is decided that a ＜ d, b ＜ e and c=f, then the protective gas flow velocity 1408 of Figure 14 A can be derived Protective gas flow velocity 1408 higher than Figure 14 B, because compared with the protective gas flow velocity 1408 of Figure 14 B, by the protection of Figure 14 A Gas flow rate 1408 is simultaneously achieved cost and time saving and integral solder quality does not has any reduction.If relatively, sentenced Determine a ＜ d, b ＞ ＞ e and c=f, then can derive compared with the protective gas flow velocity 1408 of Figure 14 B, the protective gas of Figure 14 A Flow velocity 1408 provides cost savings, and integral solder quality does not has any reduction, but time cost dramatically increases.

In this way, user by can easily verify the welding condition of change to a series of (and then corresponding Welder In skill) impact of integral solder quality.In this way, whether user can be determined that change welding condition (and in which way) Obtain more desirable welding quality, more desirable cost by enabling users to or obtain both simultaneously.Therefore, when performing more welderings When connecing and analyze the data of correspondence, can readily determine that and evaluate any one or more welding condition to integral solder The impact of technique so that the cost savings that can make more wisdom determine (such as, relative to the power of money, time and quality Weighing apparatus).

Cost analysis can be extended so that it is include extra a series of welding, wherein, in the welding of different series, no Same welding condition changes.In this way, user can verify desirable value or the setting value of multiple welding condition, to realize Results needed (such as, qualified welding quality and qualified cost).It is then possible to by the desirable value of these welding conditions or set Definite value is saved in the brief introduction (profile) being associated with welding machine and welding procedure, for follow-up identical welding machine and Welder Skill is fetched and is used, and thereby increases user and will again realize the probability of results needed.

In an exemplary embodiment, by multiple this brief introductions (that is, selected welding parameter and/or welding condition Set) save as (i.e.) and pre-set so that the user starting welding procedure can access these brief introductions.An exemplary reality Execute in scheme, present multiple pre-seting together with corresponding to each welding score pre-seted to user.Each welding Score quantifies The integral solder quality before used and pre-set the welding parameter being associated and welding condition obtains.As it has been described above, these welderings Connecing score is to measure based on the weighted statistical of more precise effects welding quality compared with only estimating welding.Then, user can select Select one of to pre-set and perform welding procedure, thus increase user and pre-set, with use before, the welding parameter being associated by realizing Formed with welding condition welds identical or substantially similar welding.In an exemplary embodiment, it is provided that user interface, Allow a user to filter out and do not mate user and input pre-seting of standard, such as, filter out the phase having less than input threshold value Those of association welding score pre-set.

Figure 15 illustrates and pre-sets 1500 according to an exemplary.Each pre-set 1500 include checking preset Put sequence number 1502, welding condition set 1504, welding machine information 1506, welding procedure information 1508, monetary cost 1510, time one-tenth Basis 1512 and the welding score 1514 being associated.Make to have pre-set sequence number 01 first preset 1516 with have value a, b, c, Welding condition 1504 and the welding machine M of d and e are associated.First pre-sets 1516 corresponding to welding procedure O.If user selects One pre-sets 1516 (that is, pre-seting 01) utilizes welding machine M to perform welding procedure O, then user under welding condition a, b, c, d and e It can be desirable to the welding obtained by welding procedure O has the time cost and substantially of the monetary cost of substantially t, substantially v Welding score for x.Pre-set 1500 and can include extra pre-seting, e.g., with welding condition 1504, welding machine 1506 and/or What the various combination of welding procedure 1508 was associated second pre-sets 1518.

In addition to the monitored welding parameter having been described, additional welding parameter can be for the one of waveform Or more state is monitored, and additional mass parameter can be calculated from described additional welding parameter, to examine more accurately Survey and differentiate weld defect.The sound that additional welding parameter can include welding torch or welding torch position, be produced by Arc Welding Process The level of sound, the Arc Welding Process frequency of at least one sound produced and the sound that produced by Arc Welding Process Pulsation rate (pulsing rate).The level of the visible ray that more additional welding parameter includes being produced by Arc Welding Process, The frequency of at least one visible ray produced by Arc Welding Process and the pulsation of visible ray produced by Arc Welding Process Rate.Further additional welding parameter includes the level of the infrared light produced by Arc Welding Process, is produced by Arc Welding Process The frequency of at least one raw infrared light, the Arc Welding Process pulsation rate of the infrared light produced and welding wire are sent into motor electricity Flow horizontal.

According to embodiment, additional welding parameter is passed through to be suitable for detecting the sensor of such welding parameter or monitoring dress Put and sense.Such as, sound can be sensed by mike, it is seen that light can be sensed by photodetector, and infrared light can To be sensed by infrared detector, welding wire is sent into motor current and can be sensed by diverter.Welding torch position can use The detection technology of one or more types senses (including, such as imaging sensor or magnetic sensor).Sensor is permissible Be arranged on various position, including, such as on welding torch, welding the helmet on or at general welding region.Additionally by Sensing welding parameter can be imported into watch-dog M by this way and by watch-dog M process, described mode be similar to as How other welding parameters previously described herein are transfused to and processed mode.Other can be monitored and be located The welding parameter of reason includes the temperature of workpiece, the level of protective gas, the composition of protective gas, the wind speed of near workpieces, workpiece Neighbouring humidity level and operator position.

Watch-dog M can be configured (the watch-dog M' of the upgrading such as, gone out as shown in Figure 16) to be come based on additionally Monitored welding parameter calculates multiple mass parameter statistical values.Various additional weldering for one or more state of waveform Connecing parameter, various mass parameter statistical values " meansigma methods ", " standard deviation ", " mean of variance " and " variance criterion is poor " can be with this The mode of sample is calculated, and described mode is similar to those mass parameters for voltage and current as previously described herein and unites The most calculated mode of evaluation.That is, mass parameter based on additional monitored welding parameter can be by this way Being calculated, described mode is similar to how QVA, QVSD, QWA and QWSD for monitored voltage are calculated to and for quilt The most calculated mode of QIA, QISD, QIVA and QIVSD of the electric current of monitoring.

Such as, watch-dog M can be configured to during welding procedure within a time period for one or more shape State calculates sound levels mass parameter, and such as quality acoustic level average (QSLA), quality acoustic level standard is poor (QSLSD), quality acoustic level variance meansigma methods (QSLVA) and quality acoustic level variance standard deviation (QSLVSD).Monitoring Device M can also be configured within a time period for one or more state computation sound frequency mass parameter, such as matter Amount sound frequency meansigma methods (QSFA), quality acoustic frequency standard poor (QSFSD), quality acoustic frequency variance meansigma methods And quality acoustic frequency variance standard deviation (QSFVSD) (QSFVA).It addition, watch-dog M can also be configured in the time For one or more state computation sound pulsation rate mass parameter, such as quality acoustic pulsation rate (pulse rate) in section Meansigma methods (QSPRA), quality acoustic pulsation rate standard deviation (QSPRSD), quality acoustic pulsation rate mean of variance (QSPRVA) with And quality acoustic pulsation rate variance criterion poor (QSPRVSD).The sound of welding procedure is by wire-electrode (wire Electrode) electric arc and between workpiece produces.Specific sound property tends to occur at the particular state of welding waveform.

Watch-dog M can be configured to during welding procedure within a time period for one or more state computation Visible light level mass parameter, such as quality visible light level meansigma methods (QVLLA), quality visible light level standard deviation (QVLLSD), quality visible light level mean of variance (QVLLVA) and quality visible light level variance criterion are poor (QVLLVSD).Watch-dog M can also be configured within a time period for one or more state computation visible frequency Mass parameter, such as quality visible frequency meansigma methods (QVLFA), quality visible frequency standard deviation (QVLFSD), quality can See light frequency mean of variance (QVLFVA) and quality visible frequency variance criterion poor (QVLFVSD).It addition, watch-dog M Can also be configured within a time period for one or more state computation visible ray pulsation rate mass parameter, such as matter Amount visible ray pulsation rate meansigma methods (QVLPRA), quality visible ray pulsation rate standard deviation (QVLPRSD), quality visible ray pulsation rate Mean of variance (QVLPRVA) and quality visible ray pulsation rate variance criterion poor (QVLPRVSD).The visible ray of welding procedure It is to be produced by the electric arc between wire-electrode and workpiece.

Watch-dog M can be configured to during welding procedure within a time period for one or more state computation Infrared light leveling qualities parameter, such as quality infrared light level average (QIRLLA), quality infrared light level standard is poor (QIRLLSD), quality infrared light level variance meansigma methods (QIRLLVA) and quality infrared light level variance standard deviation (QIRLLVSD).Watch-dog M can also be configured within a time period for the infrared optical frequency of one or more state computation Rate mass parameter, such as quality infrared light average frequency value (QIRLFA), quality infrared light frequency standard poor (QIRLFSD), matter Amount infrared light frequency variance meansigma methods (QIRLFVA) and quality infrared light frequency variance standard deviation (QIRLFVSD).It addition, prison Control device M can also be configured within a time period for one or more state computation infrared light pulsation rate mass parameter, Such as quality infrared light pulsation rate meansigma methods (QIRLPRA), quality infrared light pulsation rate standard deviation (QIRLPRSD), quality are infrared Light pulsation rate mean of variance (QIRLPRVA) and quality infrared light pulsation rate variance criterion poor (QIRLPRVSD).Welder The infrared light of skill is to be produced by the electric arc between wire-electrode and workpiece.

Watch-dog M can be configured to during welding procedure within a time period for one or more state computation Welding wire is sent into motor current mass parameter, such as quality welding wire and is sent into motor current meansigma methods (QWFMIA), the feeding of quality welding wire Motor current standard deviation (QWFMISD), quality welding wire are sent into motor current mean of variance (QWFMIVA) and quality welding wire send Enter motor current variance criterion poor (QWFMIVSD).Welding wire is sent into motor current during welding procedure by the horse of wire feeder Reach generation.When the ignition tip that ignition tip becomes abrasion or mistake is used, the displacement (shift) in motor current or spike (spike) may be observed during some state.

Again, various mass parameter statistical values " meansigma methods ", " standard deviation ", " mean of variance " and " variance criterion is poor " Can be calculated for various additional welding parameters by this way, described mode be similar to as previously described herein for Those the most calculated modes of mass parameter statistical value of voltage and current.It addition, according to embodiment, for each time The value of each mass parameter that section calculates can be compared with corresponding prospective quality parameter value, the quality calculated with judgement Whether the difference of parameter value and prospective quality parameter value exceedes predetermined threshold.If difference exceedes threshold value, can be based on described difference, with greatly Little weight determines the weight of the quality parameter value calculated, and/or based on its state relative to the waveform including described state Time contributes, and determines the weight of the quality parameter value calculated with time contribution weight.

According to embodiment of the present invention, mass parameter (that be determined weight or be not determined weight) and/or welding Parameter can be used to diagnose Arc Welding Process.Figure 16 illustrates the reality of the system 1600 for diagnosing Arc Welding Process Execute the schematic block diagram of scheme.System 1600 corresponds to a part for arc welding system and includes the watch-dog M' of upgrading 1610, the watch-dog M' of described upgrading are similar to watch-dog M but are configured to monitor additional welding discussed in this article further Parameter and calculate further correspondence additional mass parameter.System 1600 also includes logical with the watch-dog M'1610 operation of upgrading The diagnostic logic circuit (DLC) 1620 of letter.

As described in illustrated in Figure 16, the mass parameter calculated and/or the welding parameter monitored or they one A little collection is passed to DLC 1620, described DLC 1620 and produces logical consequence based on described parameter manipulation.According to embodiment party Case, DLC 1620 first pass through analyze mass parameter differentiate weld seam local or continuous print defect.The defect of local is to occur The defect in the relatively short time period (such as, 2 seconds) during welding procedure.Continuous print defect occurs from substantially welding Defect in the whole time (such as, 20 seconds) connecing technique.Some examples of defect include the gas inclusions (porous in weld seam (porosity), aperture blowing (blow hole), pore (worm hole)), the insufficient (incomplete) penetration burning, entering workpiece of workpiece, fly Space and fusion (fusion) in the joint that spatter, has not been filled, undercut, the cracking of weld seam, weld seam are not enough.So type Defect be well known in the art.Other kinds of defect can also be possible.

Some examples of the possible reason of defect include that protective gas deficiency, ignition tip to workpiece are apart from short, ignition tip To workpiece distance, blocked nozzle, surface of the work pollutes, gait of march is too slow, gait of march is too fast, feed rate of welding wire Too slow, feed rate of welding wire is too fast, sulfur content in workpiece or welding rod, from welding rod and the excess moisture of workpiece and the least Welding rod angle.The reason of other kinds of defect is also possible.

During exercise welding process, defect is relevant to the reason of defect and DLC 1620 is correspondingly programmed and will lack Fall into the reason possible with one or more to be correctly associated.Therefore, during normal (non-exercise) welding process, DLC1620 can advise one or more possible reason of one or more defect being detected.Defect and one Individual or more reasons can be apprised of operator, to allow operator to correct problem.DLC 1620 can such as organized The reason of defect is isolated by decision tree.

As embodiment, during system 1600 can detect as occurring in welding procedure by analyzing mass parameter The porous (occurring in some state) of two continuous print defects and splashing (occurring in some other state).DLC 1620 can pass through Wear welding procedure by relevant to protective gas deficiency for the appearance of two continuous print defects in respective state.Operator may be with The valve of rear discovery gas tank is pent during welding procedure.

Figure 17 is the flow chart of method 1700 using the system 1600 of Figure 16 to diagnose Arc Welding Process, and described method is led to Cross to create and for creating the actual welding parameter of weld seam thus perform electricity at arc welder between welding wire and the workpiece advanced Arc welder is monitored during arc welding technique.Welding procedure is controlled by the command signal of the power supply of welding machine.Step in method 1700 1710, the waveform of a series of quick repetitions is generated, and each waveform constitutes the weld cycle with a circulation time.In step 1720, waveform is divided into multiple state.In step 1730, the multiple welding parameters occurred in one or more state exist The time period repeated during welding procedure is interior measured with inquiry speed.

In the step 1740 of method 1700, based on the measurement of welding parameters during welding procedure, multiple mass parameter pins Each state is calculated.At least one in step 1750, multiple mass parameters and multiple welding parameter is analyzed, with logical Cross judge weld seam one or more local or one or more possible reason of continuous print defect to diagnose electric arc Welding procedure.

In a word, arc welding system and method are disclosed.During system can be according to waveform condition monitoring welding procedure Variable also correspondingly determines the weight of variable, the defect of detection weld seam, the possible reason of diagnosis defect, the entirety of quantization weld seam Quality, obtain and use represent the data of good weld seam, to improve the yield of automatic soldering technique and quality control, teaching correct Solder technology, differentiate the cost savings of welding procedure and obtain being used as the optimal weldering pre-seted of different welding procedures or application Connect setting.

Provide the above explanation to specific embodiments the most by way of example.In the disclosure be given, ability The technical staff in territory will not only understand present general inventive concept and attendant advantages, and it will also be appreciated that to disclosed structures and methods Significantly variations and modifications.Such as, present general inventive concept is typically not limited to manual welding process or automatization's (such as, machine Device people) in welding procedure one, but it is readily adapted for use in any one on the contrary.Additionally, present general inventive concept is readily adapted for use in Different welding procedures and technology (such as, all deformation of electric arc welding, e.g., Stick (manual welding) and TIC welds).Therefore, Seek, contain and fall into as in the spirit and scope of appended claims and the present general inventive concept of equivalents restriction thereof All such change and modifications.

Reference number

10 arc welder 81a subdivisions

12 power supply unit 81b stages

14 terminal 82 logics

16 terminal 84 agitators

18 inducer 90a wave filter

20 welding wire 91 stages

22 reel 92 logics

24 feeder 94 agitators

26 motor 100 waveforms

30 workpiece 102 peak point currents

32 diverter 104 background currents

34 piece of 110 line

152 pieces of 34a circuit

36 piece of 156 output

36a circuit 158 manipulator

40 160 pieces of generators

42 circuit 162 circuits

44 circuit 170 rising parts

46 drive control 172 sloping portions

46a circuit 180 threshold value

46b circuit 182 minimum level

46c encoder 184 transient state

70 interface 186 transient states

Program analyzed by 80c wave filter 200

80d wave filter 202a circuit

81 stage 202b circuits

210 piece of 270 program

210a circuit 272 enumerator

212 subprogram 280 subprograms

214 282 pieces of circuits

216 circuit 282a blocks

220 284 pieces of enumerators

220a block 286 pieces

222 enumerator 286a blocks

222a block 286b block

224 circuit 900 methods

226 piece of 902 initial step

230 piece of 904 step

234 stage 906 steps

236 piece of 908 step

238 piece of 910 step

250 analyze program 914 step

252 program step 916 steps

254 piece of 918 step

254a circuit 920 step

256 enumerator 1000 production lines

258 circuits 1002 weld score S1

260 piece of 1004 welding score S2

Score S3 is welded in 262 subprograms 1006

262a block 1010 WP2

264 program step 1012 WP3

266 subprogram 1014 welding benches

266a block 1016 watch-dog

266b subprogram 1018 appraisal platform

1020 welding order 1232 W7

1022 welding order 1234 W8

1100 method 1236 S1

1102 step 1238 S2

1104 step 1240 S3

1106 step 1242 S4

1108 step 1244 S5

1110 step 1246 S6

1112 step 1248 S7

1114 step 1250 S8

1116 step 1252 directors

1118 step 1254 PMS

1200 system 1256 networks

1202 instruct region 1258 display device

1204 workplace 1260 data storage

1206 workplace 1300 methods

1208 workplace 1302 steps

1210 workplace 1304 steps

1212 workplace 1306 steps

1214 workplace 1308 steps

1216 workplace 1310 steps

1218 workplace 1400 data

1220 W1 1402 welding conditions

1222 W2 1404 welding wire compositions

1224 W3 1406 workpiece compositions

1226 W4 1408 gas flow rates

1228 W5 1410 gas compositions

1230 W6 1412 temperature

The 1414 1514 welding scores being expressed

1416 welding scores 1516 pre-set

1418 monetary cost 1600 systems

The watch-dog of 1420 time cost 1610 upgradings

1500 pre-set 1620 DLC

1502 pre-set sequence number 1700 method

1504 welding condition 1710 steps

1506 welding machine information 1720 steps

1508 technique information 1730 steps

1510 monetary cost 1740 steps

1512 time costs

Claims (27)

1. the method diagnosing Arc Welding Process, described method by create advance welding wire (20) and workpiece (30) it Between for create weld seam actual welding parameter thus arc welder (10) perform Arc Welding Process time monitor described electricity Arc-welding machine (10), described welding procedure is controlled by the command signal of the power supply (12) of described arc welder (10), described method bag Include:

Producing the waveform (100) of a series of quick repetition, each composition in described waveform (100) has the weldering of a circulation time Connect circulation；

Described waveform is divided into multiple state；

In the time period repeated during described welding procedure, to inquire that speed measurement divides at waveform one or more described The multiple welding parameters occurred in the state become；

Based on described measurement to described welding parameter during described welding procedure, calculate each one or more waveform Multiple mass parameters of the state being divided into；And

Analyze at least one in the plurality of mass parameter and the plurality of welding parameter, with by judging the one of described weld seam One or more possible reason individual or more local or continuous print defect diagnoses described Arc Welding Process.

Method the most according to claim 1, also includes:

By each quality parameter value of calculating for each time period compared with corresponding prospective quality parameter value, to judge Whether the described quality parameter value calculated and the difference of described prospective quality parameter value exceed predetermined threshold；And

If described difference exceedes described threshold value, then based on described difference, determine the described quality parameter value calculated with size weight Weight, and the state being divided into based on described waveform is relative to the described waveform including state that described waveform is divided into Time contributes, and determines the weight of the described quality parameter value calculated with time contribution weight.

Method the most according to claim 1 and 2, the state being wherein divided into for waveform one or more described, institute State multiple welding parameter include following in two or more: arc current, arc voltage, feed rate of welding wire, described work The temperature of part, the level of protective gas, the composition of protective gas, the wind speed of described near workpieces, the humidity of described near workpieces Level and operator position.

Method the most according to claim 1, the state being wherein divided into for waveform one or more described is described many Individual welding parameter include following in two or more: welding torch position, described the Arc Welding Process water of the sound produced Flat, the frequency of at least one sound that produced by described Arc Welding Process, the sound that produced by described Arc Welding Process Pulsation rate, the level of the visible ray produced by described Arc Welding Process, produced by described Arc Welding Process at least one The frequency of visible ray, described the Arc Welding Process pulsation rate of the visible ray produced, produced by described Arc Welding Process The level of infrared light, the frequency of at least one infrared light produced by described Arc Welding Process, by described Arc Welding Process The pulsation rate of the infrared light produced and welding wire are sent into motor current level.

Method the most according to claim 1, wherein draws for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter include following in two or more: quantity count meansigma methods (QCA), quality Counting criteria poor (QCSD), quality voltage meansigma methods (QVA), quality voltage standard deviation (QVSD), quality current average (QIA), quality current standard deviation (QISD), quality voltage mean of variance (QVVA), quality voltage variance criterion are poor (QVVSD), quality electric current mean of variance (QIVA) and quality electric current variance criterion poor (QIVSD).

Method the most according to claim 1, wherein draws for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality feed rate of welding wire meansigma methods (QWA), quality feed rate of welding wire Standard deviation (QWSD), quality feed rate of welding wire mean of variance (QWVA) and quality feed rate of welding wire variance criterion are poor (QWVSD)。

Method the most according to claim 1, wherein draws for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality acoustic level average (QSLA), quality acoustic level standard are poor (QSLSD), quality acoustic level variance meansigma methods (QSLVA) and quality acoustic level variance standard deviation (QSLVSD).

Method the most according to claim 1, wherein draws for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality acoustic average frequency value (QSFA), quality acoustic frequency standard are poor (QSFSD), quality acoustic frequency variance meansigma methods (QSFVA) and quality acoustic frequency variance standard deviation (QSFVSD).

Method the most according to claim 1, wherein draws for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality acoustic pulsation rate meansigma methods (QSPRA), quality acoustic pulsation rate mark Accurate poor (QSPRSD), quality acoustic pulsation rate mean of variance (QSPRVA) and quality acoustic pulsation rate variance criterion are poor (QSPRVSD)。

Method the most according to claim 1, wherein draws for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality visible light level meansigma methods (QVLLA), quality visible light level mark Accurate poor (QVLLSD), quality visible light level mean of variance (QVLLVA) and quality visible light level variance criterion are poor (QVLLVSD)。

11. methods according to claim 1, wherein draw for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality visible frequency meansigma methods (QVLFA), quality visible frequency mark Accurate poor (QVLFSD), quality visible frequency mean of variance (QVLFVA) and quality visible frequency variance criterion are poor (QVLFVSD)。

12. methods according to claim 1, wherein draw for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality visible ray pulsation rate meansigma methods (QVLPRA), quality visible ray are pulsed Rate standard deviation (QVLPRSD), quality visible ray pulsation rate mean of variance (QVLPRVA) and quality visible ray pulsation rate variance Standard deviation (QVLPRVSD).

13. methods according to claim 1, wherein draw for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality infrared light level average (QIRLLA), quality infrared light level mark Accurate poor (QIRLLSD), quality infrared light level variance meansigma methods (QIRLLVA) and quality infrared light level variance standard deviation (QIRLLVSD)。

14. methods according to claim 1, wherein draw for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality infrared light average frequency value (QIRLFA), quality infrared light frequency mark Accurate poor (QIRLFSD), quality infrared light frequency variance meansigma methods (QIRLFVA) and quality infrared light frequency variance standard deviation (QIRLFVSD)。

15. methods according to claim 1, wherein draw for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality infrared light pulsation rate meansigma methods (QIRLPRA), quality infrared light arteries and veins Dynamic rate standard deviation (QIRLPRSD), quality infrared light pulsation rate mean of variance (QIRLPRVA) and quality infrared light pulsation rate Variance criterion poor (QIRLPRVSD).

16. methods according to claim 1, wherein draw for the described waveform of one or more within the described time period The state being divided into, the plurality of mass parameter includes: quality welding wire is sent into motor current meansigma methods (QWFMIA), quality welding wire send Enter motor current standard deviation (QWFMISD), quality welding wire is sent into motor current mean of variance (QWFMIVA) and quality welding wire It is sent into motor current variance criterion poor (QWFMIVSD).

17. methods according to claim 1, one or more defect wherein said include following in one or more Individual: the gas inclusions in described weld seam, the burning of described workpiece, to enter the insufficient (incomplete) penetration of described workpiece, splashing, be not filled Joint, undercut, the cracking of described weld seam, space in described weld seam and fusion deficiency.

18. methods according to claim 1, one or more possible reason wherein said include following in one Or more: protective gas deficiency, ignition tip to workpiece are apart from short, ignition tip to workpiece distance, blocked nozzle, workpiece Surface contamination, gait of march are too slow, gait of march is too fast, feed rate of welding wire is too slow, feed rate of welding wire is too fast, welding rod or institute State the sulfur content in workpiece, from described welding rod and the excess moisture of workpiece and the least welding rod angle.

19. 1 kinds of systems being used for diagnosing Arc Welding Process, described system is by creating at the welding wire (20) advanced and workpiece (30) monitoring when arc welder (10) performs Arc Welding Process for forming the actual welding parameter of weld seam between Described arc welder (10), described welding procedure is limited by the waveform (100) of a series of quick repetitions, described a series of quickly The waveform (100) repeated is controlled by the command signal of the power supply (12) of described arc welder (10), and described system includes:

Logic state controller, described logic state controller is for being segmented into a series of time by each described waveform (100) Fragmentation state；

For selecting the circuit of specific waveforms state；

Supervising device, described supervising device is within the time period that monitoring repeats during described welding procedure, to inquire speed Measure the multiple welding parameters occurred in waveform state one or more described, to obtain for the plurality of welding parameter The data arranged；

For calculating the circuit of the multiple mass parameters for each described waveform state based on monitored multiple welding parameters； And

Diagnostic logic circuit, described diagnostic logic circuit is used for analyzing in the plurality of mass parameter and the plurality of welding parameter At least one, with one or more local by judging described weld seam or one or more of continuous print defect can The reason of energy diagnoses described Arc Welding Process.

20. systems according to claim 19, also include:

For each quality parameter value of will calculating for each time period compared with corresponding prospective quality parameter value with Judge whether the difference of described quality parameter value and the described prospective quality parameter value calculated exceedes the circuit of predetermined threshold；And

If exceeding described threshold value for described difference, determine the described mass parameter calculated with size weight based on described difference The weight of value and contributing relative to the time of the described waveform including described waveform state with the time based on described waveform state Contribution weight determine described in the circuit of the weight of quality parameter value that calculates.

21. systems according to claim 19, wherein for waveform state one or more described, the plurality of welding Parameter include following in two or more: arc current, arc voltage, feed rate of welding wire, the temperature of described workpiece, guarantor Protect the level of gas, the composition of protective gas, the wind speed of described near workpieces, the humidity level of described near workpieces and operation Person position；And/or wherein for waveform state one or more described, the plurality of welding parameter include following in two Or more: welding torch position, described the welding procedure level of the sound produced, the frequency of the sound produced by Arc Welding Process Rate, the pulsation rate of the sound produced by described Arc Welding Process, produced by described Arc Welding Process visible ray level, The frequency of the visible ray produced by described Arc Welding Process, the pulsation rate of the visible ray produced by described Arc Welding Process, The level of the infrared light produced by described Arc Welding Process, the frequency of the infrared light produced by described Arc Welding Process, by The pulsation rate of the infrared light that described Arc Welding Process produces and welding wire are sent into motor current level；And/or wherein for One or more described waveform state in the described time period, the plurality of mass parameter include following in two or more Individual: quantity count meansigma methods (QCA), quantity count standard deviation (QCSD), quality voltage meansigma methods (QVA), quality voltage standard Difference (QVSD), quality current average (QIA), quality current standard deviation (QISD), quality voltage mean of variance (QVVA), matter Amount voltage variance criterion poor (QVVSD), quality electric current mean of variance (QIVA) and quality electric current variance criterion are poor (QIVSD)；And/or wherein for the described waveform state of one or more within the described time period, the plurality of quality is joined Number includes: quality feed rate of welding wire meansigma methods (QWA), quality feed rate of welding wire standard deviation (QWSD), quality welding wire are sent into Velocity variance meansigma methods (QWVA) and quality feed rate of welding wire variance criterion poor (QWVSD).

22. systems according to claim 19, wherein for the described waveform of one or more within the described time period State, the plurality of mass parameter includes: quality acoustic level average (QSLA), quality acoustic level standard poor (QSLSD), Quality acoustic level variance meansigma methods (QSLVA) and quality acoustic level variance standard deviation (QSLVSD)；And/or wherein for One or more described waveform state within the described time period, the plurality of mass parameter includes: quality acoustic frequency is put down Average (QSFA), quality acoustic frequency standard poor (QSFSD), quality acoustic frequency variance meansigma methods (QSFVA) and quality sound Voice frequency variance criterion poor (QSFVSD)；And/or wherein for the described wave of one or more within the described time period State, the plurality of mass parameter includes: quality acoustic pulsation rate meansigma methods (QSPRA), quality acoustic pulsation rate standard deviation (QSPRSD), quality acoustic pulsation rate mean of variance (QSPRVA) and quality acoustic pulsation rate variance criterion are poor (QSPRVSD)。

23. systems according to claim 19, wherein for the described waveform of one or more within the described time period State, the plurality of mass parameter includes: quality visible light level meansigma methods (QVLLA), quality visible light level standard deviation (QVLLSD), quality visible light level mean of variance (QVLLVA) and quality visible light level variance criterion are poor (QVLLVSD)；And/or wherein for the described waveform state of one or more within the described time period, the plurality of quality Parameter includes: quality visible frequency meansigma methods (QVLFA), quality visible frequency standard deviation (QVLFSD), quality visible ray Frequency variance meansigma methods (QVLFVA) and quality visible frequency variance criterion poor (QVLFVSD)；And/or wherein in institute Stating one or more the described waveform state in the time period, the plurality of mass parameter includes: quality visible ray pulsation rate is put down Average (QVLPRA), quality visible ray pulsation rate standard deviation (QVLPRSD), quality visible ray pulsation rate mean of variance And quality visible ray pulsation rate variance criterion poor (QVLPRVSD) (QVLPRVA).

24. systems according to claim 19, wherein for the described waveform of one or more within the described time period State, the plurality of mass parameter includes: quality infrared light level average (QIRLLA), quality infrared light level standard are poor (QIRLLSD), quality infrared light level variance meansigma methods (QIRLLVA) and quality infrared light level variance standard deviation (QIRLLVSD)；And/or wherein for the described waveform state of one or more within the described time period, the plurality of quality Parameter includes: quality infrared light average frequency value (QIRLFA), quality infrared light frequency standard poor (QIRLFSD), quality are infrared Light frequency mean of variance (QIRLFVA) and quality infrared light frequency variance standard deviation (QIRLFVSD)；And/or wherein for One or more described waveform state within the described time period, the plurality of mass parameter includes: quality infrared light is pulsed Rate meansigma methods (QIRLPRA), quality infrared light pulsation rate standard deviation (QIRLPRSD), quality infrared light pulsation rate mean of variance And quality infrared light pulsation rate variance criterion poor (QIRLPRVSD) (QIRLPRVA).

25. systems according to claim 19, wherein for the described waveform of one or more within the described time period State, the plurality of mass parameter includes: quality welding wire is sent into motor current meansigma methods (QWFMIA), quality welding wire is sent into motor Current standard deviation (QWFMISD), quality welding wire are sent into motor current mean of variance (QWFMIVA) and quality welding wire is sent into horse Reach electric current variance criterion poor (QWFMIVSD).

26. systems according to claim 19, one or more defect wherein said include following in one or more Multiple: the gas inclusions in described weld seam, the burning of described workpiece, to enter the insufficient (incomplete) penetration of described workpiece, splashing, be not filled Space in complete joint, undercut, the cracking of described weld seam, described weld seam and fusion deficiency.

27. according to a described system in claim 19 to 26, one or more possible reason bag wherein said Include following in one or more: protective gas is not enough, ignition tip to workpiece apart from short, ignition tip to workpiece distance, quilt The nozzle, the surface of the work that block pollute, gait of march is too slow, gait of march is too fast, feed rate of welding wire is too slow, welding wire is sent into speed Spend the sulfur content in workpiece the fastest, described or welding rod, from described welding rod and the excess moisture of workpiece and the least welding rod angle Degree.