JPH0497383A - Education and training device for welding skill - Google Patents

Abstract

PURPOSE:To perform rational repeated training without accompanying an individual difference caused by the degree of skill by providing a practical skill training part by simulation, a repeated training part by practical skill and a result display unit. CONSTITUTION:A light pen 4 is set as a welding arc generating source by utilizing the rectilinear propagation of light, and the practical skill training part by the simulation for executing simulation training by assuming that the change of a light quantity on a light receiving surface is the skill of a welding apprentice is provided. Then, the repeated training part by the practical skill which is provided with an execution control range setting device 11 for setting a control range in a welding operation and a welding execution control unit 13 which samples and stores the circumstances of the repeated training by the practical skill and decides that the operation is executed out of the specified control range in such a case is also provided. Thus, the training by the use of the practical skill training part by the simulation is performed as the training for initial comprehension. In order to perform the training of the practical skill in the case that basic instruction and training progresses to some extent, the repeated training is performed in an accurate and reproducible method by repeating the training until the apprentice persuades himself by performing detailed measurement and recording at the time of performing execution by the welding execution control unit of the repeated training part by the practical skill.

Description

[Detailed Description of the Invention] [Purpose of the Invention] (Industrial Application Field) The present invention provides a method for welding technicians who perform arc welding in general, to enable rational repetition without individual differences due to skill level, etc. This invention relates to an education and training device for welding skills that allows training.

(Prior Art) Conventionally, welding training for welding technicians has been carried out under the guidance of a teacher who is skilled in practical work. The reason for this is that welding work is performed on a wide variety of products, and it is necessary to handle the construction in accordance with the objects to be welded.

For example, arc welding involves generating an arc between a welding torch held by a welding technician and the groove of the workpiece to be welded, continuously forming a weld pool in the groove, and fusing the target workpieces together. It is. In this case, the state of the welding pool depending on the welding position is ideal if it is in a downward position due to the influence of gravity, but if it is in a sideways or upward position, the welding pool is pulled downward by gravity. It is difficult to work in the same condition all the time because the material sags or concentrates on one side of the groove.

On the other hand, in order to obtain the same stable penetration depth, the weld pool in which the arc is generated must be kept in the same stable state.

However, the depth of the weld pool changes from time to time depending on the temperature of the welding object and various conditions of welding work. Therefore,
Welding technicians respond to changes in welding conditions through welding techniques, such as the main elements of welding conditions and techniques such as weaving and other rod handling techniques, and the angle of the welding rod.

Therefore, the education and training of welding technicians was considered to be about acquiring skills that could be adapted to changes in welding conditions, and training on how to move the hands and how to use the stick was the mainstream. In other words, with conventional welding skills, as long as the welding results are good, there is no particular problem with the method, so there is no established theory regarding training for welding skills, and each company and workplace conducts unique training. The current situation is that

(Problem to be solved by the invention) As mentioned above, regarding the education and training of welding technicians in the past, there was no established theory regarding the training of welding skills, and each company and workplace had its own unique training. There was a problem like this.

■ Lack of common or standard educational and training equipment.

■ There are individual differences among teachers, and there is no highly reproducible educational training equipment.

■ The only way to check work progress is through practical work using test pieces.

■ There is no proper real-time evaluation method for actual arc welding training.

As mentioned above, since welding work prioritizes results, it is necessary to repeatedly train until the welding work is mastered, clarifying the construction control factors for the workpiece and the effects and purposes of these control factors. be.

However, training for initial repetitive welding work using an actual welding arc involves simultaneously training to generate a welding arc stably and continuously and learning techniques such as basic rod handling methods related to welding work. There are individual differences between the teachers and the welding technicians being trained, so it is not necessarily possible to follow the same schedule.

Therefore, the present invention aims to provide welding skills that allow welding technicians and teachers to conduct welding training with clear objectives by individually training the skills to generate and maintain a stable welding arc and welding techniques. The purpose is to provide education and training equipment for people.

[Structure of the invention]

(Means for Solving the Problems) The education and training device for welding technicians of the present invention uses a central processing unit to train welding technicians in a technical field; The practical training department uses simulation to conduct simulation training by estimating the change in light intensity on the light receiving surface as the welding technician's skill by using the welding arc as the source of the welding arc; and the construction management range setting that sets the management range for welding work. and a welding construction management device that samples and stores the situation of the repeated practical training and determines when work is performed outside of a specified control range: a practical repetitive training section; a result display that displays the training results by the training unit and the training results by the iterative training unit, and outputs necessary instructions;
It is characterized by comprising the following.

(Function) According to the education and training device of the present invention configured as described above,
For initial acquisition training, training is carried out in the simulation practical training department, and for practical training when basic education training has progressed to a certain extent, detailed training is carried out using the welding construction management device of the practical repeated training department. By measuring and recording the results, welding technicians can repeat training in an accurate and reproducible manner until they are satisfied.

(Example) Hereinafter, the present invention will be described in detail with reference to the drawings.

Figure 1 conceptually shows the overall picture of education and training using the device of the present invention.The education and training process consists of a visual education and training section A, a simulation-based practical training section B, and a practical repetitive training section C. It consists of three stages.

The visual education and training section A provides education using conventional textbook examples, and focuses on general basic knowledge as well as product-specific knowledge education related to each industry and workplace.

Practical training part B using simulation is designed to help students effectively acquire training and experience based on the idea that excellent welding skills are the result of training and experience. , welding materials, construction know-how, etc. from among the main items 1 of welding construction, such as welding materials, construction know-how, etc., a construction condition setting device 3 that sets the construction condition setting items 2 to be trained, and a welding torch equivalent that can simulate the welding arc. Light pen 4 and
Comparison of the light receiving board 5 for evaluating the welding arc as viewed from the welded material, the construction conditions set by the construction condition setting device 3, and the signal indicating the result of simulated welding by the light pen 4 received by the light receiving board 5. It is executed using a training device 6 and a result display device 7 that displays training results or gives instructions.

As shown in FIG. 2, the result display 7 is connected to an evaluator 8 and an output device 9 such as a printer. The evaluator 8 receives the setting values from the construction condition setting device 3 and the result display 7.
The output device 9 displays the training evaluation result based on the output of
prints out those results.

As shown in FIGS. 1 and 3, the practical repetitive training section C includes a construction management range setting device 1 that sets the construction management range for each practical work based on the individual training schedule 10.
1, a welding construction management device 13 that measures the main welding construction conditions for the test piece 12 to be constructed, and outputs the cause and judgment of the upper or lower limit when the welding conditions are out of the set construction condition range; This is carried out using a result display 7 that provides the teacher with the judgment results of the construction manager and gives necessary instructions, and an output device 9 that prints out the evaluation results shown on the result display.

Next, specific examples of each stage will be explained.

Visual Education and Training A This is general basic education using textbooks, etc., and is the same as before, so the explanation will be omitted.

Practical Training B Using Simulation In Fig. 4, the construction condition setting device 3 is equipped with a central processing unit that has a storage capacity and calculation capacity comparable to that of a personal computer.
An IC card is used as an external storage device, and pre-scheduled training items are set.

The construction condition setting device 3 has controllable construction factors 3a such as welding current, welding voltage, welding speed, wire feed speed, welding heat input, base material temperature, gas flow rate, arc time, idle time, etc. An item or an item that can be managed is entered.

In this case, the welding current is measured by the strength of the light from the light pen 4, and the welding voltage is measured by the strength of the light at the same current. Also,
The welding speed is the moving speed of the light from the light pen 4, the wire feeding speed is the value obtained by outputting pulsed light corresponding to the wire feeding speed from the light pen 4 and converting it to the feeding speed, and the welding heat input is the welding current or welding The value is estimated from the light intensity equivalent to the voltage, the welding speed, and base metal heat conduction.The base metal temperature is the approximate value calculated from the light amount equivalent to the welding current or welding voltage, welding speed, and base metal heat conduction.The arc time is the value estimated from the light intensity equivalent to the welding current or welding voltage, and the base metal heat conduction. The idle time, which is the total amount of time that light is being received, is the time from the start signal to the end signal.

The construction condition setter 3 selects a range 3b to be managed from among the manageable construction factors 3a, and stores the set values.

The signal generator 5a processes the optical signal received by the light receiving board 5 and generates a signal converted into a construction state.

The comparator 6 compares the range 3b to be managed with each part of the signal from the signal generator 5a, determines the difference between them, and if the difference exceeds a preset threshold, a result display is displayed. 7, the construction result is displayed or accompanying warnings and instructions are output to the welding technician or teacher.

5(a) to (d) illustrate the relationship between the angle or movement range of the light pen 4 and the light amount distribution on the light receiving board 5. FIG.

The light ben 4 is adjusted to project light 4a similar to a welding arc onto the light receiving board 5 using a built-in optical system (not shown). Therefore, when the light ben 4 is tilted or moved, a light intensity distribution 4b with a pattern corresponding to the inclination or movement of the light ben 4 is formed on the light receiving board 5, as shown in FIGS. 5(a) to 5(d). As shown in FIG. 6, a central processing unit 5 connected to a light receiving board 5
b, and the direction and angle of inclination of the light ben 4 and the movement range are calculated.

The output of the central processing unit 5b is input to the comparator 6 together with the management set value 3C, and an alarm or appropriate instruction is displayed on the result display 7 based on the deviation thereof.

Repetitive training through practical skills C In the past, skilled welding technicians judged the work status, the work result, weld bead, and non-destructive test results to judge whether the work was good or bad, and gave advice on how to deal with it. However, without real-time advice, it is not sufficient education.

Accordingly, in the present invention, as shown in FIG.
The items and content to be taught are entered into the welding construction management device 13 using an external storage device such as an IC card or by manual input, and the actual status of welding construction is evaluated and judged in real time using a reproducible method.

The welding construction management device 13 is required to be able to fully understand welding phenomena and to have excellent reproducibility.
A device with a function that can sample the welding work status every 1000 seconds and output an alarm or instruction if the control setting range is exceeded is used.

Figure 7 shows the main parts of the configuration example, including welding current, voltage, wire speed, base material, molten pool temperature, shielding gas, etc.
A construction condition element signal 14 that influences the welding result is converted into a digital signal by a signal converter 15 and input to a central processing unit 16.

The central processing unit 16 outputs the welding start signal 17 to the output converter 18.
, the welding execution conditions input from the signal converter 15 are sampled, compared with the construction management range stored in the IC memory card 19, and the results are printed out via the printer 20. In addition to the output 2, the evaluation result is output 22.

Therefore, welding technicians can continue repetitive training while constantly checking their own work status using the same criteria.

As described above, according to the device of the present invention, technicians are trained until they are satisfied with the characteristics and movements of basic welding work through simulation, and once they have reached a certain level, they can create an effective program. Under this training, you can use reproducible measurement or judgment equipment and practice with practical skills that you can understand on your own. Therefore, the following effects can be obtained.

■ You can concentrate on practicing basic movements without generating welding arcs. Also, if you adjust the light receiving board to your posture,
Postural welding training is also possible.

■ In addition to training to maintain a stable arc, you can train to repeat basic movements.

■ Unlike guidance by a skilled technician, there are no individual differences in judgment and guidance, and compatibility with the skilled technician is not required, so the suitability of the technician can be determined objectively.

■ During practical training, work is monitored at short sampling times of about 1/1000 seconds, so repetitive training with high reproducibility can be carried out until the technician is satisfied.

■ Internal factors such as the physical condition of the technician can be corrected during training with the technician's awareness.

■ Since it is possible to save data from the beginning of a technician's work, it is possible to judge suitability or unsuitability for each task administratively and accurately.

■ There is no need to use experienced technicians for welding training,
There are also great economic benefits.

The device of the present invention can be used not only for the initial education and training of welding technicians, but also for determining the skills of mid-career hires, for engineers considering the possibility of work, for special training before important work, and for collecting work records. It is also useful.

In addition to training for welding technicians, it can also be used as a monitoring device and to determine appropriate working conditions for automatic welding machines.

Furthermore, according to the device of the present invention, the know-how that was conventionally considered to be the skill of welding technicians can be accumulated as data, so that it can be utilized for complete automation of automatic welding machines.

〔Effect of the invention〕

As described above, according to the device of the present invention, it becomes possible to rationalize and standardize welding training, eliminate the need for specialized experts for training, and improve economic efficiency. In addition, even in the welding department, where there have been problems in passing on skills, specialized training will be possible based on accurate construction data.

[Brief explanation of drawings]

Fig. 1 is a schematic diagram showing the overall configuration of the device of the present invention, Fig. 2 is a block diagram showing an embodiment of the simulation training section in the device of the present invention, and Fig. 3 shows an embodiment of the practical training section in the device of the present invention. 4 is an explanatory diagram showing the operation of the light ben and the light intensity distribution on the light-receiving board when performing simulation training with the device of the present invention; FIG. 6 is a functional block diagram when simulation training is performed using the apparatus of the present invention, and FIG. 7 is a functional block diagram of a practical training section in the apparatus of the present invention. 1... Main items of welding construction, 2... Setting items of construction conditions, 3... Construction condition setting device, 4... Light pen,
5... Light receiving board, 6... Comparator, 7... Result display device, 8... Evaluator, 9... Output device, 10...
Individual education schedule, 11... Construction management range setter, 12... Test piece to be constructed, 13... Welding construction manager, 14... Construction condition element signal, 15... Signal converter, 16... Central processing unit, 17... Welding start signal, 18... Output converter, 19... IC memory card, 20... Printer, 21... Print output, 22...
...Output of evaluation results. Applicant's agent Sato -Yu No. 1 Ward Figure (C) +d) Figure No. 1

Claims (1)

[Claims] In an educational training device that uses a central processing unit to train welding skills for welding technicians; a light pen is used as a welding arc source by utilizing the straightness of light, and changes in the light intensity on the light receiving surface are used to train welding skills for welding technicians. A practical training department using simulation that conducts simulation training based on estimates of the skill of the person; A construction management range setting device that sets the management range for welding work; a welding work management device that determines when the work is out of range; displaying the training results of the practical training section and the training results of the repetitive training section; An education and training device for welding skills, comprising a result display that outputs instructions.