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In the process of metal material processing in industries such as mechanical manufacturing, aerospace, ship processing, and oil and gas pipelines, welding is one of the important means. The quality of welding is directly related to the performance and service life of products, and the analysis data of the welding process is an important basis for inspecting the welding quality.
With the application of technologies such as the Internet of Things and big data in intelligent industrial production, real-time data collection and monitoring systems for the production process are deployed in various industries. In the field of welding, the welding process analysis system of Dezhou Digete Electronics Technology Co., Ltd. installs data collection equipment on the welding machine to collect in real-time information such as the operating data of the welding equipment, welding process, and consumption of welding materials, and then displays, stores, and analyzes this information, achieving the tracking of the welding process, reducing welding abnormalities, lowering welding costs, improving welding efficiency, and ensuring welding quality.
Welding process parameters are the key data that affect the welding quality. In manual and semi-automatic welding operations, differences in the skills of operators and operators not welding according to the established parameters will affect the product quality. The welding process analysis system monitors in real-time the production data such as electricity consumption, gas consumption, and wire consumption during the welding process. When the process parameters exceed the set parameter range, the welding process analysis system will send an alarm message to remind the operator to adjust the process parameters in time to ensure the accuracy of the welding parameters.
Through the welding process analysis system, specific information about each welding machine can be obtained, such as the equipment name, operating status, usage duration, product code of the workpiece, production time, weld number, welding machine operator, etc., achieving the precise correspondence between the workpiece, production time, operator, and welding parameters, meeting the traceability requirements of the product; the establishment of an association between the operator and the workpiece also provides a basis for performance evaluation and labor billing.
The welding process analysis system records and analyzes the production consumption such as electricity, gas, and wire during the production process, so as to further analyze the material usage differences between different welding machine operators and welding robots, providing data support for better cost reduction and efficiency improvement; at the same time, it connects the information data between the material usage situation and the enterprise material system, realizing information sharing, and obtaining the remaining quantity of various consumables in real-time, providing a basis for formulating production plans and material procurement.
Some welded parts have relatively high requirements for the environment. Too high or too low temperature and humidity will affect the welding quality. The welding process analysis system can monitor the temperature and humidity information of the welding environment in real - time through environmental sensors.
The terminal of the welding process analysis system uses embedded hardware as the main control. It obtains welding parameters through voltage sensors, current sensors, gas flow sensors, etc. installed on the welding machine; transmits data to the cloud or the background management center through the internal wireless communication module; the device is equipped with a display screen to display the device's operating status and various data in real - time. Operators can modify and adjust parameter settings through the BS terminal.
Nowadays, industrial production is transforming towards informatization, digitalization, and intelligence. The welding process analysis system is the integration of enterprise production in the welding field and information technology, which is beneficial to improving the intelligent level of enterprise production, building smart factories and digital workshops, and promoting the transformation and upgrading of the manufacturing industry.
The welding process analysis system of Dezhou Digete Electronics Technology Co., Ltd. is the main product of our company, which is mainly applied to equipment such as welding machines, robots, lathes, and cutting machines. Our company cooperates with many dealers and welding machine manufacturers as the main promotion channels. This set of systems covers the following main hardware products of our company: welding data collectors, welding data conversion interfaces, gas flow sensors, wire feeding speed collectors, welding speed collectors, card readers, relays, etc. This set of products has reliable quality, can be compatible with welding machines of various brands and models, and has been well - received by our partners and users. There are currently many successful cases in on - site operation.
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