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Currently, in various large and medium-sized welding production processes, manual welding is generally relied on, which makes it difficult to control the entire welding process. In order to uniformly manage various aspects such as welding equipment, process documents, welding personnel, and welding processes, Dezhou Digete Electronics Technology Co., Ltd. has developed a welding machine networking system by adopting intelligent information collection modules and network technology according to the actual situation and requirements of welding production. The system integrates welding technology, information technology, communication control, and management concepts. Based on the functions of real-time collection, real-time monitoring, data storage, display of welding data from analog and digital welding machines, as well as personnel management and welding equipment management, it realizes the unified management of parameters such as welding equipment, process documents, welding personnel, welding processes, welding materials, and energy consumption. It can greatly improve welding efficiency, enhance comprehensive management ability, and ensure welding quality. At the same time, it provides important data support for managers in production process optimization, personnel and equipment management, and resource allocation.
1 Networked Welding Machine Data Intelligent Management System
Through the transformation and networking of intelligent welding machines, an information communication environment is constructed between welding machines and management systems, between welding machines, and between welding machines and people based on the welding process management system. This enables the data (including people, machines, materials, methods, and environment) sent from information systems such as MES to the workshop to be accurately and efficiently transmitted to the workshop, welding machines, and personnel. At the same time, it realizes the effective monitoring, control, recording, and traceability of the real-time operating data and quality data of welding machines during the welding execution process, thereby improving the quality management level and management efficiency of the welding execution process. The schematic diagram of the system structure is shown in Figure 1. With the continuous accumulation and analysis of welding process data, the system will achieve intelligent closed-loop control of instruction issuance, process monitoring, quality analysis, and process optimization, that is, construct a welding execution process management system with intelligent monitoring, intelligent control, intelligent diagnosis, intelligent decision-making, intelligent maintenance, and intelligent optimization.
2 System Introduction
The construction of the welding machine data control bus mainly includes the following contents: welding machine networking, welding machine data collection and control, welding machine status monitoring, work order execution, welding quality management, data statistical analysis, equipment operation and maintenance management, cost management, data security management, and integration with MES.
2.1 Welding machine networking
Currently, according to the different operation and control modes of welding machines, the types of welding machines include two major categories: manual welding machines and robotic welding machines. Among them, manual welding machines can be further divided into digital welding machines and non - digital welding machines. The welding machine networking system of Dezhou Digete Electronics Technology Co., Ltd. takes manual welding as an example, and its networking topology is shown in Figure 2.
The main control board of the manual digital welding machine is equipped with an I/O communication interface, and the data acquisition board can be directly connected and communicated through the communication interface. The manual non - digital welding machine does not provide a communication interface, and data can be collected by installing a Hall sensor. Then, the collected data is converted from analog to digital by using an encoder and a data acquisition board and communicated through a standard Ethernet. At the same time, wire feeding speed and gas flow sensors are installed for both types of welding machines, and the sensor data is connected to the system through the data acquisition board. In addition, for the needs of process management and human - machine interaction, devices such as a touch - screen operation panel, a barcode gun, and an infrared handheld thermometer are installed at each welding machine station. The data transmission between the data acquisition board and the devices around the welding station and the server uses wireless transmission. A wireless AP is added at the data acquisition board end to communicate with the wireless AP nodes in the workshop, and the wireless AP network in the workshop is connected to the data control bus server.
2.2 Data acquisition and control
For manual digital welding machines, based on the communication protocol, data interaction is carried out with the welding machine through specific instructions. After analyzing the data obtained from the welding machine, relevant welding machine parameters are obtained, and then the data is submitted to the server. At the same time, the server can input relevant setting parameters of the welding machine, and the remote parameter setting can be realized through direct conversion based on the communication protocol. The parameters obtained and controlled from the welding machine include: current, voltage, and alarm information. At the same time, based on the installed gas flow meter and wire feeding speed sensor, real - time gas flow information and wire feeding speed information are collected.
2.3 Welding machine status monitoring
Based on the collected welding machine parameters, the current operating status of the equipment is defined and displayed. The typical display states are: power - on, power - off, working, idle, under fault maintenance, etc., as shown in Figure 3. The welding execution process management system adopts a BS architecture. Based on this architecture, users can access through the Web client
Monitor the status of the welding machine through the enterprise terminal, mobile client, and large-screen display terminal.
Welding machine status monitoring page
2.4 Work order execution
The welding machine networking system can be integrated with the enterprise-side MES. Based on the WPS data content obtained from the MES: work order information (number, name, part number, quantity, person in charge, required completion time, etc.), relevant process documents for welded parts (3D instruction cards, 2D instruction cards, etc.), welding process requirement parameters (current, voltage, etc.), and display them on the touch terminal of the workstation. For specific work orders, operators need to use a code gun to scan the work card to authenticate their operation qualifications, and then perform operations such as viewing instruction cards and reporting work completion based on the terminal.
2.5 Welding quality management
During the actual welding operation process, if the parameters such as current and voltage set by the welding machine exceed the process design requirements, potential quality risks may occur. For example, too small a welding current may cause defects such as incomplete penetration and slag inclusion. Too large a welding current results in a large penetration depth, which is prone to defects such as burn-through and weld bead, and may also affect the mechanical properties of the weld. For key processes, the welds are numbered and managed. Operators can follow the instructions and guidance on the terminal in combination with the process card, and perform weld operations in sequence according to the welding order requirements. The weld switching is realized by the operator clicking the button on the touch terminal. The operation process of welding quality management is shown in Figure 4.
2.6 Data statistical analysis
The welding machine networking system of Dezhou Digete Electronics Technology Co., Ltd. has powerful and flexible data statistics, display, and output functions, which can automatically generate various reports or charts to meet the personalized requirements of managers in different roles. The statistical reports support multiple formats such as Excel, PDF, and html, and support the output of files for off-system applications to meet the display requirements on various terminals.
2.7 Equipment Operation and Maintenance Management
Based on the networking of welding machines, the equipment management department can obtain the real - time status of all equipment in the workshop and achieve active monitoring of global equipment. When a device fails, the system can automatically notify and remind equipment maintenance personnel via email, SMS, WeChat, etc. In addition, when on - site operators need equipment maintenance support, they can make a maintenance support request through the workstation touch - terminal.
2.8 Data Security Management
During the equipment monitoring process, in order to avoid the impact of network failures on data collection, the data collection module will provide data caching, supporting the caching of data information for more than a week. During the data collection process, the cache area of the on - site terminal will have real - time data cache management. When there are communication failures between the terminal and the server, the data will not be lost. After the communication is restored, the complete data in the cache area will be promptly transmitted to the server.
3 Conclusion
With the continuous progress of technology and the urgent need for high - quality and high - efficiency production in modern manufacturing, the digital welding workshop has become the development direction for the construction of future welding factories. According to the development trend of digital welding control and combined with fieldbus technology, the intelligent management system for the networking data of welding machines of Dezhou Digete Electronics Technology Co., Ltd. has been initially realized. It manages welding information reliably and effectively and has achieved the following results:
(1) Intelligent transformation of welding machine equipment. Through the networking of welding machines, the extraction and control of real - time operating parameters of welding machines in the workshop are realized, effectively managing and controlling the operating status of welding machines.
(2) Optimization of production task execution control. Based on the integrated MOM system, the effective transmission and feedback of production - related task data and technical data to the workshop are realized, achieving visual management of the production task execution process.
(3) Improvement of quality management level. Based on the informatized management of the workshop production execution process, on the one hand, information technology ensures that the process requirements are consistent with the actual equipment settings; on the other hand, it realizes early - warning control for abnormal welding machine control parameters, and at the same time, it realizes effective recording and traceability of production process data.
(4) Information equipment operation and maintenance. Based on the effective monitoring of the welding machine's operating parameters, realize the abnormal early warning management of the welding machine and improve the efficiency of fault reporting and response.
(5) Lean workshop operation management. Analyze the workshop operation data based on the lean production theory, provide intuitive operation indicators and management bottleneck displays for the management, and support rapid and accurate management decisions.
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