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Currently, the types of welding information systems applied in various industries are becoming more and more diverse, and the functional modules of the systems are also becoming more and more abundant. However, there are still some deficiencies. For example, the research results of each company or institution are relatively independent. Most of the developed welding information systems are only applicable to the company's internal products, lacking universality, and the communication protocols are also different, which has certain limitations at the overall application level. To solve this problem, Dezhou Digete Electronics Technology Co., Ltd. has developed a welding information system suitable for a variety of welding machine models. This system collects, manages, controls, and monitors in real-time the welding information of analog and digital welding machines in industrial sites. By combining the concepts of welding technology, information technology, communication control, and personnel management, with the goal of welding technology informatization, it conducts cluster management and control of welding machines, can collect, monitor, and trace welding data, and can also centrally manage welding personnel, thereby achieving more precise control of the welding process.
I. System Composition
The welding information system of Dezhou Digete Electronics Technology Co., Ltd. consists of a welding information software system, a server, a welding data collector, and a wireless network (or a wired network).
There are two forms of using a wireless network:
One is to set up a wireless network in the workshop. The collector uploads data via wifi. This method requires that the wifi network and the server can form a local area network.
The other is to use a 4G IoT card. This method will incur traffic fees, which need to be borne by the user. It is initially estimated that the monthly traffic is less than 3G. If working 8 hours a day, the estimated monthly traffic is less than 1G. The 4G mode requires a server with a public IP. Because the collector can only send data to the public IP via 4G.
Users can also set up a wired network by themselves. The network cable needs to be connected to each welding machine and form a local area network with the group control server.
Figure 1 Data relationship diagram of welding information system
Among them, the software part is divided into three parts: information server software, welder APP software, and large-screen display software.
Functions of the information server software:
1. Monitor welding data in real-time.
2. Upload and issue task information.
3. Manage basic information such as equipment and personnel.
4. Receive real-time data collected by the terminal.
5. Carry out calculation, analysis and storage.
6. Conduct historical traceability of welding data.
Functions of the welder APP software:
1. View the real-time status of each welding machine in real-time.
2. View data such as real-time curves.
Large-screen display software:
1. Display the real-time status of the welding machine and monitor the overall operation status of the workshop
2. Display the working hours of welders and the task completion status.
II、Data Acquisition Module
1. Welding information collection. Since the analog welding machine has no external digital interface, only two analog parameters, current and voltage, can be collected. Therefore, data such as wire feeding speed need to be estimated. The digital welding machine has digital communication interfaces, such as USB interface, network port, serial port, CAN interface, etc., and parameters such as wire feeding speed, wire diameter and material, and gas flow can be directly read from the welding machine without additional calculation by collecting analog quantities.
Receive various types of welding data collected by the welding data collector, here referring to welding current and welding voltage. Through the 4G network, WIFI or wired network gateway, transmit the data from the engineering site to the system for processing, analysis, and storage, etc., and generate it in the form of reports or curves.
2. Management of welding personnel. By distributing IC cards and ID information to each welder, precise release of welding tasks and traceability of welding records can be achieved, truly achieving a high degree of unified personnel management.
III、Part Functional Analysis of Software
1. Production equipment management is used for standardized management of equipment. Equipment can be grouped and numbered, and the maintenance information of equipment can be managed and tracked, including collection module management and welding machine equipment management.
2. Production process management is used to centrally manage the process specifications in the production process and the unified management of welders, including welder management, weld management, welding machine equipment management, and production process management.
3. The configuration management of the welding information system conducts overall management of the system's users and roles, and unified management of the workshop organizational structure. Users can establish a management network architecture of the company, production workshops, and teams according to the company's own situation. This module includes user management and role management.
4. Real-time equipment status monitoring can display the operating status of all equipment in the monitoring system, view the real-time operating status of all welding machines, real-time voltage and current, and can perform grouped screening according to information such as the equipment type or the workshop and team to which the equipment belongs.
Figure 2 Real-time status monitoring
5. The large-screen display management module is used to manage the data visualization interface, making the important welding parameters more clearly and intuitively presented to users.
After entering the system, the main page is a data visualization interface, which contains important information to be displayed, such as the welder's status and working time, welding material consumption, equipment utilization rate, etc. This page can also be displayed in full screen.
Figure 3 Visualization main page of the welding information system
III. Database functions
1. Real-time data collection management. For analog welding machines and digital welding machines, when they are in the power-on state, the parameters such as current and voltage collected by the collection equipment will continuously transmit data to the database for data insertion. The data type is judged through statements and written into different tables according to the time sequence, providing data support for subsequent analysis, query, etc.
2. Manual system entry. Basic information such as welder information, welding machine information, welding material information, organizational structure information, welding machine process specification information, account role assignment, user permission assignment, and IP address of the handheld terminal needs to be manually entered into the system, and operations such as query, addition, deletion, and modification can be performed.
The welding information system of Dezhou Digete Electronics Technology Co., Ltd. systematically incorporates multiple welding workers and welding power sources into information management. At the same time, it conducts statistical analysis of the parameters generated during welding from various dimensions and pulls data reports. The system realizes the unified management of analog welding machines and digital welding machines. Through the data acquisition module, all welding power sources are brought under unified control, and a certain degree of management and data acquisition can also be carried out for analog welding machines. The system also has functions such as perfect report output. Combined with the realization of the data visualization interface, the system can dynamically output a variety of display contents to the large screen according to user needs, that is, it can output information reports for teams, personnel, welding machines, etc., making the welding data more clear at a glance.
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