On-Line Monitoring Research Of Arc Welding Processing Based On Wireless Communication Technical

Welding quality has great impact on the quality of cars and ships, which will influence the competitiveness of enterprises in the industries. Nevertheless, these industris as traditional industry are also labor intensive area in China. The welding process is still conducted by lots of people with different technical skills, so it's very difficult to make sure the welding quality. In order to solve this problem, a set of remote welding monitor system should be introduced, which can inspect the whole welding process and make sure the stability of welding quality.This thesis researched on a key technical, communication technical, in the monitor system. It analyzed Serial Port technical, Field bus technical, Local Area Network technical, GPRS (General Packet Radio System) technical, Bluetooth, Wireless Fidelity and ZigBee technical. And ZigBee technical was selected as communication interface.Based on ZigBee wireless communication technical, this thesis designed a set of welding process on-line monitor system. This system included VSM025A voltage sensor, CS600B current sensor, ATmega8 single chip, SZ05 wireless communication module and the server. The hardware was used to establish multi-functional convenient and low-cost experiment platform.Based on ATmega8 single chip, this thesis designed 10-bit A/D transfer interface program. Interrupt triggering program was also made to realize the connection of single chip and ZigBee network. Besides programs for baud rate and sending frequency were also made. LabVIEW Based on graph programming was selected for software development. Program of receiving voltage and current signals was made and this program could make sure the veracity of data by head-tail calibration method. The multi-functional and convenient interface can show situation of welding equipment, value of voltage and current, which also make it possible to inquire historical information and to set port. Further more, this thesis researched the start of ZigBee network, node joining and leaving, the content of different data and routing calculation and established wireless network with mixed topology.At last according to 10Hz, 50 Byte communication methods the thesis designed bit error rate experiment and the result showed that signals can be transferred in this system with 95% confidence level and the bit error rate was below 10-3. Three different welding criterions were selected to conduct arc welding signal collection experiment. The signals collected can show every period of the whole welding process, which can provide basic information for equipment management and production management.