Design Of The Welding Remote Online Monitoring System Based On Zigbee Protocol

With the development of the single-chip microcomputer, computer networks, automation, virtual instrument, wireless sensor network, Internet and other techniques, it is convenient and feasible to monitor the real-time and remote data and in the process of electric arc welding. At the same time, a database is established to store the corresponding testing data in the welding, and the statistical analysis for testing data is made to evaluate the quality of welding at the end of welding. The management of welding system will be improved and the trace for the welding quality of products will be established. Finally, it can also reduce or even avoid the welding workers to be exposed to the harmful welding environment directly and make a more humanized protection for the welding workers’ health.In this thesis, a set of remote online monitoring system of electric arc welding is designed. It consists of three layers which contain the lower machine control and data acquisition module, the wireless network module based on Zigbee technology, and PC server and the remote monitoring based on C/S architecture. Thus, the remote on-line monitoring of welding is realized by the lower machine wireless network communication in combination with the PC LAN communications based on C/S architecture.Data acquisition, the wire feed speed control, and the shielding gas flow setting are implemented by MCU STC15W408 AS, The design of wireless network is achieved by CC2530. First, a wireless network is established by the Coordinator node, Second the child nodes can join the network that has been established by the Coordinator node. In addition, the child nodes communicate with STC15W408 AS via a serial port. The online monitoring software of upper machine and client software implement by MFC. The server PC can receive or record the data that has been sent to the serial port by the coordinator, send the data that needs to be set to the coordinator, manage the user login, and draw the real-time curves. At the same time, the client software module is also designed. Realizing the data sharing by database technology makes the users of remote client monitor the welding process in the online. The users remotely setting the parameters can be realized by the Socket technology. In order to make a evaluation for welding quality, the thesis makes statistical analysis for the acquiring data of monitoring parameters, and utilizes the method which combines the Mahalanobis distance with the Normal distribution to evaluate the welding quality.Finally, the experiment test is carried on, and the welding remote online monitoring system basically meets the initial requirements. The data of welding acquisition and the theoretical analysis results of the welding process are identical. Hence, it can make a basic information for the multi-user remote online monitoring welding process for many welding devices.