Wireless Welding Quality Monitoring System Based On Wi-Fi

Quality is the basis of manufacturing.Under the background of continuously upgrading of welding equipment,extensive application of network information technology and industrial control technology,it is of great significance and application value to the monitoring and control of welding process by means of convenient industrial wireless control.Visual Studio development platform is selected to build the upper system for welder monitoring,Wi-Fi technology is used as a means of remote communication,and the welding data cache module is designed by means of embedded development.The upper monitoring system sends welding parameters to the Wi-Fi module connected to the data cache module through the TCP protocol in the Socket method.The Wi-Fi module sends welding parameters to the data cache module by means of serial port communication,and the cache module transmits the parameters to the core control unit of the welder through CAN bus to realize the downlink of parameters.The core control unit of the welder collects the data through A/D sampling and transmits them back to the data cache module via CAN bus.The module then uploads the collected data to the upper system via Wi-Fi,and the upper system carries out relevant processing to realize the uplink of the welding data.The up and down transmission protocols of welding data are developed,and the bidirectional transmission of the whole data is realized through the recognition,reading and verification of the data.The algorithm of the upper monitoring system is programmed by using the C# based on the.NET framework.The monitoring of the welding status is realized through the setting and issuing of welding parameters,archiving and reading of user settings,dynamic display of welding waveform and query of welding data.The welding data were processed by statistical analysis method.With the help of LabVIEW,the analysis and calculation of U-I value,peak/base value of current,peak/base value of impedance,energy and probability density,as well as the synchronization of high-speed camera and metal transfer are realized.The evaluation of welding quality is realized by calling the above functions.The comparison test based on pulse welding is designed and implemented,and the difference of test results between Fronius welder and Self-developed welder is obtained and analyzed,which provides reference and direction for the optimization of Self-developed welder.By comparing the differences before and after the welder optimization,the validity of the analysis and calculation results of the welding quality monitoring system is supported and verified,which provides a basis for the research on improving the welding quality from the perspective of optimizing the welding equipment.