Design And Implementation Of LoRa-based Split Welder Control System

Under the background of the rapid development of Internet of Things technology and wireless communication technology,the traditional industrial field has ushered in deep reform.As a widely used processing and manufacturing technology in the industrial field,welding has played an important role in the military,aerospace,electric power,petroleum,chemical,and even nuclear industries.Among them,industrial welding machines are the core equipment of the welding industry.Progress is inseparable from the development of industrial welding machines.As an important member of the industrial welding machine family,the split-type welding machine can simultaneously support the two most extensive welding types,manual welding,and MIG welding,and is widely used in shipbuilding,construction machinery,and building materials.With the development of the Industrial Internet of Things,digitalization has become an inevitable trend of industrial development.In the actual welding scene,the distance between the welding personnel and the operation panel is far away,which leads to an inconvenient adjustment of welding parameters and greatly affects the welding efficiency.In the design of split welding machines,the application of digital technology to achieve more convenient remote adjustment has become an urgent need in the welding field.At the same time,there are higher requirements for communication and centralized management of the split welding machine equipment.The communication between the existing equipment still relies on a wired connection,and there are problems such as complicated wiring,inflexible networking,and poor scalability,which makes it impossible to remotely.The collection of welding data and the inability to visualize and analyze key indicators have also become a major pain point in the welding field.To solve the above problems,this paper fully combines the current Internet of Things technology to design a control system for industrial split welding machines.Among them,in view of the inconvenience of real-time adjustment of welding parameters and the inability to accurately quantify the welding parameters during the welding operation,the system has designed a dedicated portable panel,which is convenient for welding personnel to wear,so that the operator can accurately and quickly adjust to the desired target value.In view of the difficulty of centralized management and the inability to remotely collect real-time welding data,this system designs a dedicated LoRa gateway,which supports networking through the LoRa wireless communication protocol,which facilitates the centralized collection of welding data and provides real-time monitoring for managers and technicians.and the ability to visualize analytics.The research work of this paper includes the following:(1)Completed the software and hardware research and development of industrial welding machine control panel,portable panel,and LoRa gateway.This system combines the inverter power drive board with model NBC-500(hereinafter referred to as the welding machine power board)to complete the selection of each component and the drawing of the circuit board.These include the design and implementation of the welding parameter acquisition module,the design,and implementation of the tuning algorithm in the feedback loop,the power domain isolation design,and the basic functions compatible with traditional welding machines.(2)A highly robust message transmission mechanism is designed.This paper designs and implements mechanisms such as unique pairing,state synchronization,timeout retransmission,and priority scheduling between master and slave.(3)The wireless networking method is designed based on LoRa.In this paper,the star topology is used for networking,and the LoRa modulation and demodulation parameters such as different spreading factors,error correction rates,and preamble lengths are set to reduce the interference between welding units.The system can upload key indicators during the welding process to the cloud through the LoRa gateway.(4)A data visualization platform was built in the cloud and on the terminal,which clearly and intuitively displayed key indicators in welding,such as welding current,welding voltage,and feedback DAC output.(5)The function and performance of the key parts of the system are tested,and the results are in line with expectations through the trial in the actual welding factory.This system combines various IoT technologies such as LoRa wireless communication,which effectively solves the industry pain points in the welding field and provides a new idea for the design of an industrial split welding machine control system.