Research And Development Of Welder Training Workshop Management System

Manual arc welding has the advantages of convenience,flexibility,low cost and high adaptability,and has an irreplaceable position in industrial production.However,manual arc welding also has shortcomings such as welding quality being greatly affected by human operation,long technical training period for workers,and low production efficiency.The intelligent monitoring and evaluation of welder training process is an effective auxiliary means to improve the efficiency of welder training.Based on the design principle of virtual instrument,combined with hardware and software,a set of welder training workshop monitoring and analysis system with the functions of welding data acquisition and data analysis was developed.On this basis,it expands the welding workshop management system based on workshop database and the weld prediction system based on BP neural network,so as to realize the intelligent assistance of welder training and the digital management of welding workshop.For manual arc welding,welding speed is the most unstable process parameter controlled by welders.Firstly,the laser displacement sensor was integrated into the welding gun,and the external white partition reference was combined to realize the effective monitoring of welding speed.At the same time,the self-designed fixture was also loaded with infrared temperature measuring probe to realize the real-time measurement of the preheating temperature of the base metal on one side of the weld.The arc interference in the process of temperature measurement can be reduced by controlling the angle of infrared probe and adding porcelain nozzle shielding.Finally,combined with the actual situation of the welding training workshop,the current and voltage Hall sensor,laser rangefinder,infrared thermometer and other detection hardware equipment are integrated,and with the software design,the welding process information acquisition system was developed to realize the synchronous acquisition and storage of multi-source signals.Based on the synchronous acquisition and storage of welding multi-source signals,the query and analysis software of welding data was developed.The software can perform data query,interception,filtering,time domain analysis,frequency domain analysis,statistical analysis and other operations on welding data.Through statistical analysis,the current and voltage distribution diagram can characterize the size and distribution concentration of electrical parameters and evaluate the stability of welding process.The heat input distribution diagram is obtained by calculating welding heat input,which can characterize the heat input at different welding positions.The statistical distribution histogram of short-circuit transition period obtained by statistical analysis can characterize the length of short-circuit transition time and the concentration of distribution,and evaluate the size and stability of droplet transition.Through the correlation analysis diagram of electrical parameters obtained by time domain analysis,the autocorrelation or cross-correlation analysis of current and voltage can be carried out to evaluate the stability of electrical parameters.In order to improve the digital level of welder training workshop,Access software was used to design the database of welder training workshop.The database consists of more than ten sub databases,which are used to store the team,materials,equipment,welding standards,welding procedures,work arrangement,welding experiments data and other information of the workshop.The welding workshop database realizes the digital storage of workshop information.On this basis,a database management system is designed and developed.Through the management of database,the digital management of workshop is realized.Through the experiments of manual TIG welding and manual MAG welding,the reliabilities of the acquisition system,analysis system,database and database management system were verified.Finally,using the neural network technology,the system of weld morphology and defect prediction was developed to effectively predict the weld morphology and defects,estimate the welding material consumption according to the predicted weld morphology data,and optimize welding parameters.The developed welder training workshop management system has the functions of welding data acquisition,data analysis,workshop digital management,weld morphology prediction and defect identification,which helps to improve the digitization and intelligence level of manual arc welding,improve the efficiency of welder training and reduce the cost of welder training.