Distributed Arc Welding Monitoring And Quality Analysis System Based On Ethercat

With the proposal of "Made in China 2025",modern industry has entered into information and intelligent production.Welding technology,as an important part of manufacturing industry,occupies an irreplaceable position in the important fields of aerospace,automobile and high-speed railway.Traditional welding technology cannot meet the modern high-quality and refined production needs,and it is difficult to achieve intelligent control of welding process.New requirements are put forward for monitoring welding process,evaluating welding quality and managing welding process parameters.In this paper,a data acquisition and analysis system for arc welding process is built based on EtherCAT.Real-time data acquisition,visualization and online analysis of arc welding process are realized.In order to ensure the real-time monitoring of welding process,optimize welding process parameters and improve welding quality,according to the requirements of production site and data acquisition and analysis,a hierarchical framework model of real-time acquisition system is constructed,and a data acquisition equipment platform for arc welding process is built with sensors,analog input terminals and embedded controllers as the main hardware.Real-time acquisition and transmission of process parameters and position and posture of welding torch have the advantages of fast data acquisition,strong overall situation,high resolution and strong anti-interference ability.A video acquisition system for welding arc and pool shape during welding process is built.The remote video wireless transmission and wireless control are realized by using microwave wireless system and bidirectional remote wireless switch,which is used for real-time monitoring of arc,molten pool,weld path and weld seam.The welding data display and analysis software is developed,which integrates the functions of data acquisition,visualization and analysis.The data redrawing,filtering,eigenvalue analysis,time-frequency domain analysis,statistical analysis and UI phase diagram analysis of welding process parameters are realized.The system realizes the real-time collection and transmission of welding parameters and welding videos in the welding process,realizes the integration of digital management and information technology of welding equipment by docking with the internal management system of enterprises,improves the working environment of workers on the production site,saves production costs and improves production efficiency.The system runs stably,accurately and reliably,and has broad development space.