Network Monitoring And Management System For Arc Welding Process

In this paper, network monitoring and management system is developed to monitor the process of arc welding, which is not only able to monitor the welding parameters but also monitor the changes in welding temperature field. It also provides great convenience for judging the stability of the welding process and prediction of welding quality in advance.Firstly, the Hall current sensors, Hall-voltage sensors, ZLS series speed sensor, Platinum-rhodium thermocouple wire are selected as temperature sensors, and NI PCI-6071E, NI USB-9211 capture card and other hardware are chose to collect signal for the acquisition equipment in this paper. Then the paper develops the system with Virtual Instrument Development Platform and Graphical programming language, which includes many functions such as data collection, analysis and management functions. A data collection program named DAQmx is used to collect and display data of welding current, voltage, wire feed rate and welding temperature field.Secondly, the connection program of LabVIEW with database is written by third-party development tools LabSQL, which is used to build the welding data management module. The management system of present mature welding precedures is developed with LabSQL to achieve the functions of browsing, querying, adding and modifying them. The report generation program is prepared with Report Generation Toolkit for Microsoft Office.Thirdly, the system filters are designed based on the FIR filter and IIR filter to allow the signals of specific frequency to get through, while to attenuate other undesired frequency. Data analysis program is prepared combined with a variety of algorithms such as Fast Fourier Transform (FFT) algorithm, correlation analysis theory, wavelet transform and so on. A variety of analytical methods, including welding line energy analysis, probability density analysis, correlation analysis, UI phase diagram analysis, derivative analysis, and wavelet analysis etc are designed.Finally, the fault alarm module is set for the purpose of generating real-time alarm signal and giving the text prompts when the welding process instability is monitored. Procedures of server and client are written by using TCP/IP Agreement to monitor welding process remotely by the network. And the stability of the system is tested by the impulse TIG welding experiment.The system provides a welding quality monitoring platform for the manager of welding production quality and welding engineers. By monitoring the signal parameters during the welding process and analyzing the welding process afterward, they can effectively get information of the changes of various welding parameters, predict the welding quality and get the base to improve the welding procedures as well.