Study On The Technology Parameters Monitoring System For Resistance Seam Welding

Resista nce sea m weld ing(RSW)is a very importa nt weld ingmethod. Beca use of its inherently properties of the high prod uctivity andthe efficient robotiza tion,it is widely used in all aspects of the modernprod uction such as household applia nces(such as refrigera tor shell),aerospace (such as rocket fuel ta nk),automot ive ind ust ry, which req uest thesea l joint sometimes also used in connect ord ina ry sheet meta l pa rts .Asthe resista nce spot weld ing, resista nce sea m weld ing is a highlynonlinea rity, multiva ria te coupling course,which is effected by ma nyra ndom uncerta inty factors. As the nuclea tion course is in closed sta te andca n't be observed immed ia tely, the cha racterist ic signa ls are ha rd toextract, the nuclea tion time is very short,little fluctua tion of weld ingcond itions will bring out serious conseq uence. If check ing the weld ingqua lity after weld ing course,it not only wastes much of ma npower andma teria l resources, but also ca n't assure the qua lity.There are ma ny technolog y pa rameters and other pa rameters effecton the qua lity of resista nce sea m weld ing, includ ing weld ing current,weld ing time, electrode force and electrode size , also includ ing some ofthe non-technolog ica l pa rameters of factors ,such as the sta te of theworkpiece surface , volta ge fluctua tions and so on .Beca use of thesefactors,the weld ing process becomes complex. Especia lly, theinsta nta neous and the non -visibility of the weld ing process ma ke thecontrolling qua lity of the sea m weld ing very difficu ltly. Resista nt sea mweld ing qua lity is insta ble and difficu lt to control, which ha ve influentedthe wide applica tion of resista nce sea m weld ing technolog y seriously. Soit is necessa ry to develop a kind of online mon itoring system withnondestructive,low cost and high dia gnostic relia bility.Resea rch shows tha t dyna mic signa l of resista nce sea m weld ingprocess conta ins a lot of informa tion, which directly or ind irectly reflect s the qua lity of sea m weld ing. There are ma ny pa rameters in sea m weld ingsuch as current, volta ge, dyna mic resista nce, pressure, electrodedisplacemen t, their diversifica tion ha ve a consa nguineous rela tion to thequa lity of weld ing line, which ca n reflect the sha pe process of weld ingline and be used as the gist of qua lity. The experiment shows tha t theweld ing current ha ve a consa nguineous rela tion to the qua lity of weld ingline and the ma gnitude of weld ing current ha ve decisive effect to theweld ing qua lity. Therefore,there will be a favora ble effect by mon itoringthe weld ing current and ca lcula ting the current effective va lue.Based on the above purposes, a set of conven ient and relia blemon itoring system of technolog ica l pa rameters in resista nce sea m weld ingwas designed in this paper, which rea l time mon itor sea m weld ingtechnolog ica l pa rameters, such as weld ing current, with the function ofda ta acq uisition, da ta disposa l, da ta stora ge, da ta displa y and so on. Theha rd wa re of the system ma inly consists of a current sensor, integ ra lrevivifica tion circu it of current signa l,a da ta acq uisition ca rd and aind ust ria l computer.This system took ind ustria l computer as themeasu rement circu msta nce, ta ke high speed and precision da ta acq uisitionca rd to collect the signa ls, design the integ ra l revivifica tion circu it ofcurrent signa l to process the signa ls accord ing to the signa ls cha racterist icwhich ca n sa tisfy the need of the da ta acq uisition ca rd. The paper ta kesVisua l Stud io.N ET 2003 as the softwa re developmen t circu msta nce todesign the measu rement softwa re, which presetting with the Visua lC++.N ET,rea lizing the aim of collecting weld ing pa rameters and da tadisposa l, ca lcula ting the qua lity informa tion includ ing current effectiveva lue and weld ing time and so on, storing the result in the da tabase. Tosurpport the the norma l opera tion of the mon itoring softwa re, the paperta kes Microsoft Access 2003 as the ma na ge system of the da tabase,develop s the da tabase files da ta.md b, designs two da ta ta bles includ ingPara mer and Qua lityInfo reasona bly, sa tisfies va rious stora ge andma na gemen t needs of weld ing qua lity informa tion. The paper took pa rticu la r resea rch about the applica tion of the discreteness and controledpa rts in Visua l Stud io.N ET 2003 environmen t offered by Measuremen tStud io, designs the measu rement softwa re based on the technolog y ofvirtua l instrumen t.Fina lly, the technology pa rameters mon itoring system for resista ncesea m weld ing which was designed in this paper ha d been successfullyapplied to the sea m weld ing eq uipmen t.In allusion to the mon itoringsystem simula tion, relia bility detection, and the detection result on theweld ing field, this paper ana lysed their da ta and curve in deta il. After theactua l weld ing test,we fou nd tha t this system ca n collect weld ing currentsigna ls accura tely,adopt a reasona ble signa l processing methods,ca lcula te the eigenva lues of the weld ing current which results can be usedto jud ge the qua lity of the weld ing line.This pa rameter mon itor and qua lity ana lysis system of resista ncesea m weld ing ca n be used in practica l prod uction as an online mon itoringpla tform. The mon itoring system combining with prod ucing technolog y,could be designed ind ivid ua tion based on the req uirement of clien t,collection of da ta, disposa l and stora ge of lots of da ta to rea liza tion, it hasthe function of intelligence ana lysis, to poi nt out the disq ua lifica tiontechnolog y pa rameters. The da ta after disposa l ca n be ma na gedsynthetica lly by storing in the da tabase, offering the method for thema na gemen t of prod uction. The functions of resista nce sea m weld ing aregenera l, and ca n be used in resista nce sea m weld ing technolog ypa rameters mon itor of ma ny fields. This system ha ve ma ny ad va nta gessuch as high ga thering speed, high ga thering efficiency, big memorycapacita nce and good huma n-computer interaction interface. It ca n beused in ma ny high efficiency da ta acq uisition applica tion, and it has highuseful va lue and developmen t foregrou nd.