Flux Cored Wire Fill Rate Of Line Measurement System

Along with the increase of the requirement of flux-cored wires, how to guarantee quality and improve production efficiency are urgent questions needed to be solved for manufacturing enterprises. An on-line real-time measurement system for flux-cored wires is designed in the thesis, which can measure the weight factor of powders in flux-cored wires on production lines and send alert signals for rejects. Therefore, the quality of flux-cored wires can be improved.System designed using the virtual instrument technology and LabVIEW development platform. The on-line measurement system for flux-cored wires is consisted of the hardware system and software system developed based on LabVIEW8.6 development platform. Hardware system includes probes for measuring the powder weight factor of flux-cored wires USB data acquisition cards USB5935 and an industrial panel computer. In which, probes can transfer the weight factor of flux-cored wires into electrical signals. USB5935 data acquisition cards transfer analog signals into digital signals and communicate with the computer via USB interfaces. The industrial panel PC 6000-104TH accomplishes digital signal process from USB5935, display, storage, etc human-computer interaction functions. The software includes USB5935 drivers, data processing software, management software for real-time trend and history trend, and data stream files. Moreover, based on functional requirements and LabVIEW8.6 platform, the software achieves two main functions. One is data processing, storage, display and data stream file management in the work of forming machines of flux-cored wires. The other is the browse of historical trends formed by reading and writing of data stream files when machines are stop.The operational panel of the system is simple with a friendly and compact interface. Real-time measured data and historical data can be observed form real-time trends and historical trends. When the powder weight factor of flux-cored wires exceeds its bounds, alarm will be sent. The system has been used in practiced. The experiments show that the system proposed in the thesis operate stably and reliably, and it can monitor the powder weight factor of flux-cored wires on-line effectively.