| As China has entered the era of high-speed railway, the railway rail joint increasingly high demands for quality, how to ensure the quality of rail joint has become an urgent problem. In this thesis, the project of studying on computer system and control software of Kl 000 flash welding machine in ShiBaitan welded rail Beach in Chengdu Railway Bureau was established as the background theme. K1000 flash welding machine was produced together by United States Holland Company and the Ukrainian Research Institute Barton. It has some features, such as a high degree of automation, small size and light weight Not only can it be used for fixed plant, but also it is particularly suitable for liquid or semi-liquid plant rail welding conditions. In the actual production process, its computer monitoring system was found some shortcomings, for example:first, the monitoring system used the serial port to collect current, voltage, displacement and hydraulic parameters on the welding process, so data acquisition rate is low, which affected the accuracy of quality evaluation of welded joints, while welding joints often were not conducted a comprehensive understanding of the actual welding on the welding process debugging, as a result, the difficulty of debugging the welding process increased and the process debugging time was extended; second, this monitoring system had the criterion of welded joints of qualified design flaws and because of the low collection rate, there was error in the date during the welding process, which often caused false positives for qualified joints; third, in this monitoring system, data processing and management were not complete. For the above shortcomings, this paper was carried out the following tasks:firstly, Visual Basic 6.0 software was used to develop this new computer monitoring system, because of low frequency of data collection for the welding condition, PCI-1710L acquisition board was expanded in the computer system. The high-speed acquisition was realized and the interrupt mode was used to transfer the data, and the sampling frequency could also be manually set; secondly, criteria for the quality of welded joints to re-design, according to that whether the acceleration phase is short, whether the welding interrupt, and whether upset stage is slippery, and these data, such as flash speed, upset force, acceleration rate, the total amount of melted, the amount of upset, flash time, and upset the current size to determine the eligibility of the joint quality, thirdly, the technology of DDE was used to achieve data between PLC and VB communication, and line modification of process parameters was achieved and management of change process parameters was centralized, namely the design of all process parameters on the same interface.; fourthly, under the acquisition frequency, the historical curve of welding joints was showed, while data management was improved. Data on the welding process was calculated:for example, upset the amount of melted volume, the various stages of the average current and voltage, circuit time, short time, which provide the basis for commissioning to line judge for the joint quality and process.The production applications showed that the new computer control system had a good interactive interface and operability. It was also proved a rail joint scientific quality control and achieved traceability, which made the welding machine in railway construction in China, especially in high-speed passenger line and railway construction play a better role. |
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