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Smart Welder Equipment Monitoring System Solution
The rapid development of China's high-speed rail puts extremely stringent requirements on the welding of steel rails; the use of steel rails for dual-use steel, heavy steel workshops, lightweight steel structures, municipal thermal and gas pipeline construction, etc., without exception, requires high-quality welding quality requirements. With the rapid development of machinery manufacturing, the degree of digitalization of welding machines is getting higher and higher. The development of modern industry has increased the demand for high precision welding machines and welding quality.
In view of the current deficiencies in the monitoring of welders and customer demands, combined with actual engineering cases, Heyuan Smart put forward solutions for intelligent welding machine equipment monitoring and control systems. The built-in control unit of the welding machine uploads the operating data to the cloud server in real time through the IoT full-featured industrial communication gateway. The welder equipment management user can remotely set the welding machine's operating parameters, the welding process data, the welding history data query, and the equipment online through the Web side. Rate inquiries and other functions to achieve remote monitoring of the welder. Through the welding machine's historical work data, the welder health status is predicted. According to the welding machine's welding voltage, current, welding material and other statistical data, the welding design process is compared with the actual welding, and the welding quality is evaluated, the welder level is evaluated, and the product quality is controlled.
The solution uses a three-tier architecture design, which is the welder device awareness layer, server storage analysis layer, and user application layer.
Ø Equipment Sensing Layer: data acquisition for welding machine model, operating current and peak current, welding pressure, welding wire quantity and type, and inert gas. Welding wire remaining quantity, performing welding process, welding method, welding time, workpiece type and specifications and other parameters are fully aware. The IoT full-featured industrial communication gateway independently developed by the company realizes the transmission of device-aware data to the server.
Ø Server storage analysis layer: Analyze and compare historical operation data, analyze the causes of faults or alarms in deep-welding machines through big data, and make early warnings for welding machines to improve the efficient and safe operation of welding machines.
Ø User application layer: Through the Web, App to achieve the entire process of welding process monitoring, control the welding process, to ensure the integrity of each welding process, traceability, to achieve the purpose of high-quality welding.
(1) Basic information inquiry of welding equipment: display the geographic location, nameplate information, supplier information, etc. of the equipment.
(2) welding machine equipment status monitoring: real-time operating data query, historical data query, equipment online rate display.
(3) Early warning of equipment failure: The alarm information is pushed in time to eliminate potential failures.
(4) Remote control operation: Initialize the parameters of the welder, set the alarm threshold, and open and close the welder.