短周期螺柱焊在线分析系统

短周期电弧螺柱焊生产效率高,易于实现自动化,广泛应用于汽车工业。开发了由信号采集单元和分析软件构成的短周期螺柱焊在线分析系统。信号采集单元包含PIC18F4580单片机、电源、信号调理、外部存储器和RS485通信等电路,通过焊接状态判断、AD采样、数据存储和通信等程序,实现焊接电流和电压采集、存储和传输。分析软件采用Microsoft Visual Studio C#编写,操作界面由主窗口、焊接过程分析窗口、熔深阈值设置窗口和报警窗口等构成。DP600镀锌钢板焊接试验表明,开发的短周期螺柱焊分析系统能实时显示焊接电流和电压波形,提取焊接参数特征值,判断电弧的稳定性,熔深计算值与实测值相吻合,在线检测结论与外观目检、宏观检测和扭矩测试的结论一致。系统收集的原始数据可用于分析引起质量问题的具体原因。

Online analysis system for short-cycle arc stud welding

Due to the high production efficiency and automation applications,short cycle arc stud welding is widely used in automotive industry. A system composed of signal acquisition unit and analysis software was developed in this paper. The signal acquisition unit consisted of PIC18F4580 and circuits of power supply,signal conditioning,external storage and RS485 communication,and the signals of welding current and voltage were gathered,stored,and transferred by software of the AD sampling,data storage and communication respectively based on the judgment of welding state. The interface of the system was programmed by Microsoft Visual Studio C#,which included the main window,welding process analysis window,penetration threshold settings window and alarm window. DP600 galvanized sheet trial showed that the short cycle arc stud welding analysis system could extract the characteristic values of the welding process,judge the stability of the arc.Penetration calculated by the system coincided well with actual values. Online monitor conclusion agreed well with the results of visual inspection,macro examination and torque test. The data collected by the system could be used to identify the causes of poor quality.