• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a method and a device (1) for simulating an electrode welding method, comprising an electrode holder simulator (2) and electro-imitation (3) arranged thereon, a workpiece replica (4), an input device (6), an output device (7) and a control device (10). For optimal training of an electrode welding process under conditions that are as real as possible, the control device (10) is connected to a memory (11) for storing parameters (Pi) of ideal movement of the electrode holder simulator (2) during an ignition process and configured to Parameter (Pr) during a real movement of the electrode holder simulator (2) and compare it with the stored parameters (Ps) of the ideal movement of the electrode holder simulator during an ignition process and the deviations between the parameters (Pr) the real movement and the parameters (Pr) of the ideal movement at the output device (7).
    公开号:AT513828A4
    申请号:T50273/2013
    申请日:2013-04-22
    公开日:2014-08-15
    发明作者:
    申请人:Fronius Int Gmbh；
    IPC主号:
    专利说明:

    1
    The invention relates to a method and an apparatus for simulating an electrode welding method, comprising an electrode holder simulator and an electronic simulator arranged thereon, a workpiece replica, an input device, an output device and a control device.
    To learn welding processes, there are numerous systems with which welding processes can be simulated. In this case, the trainee welder carries out a virtual welding operation with a replica of a welding torch or a welding electrode, which is visually and possibly acoustically assessed via a screen via a screen, 3D glasses or a display in a welding helmet.
    For example, WO 2010/000003 A1 describes an apparatus and a method for simulating a welding method with a welding wire, for example a MIG (metal inert gas) or MAG (metal active gas) welding method. For electrode welding processes learning systems or simulation systems are also known. For example, US Pat. No. 4,689,021 A and US Pat. No. 4,931,018 A describe apparatuses for electrode welding processes, with which the handling of the electrode during the electrode welding process can be trained.
    Known methods and devices for simulating electrode welding processes often insufficiently replicate the welding process, which does not result in a satisfactory learning effect. In particular, little or no attention is paid to learning the ignition process in electrode welding processes. Especially the ignition is a great challenge in the electrode welding process, which also strongly influences the welding result.
    The object of the present invention is therefore to provide an abovementioned method and an apparatus for simulating an electrode welding method described above, with which optimum training of the ignition process can be carried out, if possible, under real conditions. The process should be as simple as possible and the Vorrich- 2/22 2 tion as cost-effective and robust construction. Disadvantages of known methods and devices for simulating electrode welding processes should be avoided or at least reduced.
    The object of the invention is achieved by an above-mentioned method in which an ignition process is simulated by comparing parameters during a real movement of the electrode holder simulator with stored parameters of ideal movement of the electrode holder simulator during an ignition process, and deviations between the parameters of real movement and the parameters of ideal movement are detected and displayed. The method is thus distinguished by the fact that an ideal ignition process is stored and the real ignition process compared with this ideal ignition process and used to assess the quality of the simulated ignition process. The ideal ignition process is characterized by certain parameters that are stored and stored in the system. The method allows the ignition process of electrode welding processes to be learned under virtual conditions without the need for consuming electrodes and workpieces. The ignition process of an electrode welding process is characterized by a certain movement of the electrode over the workpiece surface in a sweeping and flowing movement, the lifting of the electrode from the workpiece surface and the welding of the ignition point. Depending on how exactly an ideal ignition process is characterized, more or less parameters will be necessary to establish the ideal movement of the electrode holder simulator during the ignition process. To record the parameters of the real movement of the electrode holder simulator on the workpiece replica corresponding sensors on the electrode holder simulator of the replica electrode and the workpiece replica are required according to the parameters used, which are connected to the control device of Simulationsvorricht'ung. The replica of the workpiece can also be formed by a real workpiece, which can be introduced, for example, into an associated workpiece holder, in which a suitable sensor is provided, via which the position of the electrode holder simulator relative to the workpiece or the workpiece simulation can be detected , By way of the position of the electrode holder simulator relative to the workpiece, the workpiece simulation or a workpiece holder, the most essential parameters can be detected during the movement of the electrode holder simulator during the ignition process and thus the simulated ignition process can be assessed. The indication of the deviations between the parameters of the real movement and the parameters of the ideal movement can be done optically, acoustically or else mechanically, for example by vibration, or by combinations thereof.
    In particular, the position of the electrode holder simulator with respect to the workpiece replica, the speed of movement of the electrode holder simulator, and a sweep of the area of the workpiece replica after ignition are used as parameters for characterizing the movement during an ignition process. By means of these parameters, a simulated ignition process in an electrode welding process can be characterized very well, and thus deviations of a real ignition process from an ideal ignition process can be assessed very well. The position and the speed of movement of the electrode holder simulator can be determined, for example, via a so-called polyhemus sensor or else by other technologies, for example optically.
    To learn an ignition process, it is beneficial to see the ideal movement of the electrode holder simulator during the ignition process. The ideal movement can be described as so-called "ghost". visually displayed on a screen or the 3D glasses in the welding helmet. The welder tries to "Ghost" To follow as accurately as possible and learn in this way optimally the movement of an ideal ignition. The "Ghost" to illustrate the ideal movement during the ignition can be done, for example, in a semitransparent or blurry manner, whereas the real movement of the electrode holder simulator during the ignition in a solid representation of the electrode holder simulator can be done on a screen or the like.
    The start of the display of the ideal movement of the electrode holder simulator during the ignition process is preferably started, for example with the aid of a visually and / or acoustically reproduced countdown, so that the welder can adapt to the upcoming exercise accordingly.
    If the residence time and, if necessary, the force of a touch of the replica electrode on the workpiece replica is measured, the simulation can be assessed even better. The residence time of the replica electrode on the workpiece replica can be measured in a simple manner, for example, by detecting a short circuit between electrode replication and workpiece replication. Alternatively, this can also be done with a mechanical probe at the top of the electrode replica. For the quantitative detection of the pressing force of the replica electrode on the surface of the workpiece or the workpiece replica various mechanical or electromechanical sensors but also optical systems, which are arranged at the top of the electrode replica, can be used. When practicing the ignition process in a virtual space, the residence time and virtual contact force of the replica electrode on a non-real workpiece can also be detected via the position.
    In order to be able to adapt the simulation process even better to real conditions, sticking of the replica of the electrode on the workpiece replica, for example by activation of an electromagnet by the control device, can be simulated if the measured residence time and possibly the measured force deviates from predetermined limit values. In the case of a simulation of the ignition sequence with an electrode simulation on a workpiece simulation, sticking will then be simulated if limit values for the residence time and possibly the contact force are exceeded. If the welder resides with the replica of the electrode too long on the workpiece simulation and / or if the replica of the electrode is pressed too heavily onto the workpiece simulation, the electromagnet can be activated and sticking can be simulated. The gluing can be achieved by overcoming the force of the electromagnet or the control device dissolves the adhered electrode replica and automatically deactivates the electromagnet after a predetermined time. If the electrodes are moved in virtual space, a lower limit for the residence time and, if necessary, force can also be decisive. If there is the possibility of activating and deactivating a so-called antistick function on the simulation device, this can have an effect on the simulation of the sticking.
    Advantageously, the ignition processes are repeated until the deviations of a predetermined number of real movements of the electrode holder simulator from the ideal movement of the electrode holder simulator during an ignition process are within a predetermined tolerance range. In this way, the trainee welder can be assigned to repeat the practice of ignitions until his abilities exceed a preset value. Only then can, for example, be continued with other simulation processes.
    When the stored parameters of ideal movement of the electrode holder simulator are changed by changing influencing parameters on the input device, various scenarios occurring in reality in the method of igniting electrode welding processes can be optimally practiced. Such influencing parameters can be, for example, the activation of an anti-stick function, the activation of a hot start, the activation of a welding voltage reduction, the type and length of the electrode simulation, etc. If, for example, an anti-stick function is activated on the simulation device, then, when the electrode replica is glued to the workpiece replica, it is released more quickly than if the anti-stick function is not activated. When activating a so-called hot start, a preheating of the electrode can be simulated. With the activation of a
    Welding reduction can simulate a welding process in mines, where a voltage reduction can be prescribed (VRD Voltage Reduction Device), and the ignition can be practiced under this changed situation. Also, the type, length, sheath of the replica electrode and the like, can influence and change the stored parameters for the ideal movement during the ignition process and enable the simulation process under changed conditions. In practice, a large number of stored parameters will be stored for the characterization of different ignition processes and the corresponding input parameters will be used to select those parameters which form the basis for the comparison of the real movement with the ideal movement during the ignition process.
    If, during the actual movement of the electrode holder simulator during an ignition process, an acoustic signal of an ignition process is reproduced, the simulation process can be better adapted to real conditions. The acoustic signal may be a sound recording of a real ignition method or also a synthetically generated signal, which comes close to an ignition process.
    Preferably, the location of the electrode holder simulator with respect to the workpiece replica is calibrated prior to simulating the ignition process. If the sensors for measuring the position of the electrode holder simulator with respect to the workpiece simulation can not detect the absolute position, such a calibration may be required, which can be performed for example by performing a predetermined movement of the electrode holder simulator.
    The object according to the invention is also achieved by an above-mentioned apparatus for simulating an electrode welding method in which the control device is connected to a memory for storing parameters of an ideal movement of the electrode holder simulator during an ignition process and is adapted to the parameters during a real movement of the electrode holder simulator and to compare with the stored parameters of the ideal movement of the electrode holder simulator during an ignition process and to indicate the deviations between the parameters of the real movement and the parameters of the ideal movement on the output device. Such a device can be realized relatively easily and inexpensively. For the achievable advantages, reference is made to the above treatment of the method for simulating the electrode welding process. 7/22 7
    The memory is preferably configured to store the position of the electrode holder simulator with respect to the workpiece replica, the rate of movement of the electrode holder simulator, and the sweep of the area of the workpiece replica after ignition as a parameter.
    The dispenser is preferably configured to indicate the ideal movement of the electrode holder simulator during the ignition process. The output device may be formed by a screen, a 3D glasses, a display in a welding helmet or by an interface for exporting the data, for example to an external network.
    The output device is preferably designed to announce the start of the display of the ideal movement of the electrode holder simulator during the ignition process, which can be done for example by optical and / or acoustic reproduction of a countdown.
    If a force sensor is provided for detecting the force of contact of the replica electrode on the workpiece replica, which force sensor is connected to the control device, the ignition process performed can be assessed even better.
    By means of an electromagnet, sticking of the replica of the electrode on the replica of the workpiece can be simulated if the dwell time of the replica of the replica on the replica of the workpiece or the contact pressure of the replica of the electrode deviate from certain limits. For the purpose of the corresponding control, the electromagnet is connected to the control device.
    If the input device is designed to input influencing parameters, for example the activation of an anti-stick function, the activation of a hot start, the activation of a welding voltage reduction, the type and length of the electrode simulation, etc., and the input device is connected to the control device, the The parameters of the ideal movement of the electrode holder simulator are changed by varying the influencing parameters and practicing various types of ignition methods. The input device may be formed in the manner of a current source of a real welding device or by corresponding operating elements on the simulation device.
    If a speaker is provided for acoustically reproducing a signal of an ignition event during real movement of the electrode holder simulator during an ignition event, the virtual ignition process can be better adapted to real conditions.
    Preferably, at least one sensor for measuring the position of the electrode holder simulator with respect to the workpiece replica or a workpiece holder for receiving the workpiece holder is provided, which is connected at least one sensor to the control device. Depending on the type, number and arrangement of such sensors, a calibration of the position of the electrode holder simulator with respect to the workpiece simulation may or may not be required. As already mentioned above, the position can be determined, for example, with a so-called Polhemus sensor.
    In the case of a necessary calibration, the control device for calibrating the position of the electrode holder simulator with respect to the workpiece simulation is formed before simulating the ignition process.
    The present invention will become more apparent from the accompanying drawings which illustrate embodiments of the invention. Show in it
    Fig. 1 is a block diagram of an apparatus for simulating an electrode welding process;
    Fig. 2 shows schematically the ideal movement of an electrode during an optimal ignition process in an electrode welding process;
    Fig. 3 shows schematically the real movement of an electrode during an ignition process in an electrode welding process and the comparison with a stored ideal movement; 9/22 9
    Fig. 4 is a scheme for the referencing phase for the automatic reproduction of an ideal ignition process; and FIG. 5 shows an embodiment of an electrode holder simulator and electrode replica and workpiece replica disposed thereon.
    Fig. 1 shows a block diagram of an apparatus 1 for simulating an electrode welding process. The device 1 includes an electrode holder simulator 2 and an electrode replica 3 arranged thereon, a workpiece replica 4, which can also be formed by a real workpiece which is arranged in a corresponding workpiece holder 5. Via an input device 6, the trainee welder can operate the simulation device 1. Via a dispensing device 7, which can be formed by a screen, a 3D camera, an interface (for example to an external network) but also by a welding helmet 8 with integrated display, the welder is given feedback on the simulated ignition processes , A control device 10 processes the corresponding signals and runs the corresponding simulation methods. For the acoustic reproduction of signals or the reproduction of real noises during the welding process, a speaker 9 may be provided. The control device 10 is connected to a memory 11 for storing parameters Pi of an ideal movement of the electrode holder simulator 2 during an ignition process and adapted to detect the parameters Pr during a real movement of the electrode holder simulator 2 and with the stored parameters Pi of to compare ideal movement of the electrode holder simulator 2 during an ignition process and to indicate the deviations between the parameters Pr of the real movement and the parameters Pi of the ideal movement. In the memory 11 are thus a number of parameters P ±, which characterize an ideal movement of the electrode holder simulator 2 during an ignition process of an electrode welding process deposited. In practice, the controller 10, the memory 11, the input device 6, the output device 7 and the speaker 9 will be constituted by a computer to which the other components are connected via suitable interfaces (not shown). 10/22 10
    For detecting the parameters Pr during the real movement of the electrode holder simulator 2, corresponding sensors are arranged on the workpiece replica 4 or the workpiece holder 5 and / or the electrode holder simulator 2. For example, in the electrode holder simulator 2, a position sensor 12 and in the workpiece replica 4 or in the workpiece holder 5, a position sensor 13 may be arranged, which determine the position of the electrode holder simulator 2 with respect to the workpiece imitation 4. Via a force sensor 14 at the tip of the replica electrode 3, the contact pressure of the replica electrode 3 can be determined at the workpiece replica 4 and included in the simulation. For example, when a predetermined pressing force is exceeded, an electromagnet 15 in the workpiece holder 5 is activated and thus a sticking of the replica electrode 3 to the workpiece imitation 4 can be simulated. Instead of an electronic realization of the sticking, a Velcro fastener 16 or the like can be arranged on the workpiece replica 4 and the tip of the replica electrode 3 can be designed accordingly (not shown) and in this way, if a certain pressing force is exceeded, sticking of the replica electrode 3 to the workpiece replica 4 be simulated. In the case of sticking of the replica electrode 3, the sticking can be illustrated on the output device 7, for example by annealing the electrode replica 3 as it would occur in reality.
    FIG. 2 schematically shows the ideal movement of an electrode during an optimal ignition process in an electrode welding process. The course I is plotted by the distance y from the surface of the workpiece over the distance x. After approaching the electrode towards the workpiece, the electrode is set at an acute angle to the normal to the workpiece surface. In this position, the electrode is approximated to a certain distance above the workpiece surface, the speed should be within the tolerance range of a predetermined value. This is followed by a slow approach to the workpiece surface with a delayed speed and finally a contact of the workpiece with the electrode, wherein a certain residence time should be maintained 11/22. Starting from the starting point x0, the electrode on the workpiece surface is painted at a predetermined speed up to the point Xi at a predetermined speed and then, after the point xL, lifted off the workpiece surface to a specific height at a specific speed. After lifting the electrode from the workpiece surface and the formation of the arc, the ignition range is swept over, i. a loop back to the starting position x0 of the ignition performed with a speed characteristic for the sweeping. This is followed by a repeated brushing with the electrode over the workpiece surface to a predetermined length at a predetermined speed. By lifting the electrode from the workpiece surface to a certain height, the ignition process is terminated and continued with a normal welding process.
    3 schematically shows the real movement of an electrode during an ignition process in an electrode welding process and the comparison with a stored ideal movement according to the simulation method according to the invention. In this case, the ideal ignition process I shown in FIG. 2 is compared with a real ignition process II, which is compared and evaluated in the simulation of the ignition process. Above and below the ideal ignition process I, tolerance ranges or limits III, IV can be defined, which should not be exceeded during the actual ignition process II. Only after a predetermined number of positively completed simulated ignition processes, for example seven out of ten operations, can be continued with another welding exercise.
    4 shows a scheme for the referencing phase for the automatic reproduction of an ideal ignition process, wherein a referencing phase for starting the ideal ignition process is activated at a specific distance y '' from the workpiece 4. As soon as the electrode replica 3 reaches a certain distance y 'from the surface of the workpiece 4 or the workpiece simulation, the start phase for the ideal movement of the electrode holder simulator automatically begins: 2 during an ignition process and, for example, after a countdown, the start of this so-called "Ghosts". , The welder now has to work with the 12/22 12
    Electrode Holder Simulator 2 The ideal movement through the "G'host". understand, without exceeding the tolerance limits III, IV described in Fig. 3.
    Finally shows. 5 shows an embodiment of an electrode holder simulator 2 and an electrode replica 3 arranged thereon and a workpiece replica 4. The electrode holder simulator 2 is connected via a corresponding line 17 to the control device 10 (see FIG. 1). At the top of the replica electrode 3, a force sensor 14 for measuring the contact pressure of the replica electrode 3 can be arranged on the workpiece replica 4. In addition, the electrode replica 3 can be variably arranged in its length in order to be able to simulate an afterburn of the replica electrode 3 by reducing the length of the replica electrode 3. This can be achieved, for example, by reducing the distance of the free end of the replica electrode 3 from the electrode holder simulator 2. 13/22
    权利要求:
    Claims (20)
    [1]
    A method for simulating an electrode welding method, comprising an electrode holder simulator (2) and an electric simulator (3) arranged thereon, a workpiece replica (4), an input device (6), an output device (7) and a control device (10). characterized in that an ignition process is simulated by comparing parameters (PE) during a real movement of the electrode holder simulator (2) with stored parameters (P.) of an ideal movement of the electrode holder simulator (2) during an ignition process, and Deviations between the parameters (Pr) of the real movement and the parameters (Pi) of the ideal movement are detected and displayed.
    [2]
    2. The method according to claim 1, characterized in that as a parameter (Pr, Ρ ±) the position of the electrode holder simulator (2) with respect to the workpiece simulation (4), the speed of movement of the electrode holder simulator (2) and a Passing over the area of the workpiece simulation (4) after ignition has been used.
    [3]
    3. The method according to claim 1 or 2, characterized in that the ideal movement of the electrode holder simulator (2) is displayed during the ignition process.
    [4]
    4. The method according to claim 3, characterized in that the start of the display of the ideal movement of the electrode holder simulator (2) is announced during the ignition process.
    [5]
    5. The method according to any one of claims 1 to 4, characterized in that the residence time and possibly force of a touch of the electrode replica (3) on the workpiece replica (4) is measured.
    [6]
    6. The method according to claim 5, characterized in that a sticking of the replica electrode (3) on the workpiece replica (4), for example by activation of an electromagnet (15) by the control device (10) is simulated when the measured residence time and possibly the measured 14/22 14 force deviates from specified limits.
    [7]
    7. The method according to any one of claims 1 to 6, characterized in that the ignition processes are repeated until the deviations of a predetermined number of real movements of the electrode holder simulator (2) from the ideal movement of the electrode holder simulator (2) during a Ignition process within a predetermined tolerance range.
    [8]
    8. The method according to any one of claims 1 to 7, characterized in that the stored parameters (Pi) of an ideal movement of the electrode holder simulator (2) by changing influencing parameters (PE), for example, the activation of an an-tickick function Activation of a hot start, the activation of a welding voltage reduction, the type and length of the electrode simulation (3), etc., are changed on the input device (6).
    [9]
    9. The method according to any one of claims 1 to 8, characterized in that during the actual movement of the electrode holder simulator (2) during an ignition process, an acoustic signal of an ignition process is reproduced.
    [10]
    10. The method according to any one of claims 2 to 9, characterized in that the position of the electrode holder simulator (2) with respect to the workpiece replica (4) is calibrated before simulating the ignition process.
    [11]
    11. An apparatus (1) for simulating an electrode welding method, comprising an electrode holder simulator (2) and electrode replica (3) arranged thereon, a workpiece replica (4), an input device (6), an output device (7) and a control device (10). characterized in that the control means (10) is connected to a memory (11) for storing parameters (Pi) of ideal movement of the electrode holder simulator (2) during a firing operation and adapted to cause the parameters (Pr) to be during a firing operation real movement of the electrode holder simulator (2) and compare with the stored parameters (P ±) of the ideal movement of the electrode holder simulator during an ignition process and 15/22 15 the deviations between the parameters (Pr) of the real movement and the Indicate parameters (Pj.) Of the ideal movement on the output device (7).
    [12]
    12. Device (1) according to claim 1.1, characterized in that the memory (11) for storing the position of the Elektrodenhal ter-Simülators (2) with respect to the workpiece replica (4), the speed of movement of the electrode holder simulator ( 2) and the sweeping of the area of the workpiece replica (4) after ignition is formed as a parameter (Pr, P ±).
    [13]
    13. Device (1) according to claim 11 or 12, characterized in that the output device (7) is designed to indicate the ideal movement of the electrode holder simulator (2) during the ignition process.
    [14]
    Device (1) according to claim 13, characterized in that the output device (7) is designed to announce the start of the indication of the ideal movement of the electrode holder simulator (2) during the ignition process.
    [15]
    15. Device (1) according to one of claims 11 to 14, characterized in that a force sensor (14) for detecting the force of a contact of the electrode replica (3) on the workpiece replica (4) is provided, which force sensor (14) with the Control device (10) is connected.
    [16]
    16. Device (1) according to claim 15, characterized in that an electromagnet (15) for simulating a gluing of the replica electrode (3) on the workpiece replica (4) is provided, which electromagnet (15) is connected to the control device (10) ,
    [17]
    17. Device (1) according to one of claims 11 to 16, characterized in that the input device (6) for input of Einflüssparametern (PE), for example, the activation of an an-tickick function, the activation of a hot start, the activation of a welding voltage reduction , the type and length of the replica electrode (3), etc., is formed, and the input device (6) is connected to the control device (10), so that the stored parameters (Pi) of the ideal movement of the electrode holder Simulator (2) by the influence parameters (PE) are variable.
    [18]
    18. Device (1) according to any one of claims 11 to 17, characterized in that a loudspeaker (9) for acoustic reproduction of a signal of an ignition during the real movement of the electrode holder simulator (2) during an ignition process: is provided.
    [19]
    19. Device (1) according to one of claims 11 to 18, characterized in that at least one sensor (12, 13) for measuring the position of the electrode holder simulator (2) with respect to the workpiece replica (4) or a workpiece holder (5 ) is provided for receiving the workpiece holder (4), which at least one sensor (12, 13) is connected to the control device (10). to 19, thereby for calibration reference to the ignition process
    [20]
    20. Device (1) according to any one of claims 11, characterized in that the control device (10) of the position of the electrode holder simulator (2) in workpiece replica (4) is formed before simulating. 17/22
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    同族专利:
    公开号 | 公开日
    CN104112388A|2014-10-22|
    US9786198B2|2017-10-10|
    CN104112388B|2017-11-03|
    DE102014207579A1|2014-10-23|
    IN2014DE01080A|2015-06-05|
    AT513828B1|2014-08-15|
    US20140315167A1|2014-10-23|
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    ATA50273/2013A|AT513828B1|2013-04-22|2013-04-22|Method and apparatus for simulating an electrode welding process|ATA50273/2013A| AT513828B1|2013-04-22|2013-04-22|Method and apparatus for simulating an electrode welding process|
    US14/256,155| US9786198B2|2013-04-22|2014-04-18|Method and device for simulating an electrode welding process|
    IN1080DE2014| IN2014DE01080A|2013-04-22|2014-04-21|
    DE102014207579.3A| DE102014207579A1|2013-04-22|2014-04-22|Method and apparatus for simulating an electrode welding process|
    CN201410161777.6A| CN104112388B|2013-04-22|2014-04-22|Method and apparatus for simulation electrode welding process|
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