基于LabVIEW的CO_2焊接过程实时监测与诊断系统的研究
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摘要
弧焊品质反映了焊机的性能和焊接过程的稳定程度,是决定焊件质量的关键。由于弧焊过程的复杂性,弧焊品质分析面临许多困难,是焊接界的一个研究热点。本文根据虚拟仪器的思想和特点,初步建立了基于虚拟仪器LabVIEW的CO2焊接质量实时监测与诊断分析系统。
该系统由硬件信号采集电路和以LabVIEW作为平台的软件组成。根据弧焊的特点,硬件采集电路设计采用了双MCU结构,利用高速双口RAM实现双MCU间的信息共享,并完成了双MCU结构中的通讯板和采集板的电路设计。将编写好的C51程序写入单片机后,对采集系统的软件进行调试。在完成硬件采集装置的设计后,系统采用LabVIEW编制质量监测与分析系统。由信号采集、实时波形显示、波形回放、文件保存及调用、信号分析、数据库连接六大模块组成。
该系统具有实时采集并显示焊接过程电参数波形;通过LabSQL与数据库建立连接,可调用数据库函数实现数据的存储及调用;可使用不同的分析工具对焊接过程进行分析;可以以文本文件方式存储焊接过程的实时信息;可回放焊接电流、电压波形。
通过对熔滴短路过渡CO2焊接实验,证明设计的硬件采集电路和编制的软件程序是可行的。采集数据完整可靠,通过实验给出的电流和电压实时波形图、U-I图、波形导数图、短路统计图等,可以达到预期的分析效果。
本系统一方面能对焊接质量的在线监测分析提供一定的参考和指导作用。另一方面也能够对焊后电参数进行分析研究,得到焊接质量的信息,为更深入地研究焊接过程电弧燃烧、熔滴短路过渡特性、机理,优化焊接系统设计提供了理论依据及标准。仪器的功能强大,且易于根据实际需要对功能进行扩展、修改,具有广阔的应用前景。
The quality of arc welding reflects the performance of welding machine and the stabilization degree of operation process, which mainly determines the quality of welding. Because of the complexity of welding process, the quality analysis of arc welding faces many problems, and is a hot research problem of welding. According to idea and feature of virtual apparatus, the system of CO2 welding quality real time monitoring and analysis based on LabVIEW is building preliminarily.
The system is constituted of hardware of signal collecting circuit and the correlated software. According to the characteristic of arc welding, the design of signal collecting circuit adopts double MCU structure, the information sharing between double MCU is realized by high rate double port RAM, the design of the communication hardware and signal collecting hardware is implemented, after the C51 programmer written into chip microcomputer, the software of collecting system is debugged, after the design of signal collecting hardware, the system of real time welding process monitoring and quality analysis is developed by LabVIEW, the whole system is constituted of such six modules as signal collecting, real time waveform display, waveform playback, file saving and calling, signal analysis, database connection.
The system has the performance of real time collection and display arc welding parameters waveform, through the connection between LabSQL and database and calling database function, the performance of data storage and calling is realized, the system can use different analysis methods to analyze the whole welding process. This system can use txt form to deport the real time information of welding process.
Through the short circuiting transfer CO2 welding experience, the signal collecting circuit and the program are feasible, and the data collected is complete and reliable, the real time waveform of current and voltage ,U-I graph, waveform derivation graph, Short circuiting statistic graph are presented, which can get the expected analysis results.
On the one hand, this system provides some degree of reference and guiding effect on online monitoring and analysis of welding quality, on the other hand, the system also can analyze the electrical parameters after the welding, and get the information of welding quality, which provides theoretical evidence and standard for the further research of arc combustion, characteristic and mechanics of droplet short circuiting, optimizing the design of welding system. The function of virtual apparatus is great, and which is easily expanded and modified according to the actual demand, so it has extensive application prospect.
该系统由硬件信号采集电路和以LabVIEW作为平台的软件组成。根据弧焊的特点,硬件采集电路设计采用了双MCU结构,利用高速双口RAM实现双MCU间的信息共享,并完成了双MCU结构中的通讯板和采集板的电路设计。将编写好的C51程序写入单片机后,对采集系统的软件进行调试。在完成硬件采集装置的设计后,系统采用LabVIEW编制质量监测与分析系统。由信号采集、实时波形显示、波形回放、文件保存及调用、信号分析、数据库连接六大模块组成。
该系统具有实时采集并显示焊接过程电参数波形;通过LabSQL与数据库建立连接,可调用数据库函数实现数据的存储及调用;可使用不同的分析工具对焊接过程进行分析;可以以文本文件方式存储焊接过程的实时信息;可回放焊接电流、电压波形。
通过对熔滴短路过渡CO2焊接实验,证明设计的硬件采集电路和编制的软件程序是可行的。采集数据完整可靠,通过实验给出的电流和电压实时波形图、U-I图、波形导数图、短路统计图等,可以达到预期的分析效果。
本系统一方面能对焊接质量的在线监测分析提供一定的参考和指导作用。另一方面也能够对焊后电参数进行分析研究,得到焊接质量的信息,为更深入地研究焊接过程电弧燃烧、熔滴短路过渡特性、机理,优化焊接系统设计提供了理论依据及标准。仪器的功能强大,且易于根据实际需要对功能进行扩展、修改,具有广阔的应用前景。
The quality of arc welding reflects the performance of welding machine and the stabilization degree of operation process, which mainly determines the quality of welding. Because of the complexity of welding process, the quality analysis of arc welding faces many problems, and is a hot research problem of welding. According to idea and feature of virtual apparatus, the system of CO2 welding quality real time monitoring and analysis based on LabVIEW is building preliminarily.
The system is constituted of hardware of signal collecting circuit and the correlated software. According to the characteristic of arc welding, the design of signal collecting circuit adopts double MCU structure, the information sharing between double MCU is realized by high rate double port RAM, the design of the communication hardware and signal collecting hardware is implemented, after the C51 programmer written into chip microcomputer, the software of collecting system is debugged, after the design of signal collecting hardware, the system of real time welding process monitoring and quality analysis is developed by LabVIEW, the whole system is constituted of such six modules as signal collecting, real time waveform display, waveform playback, file saving and calling, signal analysis, database connection.
The system has the performance of real time collection and display arc welding parameters waveform, through the connection between LabSQL and database and calling database function, the performance of data storage and calling is realized, the system can use different analysis methods to analyze the whole welding process. This system can use txt form to deport the real time information of welding process.
Through the short circuiting transfer CO2 welding experience, the signal collecting circuit and the program are feasible, and the data collected is complete and reliable, the real time waveform of current and voltage ,U-I graph, waveform derivation graph, Short circuiting statistic graph are presented, which can get the expected analysis results.
On the one hand, this system provides some degree of reference and guiding effect on online monitoring and analysis of welding quality, on the other hand, the system also can analyze the electrical parameters after the welding, and get the information of welding quality, which provides theoretical evidence and standard for the further research of arc combustion, characteristic and mechanics of droplet short circuiting, optimizing the design of welding system. The function of virtual apparatus is great, and which is easily expanded and modified according to the actual demand, so it has extensive application prospect.
引文
1张志檩. 21世纪国外石油化工智能化生产技术进展. http://bbs.soft.supcon. /com/htm_data/18/0603/2101.html
2姜焕中主编.电弧焊及电渣焊.北京:机械土业出版, 1988:15~17
3李建国.深化改革,艰苦奋斗,努力振兴我国的电焊机行业一电焊机行业总结及今后任务.电焊机, 1998, (6):1~4
4中国机械工程学会焊接学会.焊接手册(焊接方法及设备).机械工业出版社, 1992:156~162
5李柏姝.用面向对象方法开发现代制造企业的管理信息系统.柴油机设计与制造. 2002, (1):53~56
6徐胜龙,金建新.现场总线技术在汽车生产物流管理中的应用.学术论坛. 2003, (10):34~35
7李虹.现代物流管理信息系统设计方法研究.重庆教育学院学报. 2005, 18(3):32~34
8杨乐平,李海涛,赵勇. LabVIEW高级程序设计.清华大学出版社, 2004:200~249
9张爱平. LabVIEW入门与虚拟仪器.电子工业出版社, 2004:154~158
10廖开俊,刘志飞.虚拟仪器技术综述.国外电子测量技术. 2006, 125(2):6~8
11曹会国.基于LabVIEW的虚拟仪器VI(Virtual Instrument)及应用.潍坊学院学报. 2005, 15(2):14~15
12 F.J.Jimenez, J.De Frutos. Virtual Instrument for Measurement, Processing Data, and Visualization of Vibration Patterns of Piezoelectric Devices. Computer Standards & Interface. 2005, (27):653~663
13 Adrian Mihalcioiu, Lucian Dascalescu, Subhankar Dasa. Virtual Instrument for Statistic Control of Powder Tribo-charging Processes. Journal of Electrostatics. 2005, (63):565~570
14范寿康.基于LabVIEW平台的虚拟仪器实验室的实现.三江学院学报. 2005, 1(12):92~94
15林正盛.虚拟仪器技术及其发展.现代计量测试. 1997, (4):10~16
16 Ian R Harrison. Thermal Analysis of Polymers using Virtual Instruments, aTool for Teaching and Training. Thermochimica Acta. 2001, (367):85~92
17 John C, Wallera, Natalie Fosterb. Training via the Web, a Virtual Instrument. Computers & Education. 2000, (35):161~167
18 A.Economou, S.D.Bolis, C.E.Efstathiou. A“Virtual”Electroanalytical Instrument for Square Wave Voltammetry. Analytica Chimica Acta. 2002, (467):179~188
19 Jen Hao Teng, Roy Lee, Yi Hwa Liu. Integration of Internet and Virtual Instruments to Develop an Industrial SCADA. IEEE. 2001:1509~1514
20 Grzegorz Czajkowski, Michal Wegiel, Laurent Daynes. Resource Management for Clusters of Virtual Machines. IEEE International Symposium on Cluster Computing and the Grid. 2005:382~388
21 We Fu Chang, Yu Chi Wu, Chui Wen Chiu. Development of a Web-Based Remote Load Supervision and Control System. Electrical Power and Energy Systems. 2006, (28):401~407
22 Kevin J Watson, John H Blackstone, Stanley C Gardiner. The Evolution of a Management Philosophy. Journal of Operations Management. 2006:1~12
23曲春军.工业控制系统的网络化的应用现状与发展.中国科技信息. 2005, (4):24
24刘洪. NI全面打造汽车测试平台.今日电子. 2004, (3):72~73
25 Jim Morrison, Chuck Patterson.使用NI Test Stand测试手机基战.今日电子. 2003, (4):10
26杨泽富,肖波,李军.电工试验虚拟仪器的研制.实验技术与管理. 2003, 20(6):83~86
27代富平,吕淑媛,冯博学.基于LabVIEW的电化学测试系统的设计与应用.兰州大学学报. 2002, 38(6):44~47
28 Sun Qiuli. Internet-Based Distributed Collaborative Environment for Engineering Education and Design. The University of Oklahoma, 2001:23~27
29 Luis M Martinez, Franjo Cecelja, Ryszard Rakowski. A Virtual Instrument for the Characterisation of Magneto-Optical Materials. Measurement Technology Conference. 2004:119~122
30瑞莉,南利平,李学华.基于LabVIEW的通信专业远程虚拟实验室.国外电子测量技术. 2005, (3):4~7
31史涛,罗震,单平.基于LabVIEW的铝合金点焊数据采集系统的设计.中国科技论文在线. 2005:1~4
32 A.Economou, S.D.Bolis, C.E.Efstathiou. A“Virtual”Electroanalytical Instrument for Square Wave Voltammetry. Analytica Chimica Acta. 2002, (467):179~188
33 Adrian Mihalcioiu, Lucian Dascalescu, Subhankar Dasa. Virtual Instrument for Statistic Control of Powder Tribo-charging Processes. Journal of Electrostatics. 2005, (63):565~570
34 Sti R.Kolla, shawn D.Altman. Artificial neural network based fault identification scheme implementationfor a three-phase induction motor. ISA Transactions 46. 2007:261~266
35吴爱国,梁瑾,金文.工业以太网的发展现状.信息与控制. 2003, 32(5):459~466
36马利,李佐儒,杨四海.实现电子设备的网络化解决方案.单片机与嵌入式系统应用. 2002, 4(2):8~10
37潘涿金,施国君. C8051Fxxx高速SOC单片机原理及应用.北京:北京航空航天大学出版社, 2002:54~150
38许洪华.确定性工业以太网Ethernet Powerlink.冶金自动化. 2004, (4):23~25
39 Cygnal Integrated Products, Inc.C8051F020 Product Data Sheet. 2003:1~245
40黄国刚,陈明,许海岗.基于CS8900A的工业级嵌入式网络接口实现.新技术新仪器. 2005, 25(1):16~18
41李迎春.基于CS8900A的电力监控系统以太网接口设计.西安邮电学院学报. 2004, 9(3):38~40
42 Cirrus Logic, Inc.CS8900A Product Data Sheet. 2001:1~138
43 Cirrus Logic, Inc.CS8900A Technical Reference Manual. 2001:1~6
44 Commission III. Resistance Welding and Allied Joining: Document of 1996~1997. Welding in the World. 1999, 43(4):136~143
45 Kirk Zurell. C Programming for Embeded Systems. Byte Craft Limited. 2002: 124~201
46 LabVIEW Advanced Performance & Communication Course Manual. National Instruments Corporation, 2001:142~153
47仇斌,要利鑫,鲍其莲.虚拟仪器在压力测量及数据管理系统中的应用.自动化技术与应用. 2006, 25(8):50~52
48 XIA Hongmei, HU Baiqing, PAN Hua. Design of the Library Management System Based on LabVIEW. LabVIEW Science Technology and Engineering. 2007, 7(3):402~405
49王洪波,王枫,张彦斌. LabVIEW与Access数据库访问接口研究.测控自动化. 2004, 20(6):56~57
50蔡尚峰.随机控制理论.上海交通大学出版社, 1987:45~46
51杨春利,林三宝.电弧焊基础.哈尔滨工业大学出版社, 2003:128~167
52黄辉宁,李永庆,梅文博.随机信号分析.北京理土大学出版社,1989:101~132
53胡广书.数字信号处理-理论算法与实现.清华大学出版社, 1997:89~91
54蔡艳,吴毅雄.虚拟仪器在CO2弧焊品质分析中的应用.电焊机. 2002, 32(12):5~7
55梁文广,杨颖镇,赵振海. CO2气体保护焊.辽宁科学技术出版社, 2007:233~234
2姜焕中主编.电弧焊及电渣焊.北京:机械土业出版, 1988:15~17
3李建国.深化改革,艰苦奋斗,努力振兴我国的电焊机行业一电焊机行业总结及今后任务.电焊机, 1998, (6):1~4
4中国机械工程学会焊接学会.焊接手册(焊接方法及设备).机械工业出版社, 1992:156~162
5李柏姝.用面向对象方法开发现代制造企业的管理信息系统.柴油机设计与制造. 2002, (1):53~56
6徐胜龙,金建新.现场总线技术在汽车生产物流管理中的应用.学术论坛. 2003, (10):34~35
7李虹.现代物流管理信息系统设计方法研究.重庆教育学院学报. 2005, 18(3):32~34
8杨乐平,李海涛,赵勇. LabVIEW高级程序设计.清华大学出版社, 2004:200~249
9张爱平. LabVIEW入门与虚拟仪器.电子工业出版社, 2004:154~158
10廖开俊,刘志飞.虚拟仪器技术综述.国外电子测量技术. 2006, 125(2):6~8
11曹会国.基于LabVIEW的虚拟仪器VI(Virtual Instrument)及应用.潍坊学院学报. 2005, 15(2):14~15
12 F.J.Jimenez, J.De Frutos. Virtual Instrument for Measurement, Processing Data, and Visualization of Vibration Patterns of Piezoelectric Devices. Computer Standards & Interface. 2005, (27):653~663
13 Adrian Mihalcioiu, Lucian Dascalescu, Subhankar Dasa. Virtual Instrument for Statistic Control of Powder Tribo-charging Processes. Journal of Electrostatics. 2005, (63):565~570
14范寿康.基于LabVIEW平台的虚拟仪器实验室的实现.三江学院学报. 2005, 1(12):92~94
15林正盛.虚拟仪器技术及其发展.现代计量测试. 1997, (4):10~16
16 Ian R Harrison. Thermal Analysis of Polymers using Virtual Instruments, aTool for Teaching and Training. Thermochimica Acta. 2001, (367):85~92
17 John C, Wallera, Natalie Fosterb. Training via the Web, a Virtual Instrument. Computers & Education. 2000, (35):161~167
18 A.Economou, S.D.Bolis, C.E.Efstathiou. A“Virtual”Electroanalytical Instrument for Square Wave Voltammetry. Analytica Chimica Acta. 2002, (467):179~188
19 Jen Hao Teng, Roy Lee, Yi Hwa Liu. Integration of Internet and Virtual Instruments to Develop an Industrial SCADA. IEEE. 2001:1509~1514
20 Grzegorz Czajkowski, Michal Wegiel, Laurent Daynes. Resource Management for Clusters of Virtual Machines. IEEE International Symposium on Cluster Computing and the Grid. 2005:382~388
21 We Fu Chang, Yu Chi Wu, Chui Wen Chiu. Development of a Web-Based Remote Load Supervision and Control System. Electrical Power and Energy Systems. 2006, (28):401~407
22 Kevin J Watson, John H Blackstone, Stanley C Gardiner. The Evolution of a Management Philosophy. Journal of Operations Management. 2006:1~12
23曲春军.工业控制系统的网络化的应用现状与发展.中国科技信息. 2005, (4):24
24刘洪. NI全面打造汽车测试平台.今日电子. 2004, (3):72~73
25 Jim Morrison, Chuck Patterson.使用NI Test Stand测试手机基战.今日电子. 2003, (4):10
26杨泽富,肖波,李军.电工试验虚拟仪器的研制.实验技术与管理. 2003, 20(6):83~86
27代富平,吕淑媛,冯博学.基于LabVIEW的电化学测试系统的设计与应用.兰州大学学报. 2002, 38(6):44~47
28 Sun Qiuli. Internet-Based Distributed Collaborative Environment for Engineering Education and Design. The University of Oklahoma, 2001:23~27
29 Luis M Martinez, Franjo Cecelja, Ryszard Rakowski. A Virtual Instrument for the Characterisation of Magneto-Optical Materials. Measurement Technology Conference. 2004:119~122
30瑞莉,南利平,李学华.基于LabVIEW的通信专业远程虚拟实验室.国外电子测量技术. 2005, (3):4~7
31史涛,罗震,单平.基于LabVIEW的铝合金点焊数据采集系统的设计.中国科技论文在线. 2005:1~4
32 A.Economou, S.D.Bolis, C.E.Efstathiou. A“Virtual”Electroanalytical Instrument for Square Wave Voltammetry. Analytica Chimica Acta. 2002, (467):179~188
33 Adrian Mihalcioiu, Lucian Dascalescu, Subhankar Dasa. Virtual Instrument for Statistic Control of Powder Tribo-charging Processes. Journal of Electrostatics. 2005, (63):565~570
34 Sti R.Kolla, shawn D.Altman. Artificial neural network based fault identification scheme implementationfor a three-phase induction motor. ISA Transactions 46. 2007:261~266
35吴爱国,梁瑾,金文.工业以太网的发展现状.信息与控制. 2003, 32(5):459~466
36马利,李佐儒,杨四海.实现电子设备的网络化解决方案.单片机与嵌入式系统应用. 2002, 4(2):8~10
37潘涿金,施国君. C8051Fxxx高速SOC单片机原理及应用.北京:北京航空航天大学出版社, 2002:54~150
38许洪华.确定性工业以太网Ethernet Powerlink.冶金自动化. 2004, (4):23~25
39 Cygnal Integrated Products, Inc.C8051F020 Product Data Sheet. 2003:1~245
40黄国刚,陈明,许海岗.基于CS8900A的工业级嵌入式网络接口实现.新技术新仪器. 2005, 25(1):16~18
41李迎春.基于CS8900A的电力监控系统以太网接口设计.西安邮电学院学报. 2004, 9(3):38~40
42 Cirrus Logic, Inc.CS8900A Product Data Sheet. 2001:1~138
43 Cirrus Logic, Inc.CS8900A Technical Reference Manual. 2001:1~6
44 Commission III. Resistance Welding and Allied Joining: Document of 1996~1997. Welding in the World. 1999, 43(4):136~143
45 Kirk Zurell. C Programming for Embeded Systems. Byte Craft Limited. 2002: 124~201
46 LabVIEW Advanced Performance & Communication Course Manual. National Instruments Corporation, 2001:142~153
47仇斌,要利鑫,鲍其莲.虚拟仪器在压力测量及数据管理系统中的应用.自动化技术与应用. 2006, 25(8):50~52
48 XIA Hongmei, HU Baiqing, PAN Hua. Design of the Library Management System Based on LabVIEW. LabVIEW Science Technology and Engineering. 2007, 7(3):402~405
49王洪波,王枫,张彦斌. LabVIEW与Access数据库访问接口研究.测控自动化. 2004, 20(6):56~57
50蔡尚峰.随机控制理论.上海交通大学出版社, 1987:45~46
51杨春利,林三宝.电弧焊基础.哈尔滨工业大学出版社, 2003:128~167
52黄辉宁,李永庆,梅文博.随机信号分析.北京理土大学出版社,1989:101~132
53胡广书.数字信号处理-理论算法与实现.清华大学出版社, 1997:89~91
54蔡艳,吴毅雄.虚拟仪器在CO2弧焊品质分析中的应用.电焊机. 2002, 32(12):5~7
55梁文广,杨颖镇,赵振海. CO2气体保护焊.辽宁科学技术出版社, 2007:233~234