基于以太网的点焊过程质量监测方法与系统研究
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摘要
电阻点焊具有生产效率高和易于实现自动化等优点，是汽车白车身主要生产工艺。在白车身点焊过程中，存在较多影响焊接质量稳定性的因素，而且在焊装过程中经常出现各种异常情况，造成较多质量问题。目前，由于焊装车间缺乏相应的监测技术，无法对生产信息进行分析，异常情况也得不到及时处理，在一定程度上限制了企业生产效率和产品质量的进一步提高。本研究以焊装车间点焊过程为研究对象，研究监测技术和基于以太网技术的生产过程监测系统。
本文提出了基于以太网的监测技术的总体框架，按照功能将监测系统分为四个不同层次：企业信息管理层、现场信息管理层，生产监测层和生产设备层。生产监测层采用集散监测的方式，对汽车焊装车间各个工位的点焊过程进行监测，通过以太网将信息传输到计算机管理系统。提出了生产过程信息管理系统的总体模型，主要分为四个模块：实时信息管理、设备信息管理、生产信息管理和系统信息管理模块。在监测系统实现过程中，解决了利用8位单片机实现工业以太网通信和生产过程信息管理方法两个关键技术。
为了能够获得生产过程中的实时信息，本研究以双单片机作为核心，双口RAM作为数据共享单元，专用的网络芯片作为网络控制器，设计和开发了基于以太网的点焊监测系统，能够独立完成信号的调理、模数转换、数据本地暂存和以太网传输等功能。设计了数码显示模块，可实时显示工件数、焊点数、焊接电流、焊接时间和导通率等信息，便于现场管理人员控制生产进度和优化产品质量。针对焊装过程中电极失效以及漏焊等异常情况，设计了拥有8段独立语音的报警系统，通过语音提示操作人员对异常情况进行及时处理。同时，在不改变现场设备的前提下，利用车型识别和焊点计数的方法，设计焊接规范自动转换模块，实现工件不等厚板的焊接工艺自动调整。系统软件采用C语言编写，在统一的逻辑控制信号和时钟信号的控制下，实现上述各个监测功能。
点焊喷溅时，由于喷出的金属将引起动态电阻幅值突变，提出了以动态电阻突降幅值作为判断喷溅的特征量。研究了电极寿命与动态电阻之间的关系，提出了以动态电阻幅值的整体突降作为电极寿命判断依据，为电极状态在线实时监测提供理论基础。为了防止工艺规范转换出现混乱，研究了板厚与动态电阻之间的关系，提出了利用动态电阻幅值差异作为间接测量焊点处板厚的方法。考虑支持向量机算法内部二次规划占用较多资源等问题，提出了以“顺次最小优化算法”作为分类算法，并介绍了该算法的基本原理、程序流程和具体实现等。应用大量的数据样本进行训练，结果表明所建立的分类器具有较高的准确性。
在充分了解汽车焊装车间生产流程和工艺特点的基础上，建立了生产过程信息管理系统，实现设备静态信息、点检信息以及故障信息的准确记录和反馈，各个工位的合件信息，工艺规范信息和操作人员信息等的有序管理，以及点焊过程实时信息的准确记录和有序管理。在分析以上信息的类型和基本流程的基础上，建立了信息的基本模型，同时采用模块化的方法，确定了信息之间的约束条件。利用LabView作为开发工具，设计和开发了计算机信息管理系统，利用数据库技术实现了信息的存储和管理。采用ODBC技术作为异构数据库的访问接口，实现了点焊过程信息的实时显示和存储，生产信息和设备信息的存储和查询，过程信息分析等功能。
监测系统利用分类结果对电极的运行状态进行在线监测，当电极失效时，通过语音报警提示操作人员进行及时处理，应用结果表明电极寿命的识别准确率较高。为了能够实现不等厚板焊点工艺自动调整和工艺规范评判功能，设置了两个并行的具有二次脉冲的点焊工艺规范，实现焊接工艺的实时调整和评判。现场应用表明工艺规范转换的准确率达到了98.8%以上，满足焊装车间的实际应用要求。
通过研究基于以太网的汽车焊装监测技术，不仅提高了汽车焊装车间信息化管理水平，实现焊装过程信息的可视化和相关信息的有序存储和管理，为企业技术改进提供了最基础的资源，而且保证了现场生产的稳定性和连续性，减少汽车焊装过程的漏焊现象，改善不等板厚的焊接工艺，实现点焊电极寿命的在线监测。
Because of its high production efficiency and easy realization of automation,the resistance spot welding is the main sheet-metal joining method for body in whiteassembly. Many factors that influence welding quality stability exist in weldingprocess, and some abnormal phenomena often occur in body in white assembly,which case multiple quality problems. At present, it is lack of monitoringtechnology at automobile assembly field, the manufacture information can not beanalyzed, and the abnormal phenomena are not processed timely, so the productionefficiency and quality improvement are restricted at some degree. This dissertationtakes resistance spot welding in automobile assembly process as the leadinginvestigated subjects, and the monitoring technology and process monitoring systembased on Ethernet are researched.
The overall architecture of monitoring technology based on Ethernet isestablished, according to different functions, the Ethernet-based monitoring systemis divided into four parts: enterprise information management layer, fieldinformation management layer, process monitoring layer and production equipmentlayer. The mode of distribute monitoring is adopted in process monitoring layer, theseveral monitoring systems are used to monitor welding process of different workstations dispersedly, and all the sampling data are sent to computer informationmanagement system via Ethernet. The structure of information management systemis proposed, which includes four parts: real time information management,equipment information management, process information management and systeminformation management. The key technologies of utilizing eight bit microcontrollerunit to realize Ethernet data communication and information management methodsare solved in monitoring system realization process.
In order to obtain real time information in welding process, the Ethernet-basedresistance spot welding monitoring system is designed and developed, which usesdouble MCUs as the core, dual-port RAM as the data shared cell, and dedicatednetwork chip as the Ethernet controller, the monitoring system can independentlyfulfill the functions of signal conditioning, A/D conversion, data local temporarystorage, Ethernet communication and so on. Digital display model displays numberof workpiece and joint, welding current, welding time and electrical conductivity, sothe assembly field executives can easily adjust production schedule and improveproduction quality. The alarm system with eight independent voice segments isdesigned, according to the voice prompt, the operators can deal with such abnormalphenomena as electrode invalidation and lack of joints timely. At the same time, on the precondition of unchanging the current production equipments, the methods ofvehicle classification and joint counting are utilized to design the welding craftautomatic adjustment model, the problem of utilizing the same welding process tofinish different thickness panels is solved. The software of system is programmed byC language, under the control of unified logical signal and time signal, the abovemonitoring functions are accomplished.
The splash metal cases amplitude sudden change of dynamic resistance whenspatter occurs, so the amplitude sudden change is the characteristic quantity toreflect spatter. The relationship between electrode life and dynamic resistance isresearched, and the whole amplitude sudden change of dynamic resistance isproposed as the characteristic quantity to reflect electrode life, which provides withtheoretical foundations for on-line electrode life monitoring. In order to identifyaccuracy of welding process conversion, the relationship between thickness anddynamic resistance is researched, and the dynamic resistance amplitude differencecan be utilized as the indirect mean for thickness measurement. The support vectormachine basic principles are introduced, the problem that quadratic programmingproblem consumes excessive resources in calculation process is fully considered,Sequential Minimal Optimization(SMO) is proposed as information classificationmethod. The basic principles, program flow and the concrete realization methods ofSMO are discussed in detail. It is showed experimentally that criterions built in thisdissertation can recognize weld defects and reflect the status of machine operationby applying a large amount of data sample.
Based on the fully understanding of production flows and process features atbody in white assembly field, information management system is built, which canaccurately record and feedback of static equipment information, spot inspection, andfault information, process information of workpiece, welding process and operatorsare orderly managed, and real time information of welding process are accuratelyrecorded and orderly managed. Based on analysis of the information styles and basicinformation flow, the process information models are built, modularization andobject-oriented knowledge representation are used to describe each research objects,constraint conditions between information are defined through correlation betweeninvestigated subjects. The development environment LabView is utilized to establishinformation management system, the database technology is utilized to store andmanage process information. The ODBC technology is adopted as the data access ofdifferent databases, the functions of real time information displaying, storage andquerying of process and equipment information are realized.
The classification results are using to on-line monitor the status of electrode,when the abnormal status occurred, the alarm is generated to suggest the operatordeal with the abnormal in real time, and the results indicate that electrode status identification accurate rate is high. Aiming at fulfill the functions of weldingprocess auto conversion and welding process evaluation, two concurrent weldingcrafts with two impulses are set, and the functions of craft conversion and real timeevaluation are obtained, it is proved that craft conversion accuracy ratio is about98.8%, which is fit for industrial production application.
The research of monitoring technology based on Ethernet for body in whiteassembly not only improves the informatization level of workshop, the functions ofprocess information visualization and related information accurately record andmanagement are realized, which provides resources for future technologyimprovement, and also guarantees the stability and continuity of production process,the phenomenon of welding lack is reduced, the welding process for differentthickness are improved, and the function of on-line monitoring of electrode life isimplemented.
本文提出了基于以太网的监测技术的总体框架，按照功能将监测系统分为四个不同层次：企业信息管理层、现场信息管理层，生产监测层和生产设备层。生产监测层采用集散监测的方式，对汽车焊装车间各个工位的点焊过程进行监测，通过以太网将信息传输到计算机管理系统。提出了生产过程信息管理系统的总体模型，主要分为四个模块：实时信息管理、设备信息管理、生产信息管理和系统信息管理模块。在监测系统实现过程中，解决了利用8位单片机实现工业以太网通信和生产过程信息管理方法两个关键技术。
为了能够获得生产过程中的实时信息，本研究以双单片机作为核心，双口RAM作为数据共享单元，专用的网络芯片作为网络控制器，设计和开发了基于以太网的点焊监测系统，能够独立完成信号的调理、模数转换、数据本地暂存和以太网传输等功能。设计了数码显示模块，可实时显示工件数、焊点数、焊接电流、焊接时间和导通率等信息，便于现场管理人员控制生产进度和优化产品质量。针对焊装过程中电极失效以及漏焊等异常情况，设计了拥有8段独立语音的报警系统，通过语音提示操作人员对异常情况进行及时处理。同时，在不改变现场设备的前提下，利用车型识别和焊点计数的方法，设计焊接规范自动转换模块，实现工件不等厚板的焊接工艺自动调整。系统软件采用C语言编写，在统一的逻辑控制信号和时钟信号的控制下，实现上述各个监测功能。
点焊喷溅时，由于喷出的金属将引起动态电阻幅值突变，提出了以动态电阻突降幅值作为判断喷溅的特征量。研究了电极寿命与动态电阻之间的关系，提出了以动态电阻幅值的整体突降作为电极寿命判断依据，为电极状态在线实时监测提供理论基础。为了防止工艺规范转换出现混乱，研究了板厚与动态电阻之间的关系，提出了利用动态电阻幅值差异作为间接测量焊点处板厚的方法。考虑支持向量机算法内部二次规划占用较多资源等问题，提出了以“顺次最小优化算法”作为分类算法，并介绍了该算法的基本原理、程序流程和具体实现等。应用大量的数据样本进行训练，结果表明所建立的分类器具有较高的准确性。
在充分了解汽车焊装车间生产流程和工艺特点的基础上，建立了生产过程信息管理系统，实现设备静态信息、点检信息以及故障信息的准确记录和反馈，各个工位的合件信息，工艺规范信息和操作人员信息等的有序管理，以及点焊过程实时信息的准确记录和有序管理。在分析以上信息的类型和基本流程的基础上，建立了信息的基本模型，同时采用模块化的方法，确定了信息之间的约束条件。利用LabView作为开发工具，设计和开发了计算机信息管理系统，利用数据库技术实现了信息的存储和管理。采用ODBC技术作为异构数据库的访问接口，实现了点焊过程信息的实时显示和存储，生产信息和设备信息的存储和查询，过程信息分析等功能。
监测系统利用分类结果对电极的运行状态进行在线监测，当电极失效时，通过语音报警提示操作人员进行及时处理，应用结果表明电极寿命的识别准确率较高。为了能够实现不等厚板焊点工艺自动调整和工艺规范评判功能，设置了两个并行的具有二次脉冲的点焊工艺规范，实现焊接工艺的实时调整和评判。现场应用表明工艺规范转换的准确率达到了98.8%以上，满足焊装车间的实际应用要求。
通过研究基于以太网的汽车焊装监测技术，不仅提高了汽车焊装车间信息化管理水平，实现焊装过程信息的可视化和相关信息的有序存储和管理，为企业技术改进提供了最基础的资源，而且保证了现场生产的稳定性和连续性，减少汽车焊装过程的漏焊现象，改善不等板厚的焊接工艺，实现点焊电极寿命的在线监测。
Because of its high production efficiency and easy realization of automation,the resistance spot welding is the main sheet-metal joining method for body in whiteassembly. Many factors that influence welding quality stability exist in weldingprocess, and some abnormal phenomena often occur in body in white assembly,which case multiple quality problems. At present, it is lack of monitoringtechnology at automobile assembly field, the manufacture information can not beanalyzed, and the abnormal phenomena are not processed timely, so the productionefficiency and quality improvement are restricted at some degree. This dissertationtakes resistance spot welding in automobile assembly process as the leadinginvestigated subjects, and the monitoring technology and process monitoring systembased on Ethernet are researched.
The overall architecture of monitoring technology based on Ethernet isestablished, according to different functions, the Ethernet-based monitoring systemis divided into four parts: enterprise information management layer, fieldinformation management layer, process monitoring layer and production equipmentlayer. The mode of distribute monitoring is adopted in process monitoring layer, theseveral monitoring systems are used to monitor welding process of different workstations dispersedly, and all the sampling data are sent to computer informationmanagement system via Ethernet. The structure of information management systemis proposed, which includes four parts: real time information management,equipment information management, process information management and systeminformation management. The key technologies of utilizing eight bit microcontrollerunit to realize Ethernet data communication and information management methodsare solved in monitoring system realization process.
In order to obtain real time information in welding process, the Ethernet-basedresistance spot welding monitoring system is designed and developed, which usesdouble MCUs as the core, dual-port RAM as the data shared cell, and dedicatednetwork chip as the Ethernet controller, the monitoring system can independentlyfulfill the functions of signal conditioning, A/D conversion, data local temporarystorage, Ethernet communication and so on. Digital display model displays numberof workpiece and joint, welding current, welding time and electrical conductivity, sothe assembly field executives can easily adjust production schedule and improveproduction quality. The alarm system with eight independent voice segments isdesigned, according to the voice prompt, the operators can deal with such abnormalphenomena as electrode invalidation and lack of joints timely. At the same time, on the precondition of unchanging the current production equipments, the methods ofvehicle classification and joint counting are utilized to design the welding craftautomatic adjustment model, the problem of utilizing the same welding process tofinish different thickness panels is solved. The software of system is programmed byC language, under the control of unified logical signal and time signal, the abovemonitoring functions are accomplished.
The splash metal cases amplitude sudden change of dynamic resistance whenspatter occurs, so the amplitude sudden change is the characteristic quantity toreflect spatter. The relationship between electrode life and dynamic resistance isresearched, and the whole amplitude sudden change of dynamic resistance isproposed as the characteristic quantity to reflect electrode life, which provides withtheoretical foundations for on-line electrode life monitoring. In order to identifyaccuracy of welding process conversion, the relationship between thickness anddynamic resistance is researched, and the dynamic resistance amplitude differencecan be utilized as the indirect mean for thickness measurement. The support vectormachine basic principles are introduced, the problem that quadratic programmingproblem consumes excessive resources in calculation process is fully considered,Sequential Minimal Optimization(SMO) is proposed as information classificationmethod. The basic principles, program flow and the concrete realization methods ofSMO are discussed in detail. It is showed experimentally that criterions built in thisdissertation can recognize weld defects and reflect the status of machine operationby applying a large amount of data sample.
Based on the fully understanding of production flows and process features atbody in white assembly field, information management system is built, which canaccurately record and feedback of static equipment information, spot inspection, andfault information, process information of workpiece, welding process and operatorsare orderly managed, and real time information of welding process are accuratelyrecorded and orderly managed. Based on analysis of the information styles and basicinformation flow, the process information models are built, modularization andobject-oriented knowledge representation are used to describe each research objects,constraint conditions between information are defined through correlation betweeninvestigated subjects. The development environment LabView is utilized to establishinformation management system, the database technology is utilized to store andmanage process information. The ODBC technology is adopted as the data access ofdifferent databases, the functions of real time information displaying, storage andquerying of process and equipment information are realized.
The classification results are using to on-line monitor the status of electrode,when the abnormal status occurred, the alarm is generated to suggest the operatordeal with the abnormal in real time, and the results indicate that electrode status identification accurate rate is high. Aiming at fulfill the functions of weldingprocess auto conversion and welding process evaluation, two concurrent weldingcrafts with two impulses are set, and the functions of craft conversion and real timeevaluation are obtained, it is proved that craft conversion accuracy ratio is about98.8%, which is fit for industrial production application.
The research of monitoring technology based on Ethernet for body in whiteassembly not only improves the informatization level of workshop, the functions ofprocess information visualization and related information accurately record andmanagement are realized, which provides resources for future technologyimprovement, and also guarantees the stability and continuity of production process,the phenomenon of welding lack is reduced, the welding process for differentthickness are improved, and the function of on-line monitoring of electrode life isimplemented.
引文
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