CN109675824A - The product quality control method of device for ultrasonic welding - Google Patents
The product quality control method of device for ultrasonic welding Download PDFInfo
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- CN109675824A CN109675824A CN201811641889.6A CN201811641889A CN109675824A CN 109675824 A CN109675824 A CN 109675824A CN 201811641889 A CN201811641889 A CN 201811641889A CN 109675824 A CN109675824 A CN 109675824A
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- ultrasonic welding
- limit threshold
- upper limit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/26—Auxiliary equipment
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
The invention discloses a kind of product quality control methods of device for ultrasonic welding, including the subsequent parameter data in an acquisition welding process；The subsequent parameter data are compared with upper limit threshold and lower threshold, when the subsequent parameter data are greater than the upper limit threshold or are less than the lower threshold, alarm signal is sent to device for ultrasonic welding, so that the device for ultrasonic welding removes defective products corresponding with the subsequent parameter data from the device for ultrasonic welding.The present invention carries out real-time analysis processing to the technological parameter of processing, the automatic manipulator being furnished with can automatically take out product, according to welding effect, product will not be measured and be placed in defective region, good product is placed in non-defective unit region, greatly reduces the labor intensity of operator, realize that data creation data is information-based, production statistics is convenient, is produced using big data technical optimization, realizes a kind of rotating disc type ultrasonic welding machine with Process Quality Monitoring.
Description
Technical field
The invention belongs to the monitoring fields of ultrasonic bonding machine, and in particular to the product quality control of device for ultrasonic welding
Method.
Background technique
Existing common single head ultrasonic welding machine, operator's processing intensity is big, after processing every time, all needs to rely on
Manpower takes out product, rather than manipulator is relied on to take out；It is not comprehensive not have electrical monitoring.Typically just monitoring current overloads
Situation can only realize local light warning；And " voltage, frequency, weld time, pressure abnormity " warning function does not have, and does not give birth to
The function of production. art parameter preservation data；And for the data of common rotating disc type ultrasonic welding machine " yield ", firstly, by
Personnel read the data of each rotating disc type ultrasonic welding machine " yield ", and are kept a record with paper and pen, then, by personnel
The data of " yield " are recorded in Excel table, finally, the just total amount of available same day production, seem trouble in this way.
Common rotating disc type ultrasonic welding machine does not have defective products sorting function yet.Common turntable type ultrasonic wave weldering
It picks after only simple completion processing, the product processed is taken out, does not have bad discrimination function；Although utilizing PLC program
Control, programming is simple, but unit price is high, does not have cost advantage；Certain intelligent rotating disc type ultrasonic welding machines do not measure gas
The function of pressure；Although there is processing parameter to save the function of data, data can only be stored in rotating disc type ultrasonic welding machine
On memory, data are read with u disk.
In short, the portioned product of the prior art uses, manipulation strength is big, and the data of monitoring are not comprehensive enough, data storage
Inconvenience, data cannot network, not analysis and utilization data.Some traditional ultrasonic welding machines are monitoring current, and common
Rotating disc type ultrasonic welding machine have the function of a large amount of technological parameters of measurement, but data cannot network, needless to say using big
Data technique produces to optimize.The shortcomings that prior art, mainly ultrasonic welding machine manufacturer technology thinked little of the prison of data
It surveys, saves the cost of equipment production, caused by not growing up there are also the technologies such as Internet of Things and big data at that time.
To solve the above-mentioned problems, the present invention provides a kind of product quality control methods of device for ultrasonic welding.
Summary of the invention
The present invention is directed to the drawbacks of prior art, provides a kind of product quality control method of device for ultrasonic welding, solves
Certainly ordinary turntable formula ultrasonic welding machine does not have the problem of defective products judgement, realizes bad by the taking-up of defective products manipulator
Product.
It is a further aim of the invention the informationization of rotating disc type ultrasonic welding machine data is realized, it can be long-range
Control bonding machine.
For this purpose, the present invention provides a kind of product quality control methods of device for ultrasonic welding, comprising the following steps:
Acquire the subsequent parameter data in welding process；
The subsequent parameter data are compared with upper limit threshold and lower threshold, when the subsequent parameter data are greater than
The upper limit threshold or be less than the lower threshold when, to device for ultrasonic welding send alarm signal so that the ultrasound
Wave welding equipment removes defective products corresponding with the subsequent parameter data from the device for ultrasonic welding.
Preferably, before the follow-up data in acquisition welding process, further includes:
The first supplemental characteristic in welding process is acquired, and is sent to Cloud Server, so that Cloud Server is by described first
Supplemental characteristic is compared with the upper limit threshold and the lower threshold；
Receive the upper limit threshold and lower threshold and/or alarm signal that the Cloud Server is sent, wherein the report
When alert signal is that first supplemental characteristic is greater than the upper limit threshold or is less than the lower threshold, the Cloud Server hair
It send；
It stores the upper limit threshold and lower threshold and the alarm signal is sent to the device for ultrasonic welding, with
Move up the device for ultrasonic welding defective products corresponding with first supplemental characteristic from the device for ultrasonic welding
Out.
Preferably, before the subsequent parameter data being compared with upper limit threshold and lower threshold, further includes:
When the upper limit threshold and the lower threshold update, receive and store the new institute that the Cloud Server is sent
State upper limit threshold and the new lower threshold.
Preferably, first supplemental characteristic and the subsequent parameter data include voltage, it is electric current, air pressure, amplitude, wet
Degree, frequency and weld time, the voltage are acquired by voltage transformer, and the electric current is acquired by current sensor,
The air pressure is acquired by baroceptor, and the frequency and weld time are adopted by frequency and weld time observation circuit
Collection, the amplitude are acquired by vibrating sensor, and the humidity is acquired by humidity sensor；
Wherein, first supplemental characteristic being collected and the subsequent parameter data, are sent to institute by serial ports UART
Device for ultrasonic welding is stated, meanwhile, the Cloud Server is sent to by interchanger by too steel wire rack piece.
Preferably, the upper limit threshold and lower threshold respectively include upper voltage limit threshold value and lower voltage limit threshold value, electricity
Flow upper limit threshold and lower current limit threshold value, the gentle pressure lower threshold of air pressure upper limit threshold, upper frequency limit threshold value and lower-frequency limit threshold
Value, weld time upper limit threshold and weld time lower threshold, yield upper limit threshold and yield lower threshold；
Preferably, the upper limit threshold and the lower threshold are terminal setting, and are sent to Cloud Server.
Preferably, the terminal is computer or mobile terminal.
Preferably, described to send alarm signal to device for ultrasonic welding, so that the device for ultrasonic welding will be with
The corresponding defective products of the subsequent parameter data is removed from the device for ultrasonic welding, comprising:
Alarm signal is sent to device for ultrasonic welding, so that the device for ultrasonic welding will be with the subsequent parameter number
It is removed from the device for ultrasonic welding according to corresponding defective products, meanwhile, Xiang Suoshu Cloud Server sends the alarm signal,
So that the Cloud Server sends the alarm signal to the terminal.
Beneficial effects of the present invention
1, the product quality control method of device for ultrasonic welding provided by the invention, can to the technological parameter of processing into
The real-time analysis processing of row, defective products is rejected.
2, the product quality control method of device for ultrasonic welding provided by the invention, greatly reduces operator's
Labor intensity improves work efficiency.
3, the product quality control method of device for ultrasonic welding provided by the invention, data network, convenient for unified pipe
It manages, not only convenient storage, but also capacity is big, display data is more convenient.
Detailed description of the invention
Fig. 1 is the flow chart of the embodiment of the product quality control method of device for ultrasonic welding of the present invention；
Fig. 2 is the flow chart of another embodiment of the product quality control method of super refreshing wave welding equipment of the present invention
Fig. 3 is the system construction drawing of device for ultrasonic welding of the present invention；
Fig. 4 is the system construction drawing of monitor of the present invention；
Fig. 5 is the working principle circuit diagram of voltage transformer of the present invention；
Fig. 6 is the working principle circuit diagram of current sensor of the present invention；
Fig. 7 is the working principle diagram of baroceptor of the present invention；
Fig. 8 is frequency of the present invention and weld time observation circuit figure；
Fig. 9 is product of the present invention quality discrimination flow chart；
Figure 10 is the flow chart that alarm of the present invention is realized；
Figure 11 is the work flow diagram of device for ultrasonic welding of the present invention；
Figure 12 is the circuit diagram of clock circuit of the present invention；
Figure 13 is vibrating sensor application circuit；
Figure 14 is humidity sensor application circuit.
Specific embodiment
Present invention will be described in further detail below with reference to the accompanying drawings, to enable those skilled in the art referring to specification text
Word can be implemented accordingly.
As depicted in figs. 1 and 2, monitoring method of the invention is illustrated mainly with Fig. 1 and Fig. 2, as shown in Figure 1, in step
Executing subject be monitor, setting connect in the device for ultrasonic welding, and with the device for ultrasonic welding,
A kind of disclosure of the invention product quality control method of device for ultrasonic welding comprising:
Step 101, the subsequent parameter data in welding process are acquired；Executing subject is monitor；
Step 102, the subsequent parameter data are compared with upper limit threshold and lower threshold, when the subsequent parameter
When data are greater than the upper limit threshold or are less than the lower threshold, alarm signal is sent to device for ultrasonic welding, so that
The device for ultrasonic welding removes defective products corresponding with the subsequent parameter data from the device for ultrasonic welding.
In step 101, acquire welding process in subsequent parameter data, including voltage, electric current, air pressure, yield, frequency,
Weld time, amplitude and humidity, the voltage are acquired by voltage transformer, and the electric current is adopted by current sensor
Collection, the air pressure are acquired by baroceptor, and the amplitude is acquired by vibrating sensor, and the humidity passes through humidity
Sensor acquires, and the frequency and weld time are acquired by frequency and weld time observation circuit, the yield passes through
The number that completes the process is measured to determine；First supplemental characteristic being collected and the subsequent parameter data, pass through serial ports
UART is sent to the device for ultrasonic welding, meanwhile, the Cloud Server is sent to by interchanger by too steel wire rack piece.
In step 102, subsequent parameter data and bound threshold value are compared, under the upper voltage limit threshold value and voltage
Limit threshold value is respectively 250V and 200V, and the upper current limit threshold value and lower current limit threshold value are respectively 4000MA and 300MA, described
The gentle pressure lower threshold of air pressure upper limit threshold is respectively 720kpa and 190kpa, the upper frequency limit threshold value and lower-frequency limit threshold value
Respectively 21000Hz and 19000Hz, the weld time upper limit threshold and weld time lower threshold be respectively 0.2s and
0.020s。
Wherein, it includes: ultrasonic drilling machine bonding machine by 220V that the yield is determined by measuring the number that completes the process,
50HZ is changed into the electric energy of 20KHZ.The electric energy of about 20KHZ can be checked when processing.When not processing, then the not no electricity of 20KHZ
Energy.Frequency and weld time observation circuit acquire, and when the electric energy for detecting 20KHZ, yield then adds 1, and so on.
Before carrying out step 101, include the steps that it is as shown in Figure 2, similarly the executing subject in step be monitor,
Its setting is connect in the device for ultrasonic welding, and with the device for ultrasonic welding, comprising the following steps:
Step 201, the first supplemental characteristic in welding process is acquired, and is sent to Cloud Server, so that Cloud Server will
First supplemental characteristic is compared with the upper limit threshold and the lower threshold；
Step 202, the upper limit threshold and lower threshold and/or alarm signal that the Cloud Server is sent are received,
In, it is described when the alarm signal is that first supplemental characteristic is greater than the upper limit threshold or is less than the lower threshold
What Cloud Server was sent；
Step 203, the upper limit threshold and lower threshold are stored and the alarm signal is sent to the supersonic welding
Connect equipment so that the device for ultrasonic welding will defective products corresponding with first supplemental characteristic from the ultrasonic bonding
It is removed in equipment.
It can guarantee that monitoring data are synchronized on monitor and Cloud Server in this way, accelerate monitoring velocity, improve work effect
Rate.
Before carrying out step 102, when the upper limit threshold and lower threshold update, receives and store the cloud
The new upper limit threshold and the new lower threshold that server is sent, by subsequent parameter data and updated bound
Threshold value is compared.
Above-mentioned executing subject is monitor, as shown in figure 3, the monitor is arranged in the device for ultrasonic welding,
And it is connect with the device for ultrasonic welding；As shown in figure 4, the monitor includes that controller (its be ARM chip), voltage are mutual
Sensor, current sensor, baroceptor, frequency and weld time observation circuit, clock circuit (as shown in figure 12), acousto-optic report
Alert device and power supply, the controller are connect with the single-chip microcontroller in the device for ultrasonic welding, the voltage transformer, the electricity
Flow sensor, the baroceptor, the observation circuit, the clock circuit, the combined aural and visual alarm and the power supply are equal
It is connect with the controller, after the monitor handles data well, the supersonic welding is transferred data to by serial ports UART
It connects in the single-chip microcontroller in equipment；
Further include interchanger, is connect with the monitor；Cloud Server is connect with the switch communication；Data
Library is communicated to connect with the Cloud Server；Terminal is connected to the network with the Cloud Server by Ethernet, and institute
Stating terminal is computer or mobile terminal, and terminal is PC terminal in the present invention；
As shown in figure 4, the controller in monitor is made of ARM chip, it is responsible for the collection of data, the biography of network data
It is defeated, it is communicated with ultrasonic wave rotating disc type bonding machine main body.Voltage, electricity when collection ultrasonic wave rotating disc type welding machinofacture
Stream, air pressure, frequency, yield, weld time, amplitude and humidity data realize that implementation is as follows, voltage transformer and electric current
Sensor realizes monophase current voltage, and air pressure is collected by baroceptor, the frequency and ultrasonic drilling machine weld time of ultrasonic wave
It is realized by ARM chip interior resource and external circuit, yield is then determined by the number of measurement data upload.Sensor will
" electric current, voltage, air pressure, amplitude, humidity " analog information of welding process is exported to the port A/D of ARM chip, frequency and welding
Time supervision circuit output digital quantity after the good data of ARM chip processing, is transferred to data by serial ports UART to ARM chip
Ultrasonic wave rotating disc type bonding machine main body, simultaneously with this, the data handled well are transmitted to cloud by way of wired network or wireless network
Server.
So cooperate monitor, as shown in figure 11, the workflow of the device for ultrasonic welding in the present invention are as follows: single head is super
Linear guide elevating movement system inside sound wave bonding machine drives soldering tip to complete welding procedure, specific to act i.e.: soldering tip decline
→ → Time-delayed trigger → → triggering ultrasound → → pressure maintaining → → soldering tip rises.
Ultrasonic wave rotating disc type bonding machine main body, including movement: the movement of turntable rotation → → single head ultrasonic welding machine → →
Monitor monitoring data simultaneously return the result → → turntable rotation → → manipulator taking-up product.
The turntable has multiple machining positions (3~24), and turntable intermittently turns under the driving effect of servo-actuating device
Dynamic, when turntable pause, product to be measured is placed in machining position by operator；Subsequent turntable again pauses for after rotating 45 °, recycles
Back and forth.Product to be measured is transported to unloading station and is detected；The product to be measured is transported to by manipulator according to the result of detection
Corresponding placement location (non-defective unit placement location, defective products placement location), to complete the entire production of automatic detection sorting system
Product examine is surveyed and sorting function.
Here illustrated with 8 stations, 8 equal portions of machining position (45 °) are fixed on turntable, machining position label 1~8 respectively.
Rotating disc type ultrasonic welding machine starting, turntable find origin, are herein the position of processing, and soldering tip is aligned with No. 1 machining position at this time,
Whether monitoring machining position has product, if there is product, soldering tip movement, if soldering tip is failure to actuate without product.
Turntable rotates (45 °), and machining position (being labeled as 2) is moved at processing, and monitoring origin does not have product, if there is product,
Soldering tip movement, if soldering tip is failure to actuate without product.As unit of 8 stations, move in circles.
Wherein, database of the invention is peach beautiful jade information management platform (hereinafter referred to as TIMP-Taolin Information
Management Platform), as shown in figure 3, monitor is fixedly installed in rotating disc type ultrasonic welding machine, and with ultrasound
Wave soldering, which picks, to be connected, monitor acquisition fusion process " voltage, electric current, air pressure, frequency, yield, weld time, amplitude, it is wet
Degree " data, monitor and interchanger pass through interchanger by Ethernet chip by network cable transmission data, by the data being collected into
It being transferred to Cloud Server and carries out data displaying in TIMP system, Cloud Server is connected using Ethernet with workshop computer network,
So that personnel carry out equipment monitoring in computer login TIMP system.On the one hand, in the settable alarm ginseng of the TIMP system of page end
Several bounds, and alarm parameters are synchronized to monitor, the judgement whether alarmed is achieved that in monitor, if parameter all exists
In setting range, any alarm signal will not be generated, illustrates that product is non-defective unit, manipulator clamps product, product is placed into good
Inside product chest；If parameter goes beyond the scope, make a sound with word alarm signal, illustrate that product is defective products, manipulator folder
Product is taken, product is placed into inside defective products chest.In terms of alarm, rotating disc type ultrasonic welding machine main body can sound report
It warns and corresponding word alarm is prompted to prompt, TIMP system also issues word alarm information, on the other hand, will a large amount of " voltages, electricity
Stream, air pressure, frequency, yield, weld time, amplitude, humidity " creation data stores, and optimizes life using big data technology
It produces, such as the decision recommendation of " production equipment Improving advice " is provided, such as discovery voltage instability, then " installation power supply can be provided
The Improving advice of voltage-stablizer ".To realize the monitoring and optimization production of the product quality of ultrasonic welding machine production process.
Wherein, the present invention relates to technological parameter include electric current, voltage, frequency and welding when, air pressure, amplitude, humidity
(electric current, voltage refer to actual current, voltage when current time is processed, and frequency refers to actual resonance frequency when current time processing,
Weld time issues the time of resonance frequency when referring to converted products, the pressure of product, amplitude refer to ultrasonic waves when air pressure refers to processing
The amplitude of energy device and luffing bar apparatus, humidity refer to the humidity of current environment) it will affect the effect that product is processed, plastic product
Defective products works as electric current, voltage, frequency, weld time, air pressure is too small to be will cause mainly due to welding deficiency and welding excessively cause
Welding is insufficient, if electric current, voltage, frequency, weld time, air pressure is excessive to will cause that welding is excessive, and weld time is imitated to welding
Fruit has the factor of decisive influence, the only setting " weld time " on general ultrasonic welding machine, but without monitoring " welding
Time ", the weld time whether actual " weld time " reaches setting is unknown, therefore monitors " weld time " and very must
It wants.Each purposes suitable weld interval is determined by test.Weld strength can be improved until when reaching best by increasing weld interval
Between until.Further increasing weld interval will lead to weld strength reduction or only increases intensity slightly, and at the same time can
Increase weld seam overlap and improves a possibility that generating part impression.It is critically important for avoiding weldering, because can generate need to modify
Excessive overlap, this may be decreased weldquality, and leak is generated in the part for needing seal nipple.Soldering tip may abrade surface.Compared with
Fusing and fracture are also possible that in the part portion far from joint area when long weld interval, the hole especially in moulded parts
Hole, welding line and sharp corner are in this way.
Amplitude is the important parameter that a control thermoplastic squeezes flow rate.In ultrasonic welding process, if
Amplitude is too small, and welding energy is inadequate, and the place weldering of the weldering is loosely.If amplitude is too big, weldering, gummosis or burn-through were caused.Gao Zhen
When width, weld interface heating speed is higher, and temperature rises, and molten material flows fast speed, and molecularly oriented is caused to increase, and generates
A large amount of overlaps and weld strength are lower.High amplitude is required for starting fusing.Too low amplitude generates non-uniform beginning
Fusing and the solidification of premature melt.When increasing amplitude, a greater amount of vibrational energies consumes the part to be welded in thermoplastic
Bear bigger stress.During entire weld cycle when amplitude constant, what is generallyd use is to be unlikely to generate to part to be welded
The crest amplitude excessively damaged.For crystalline plastic such as polyethylene and polypropylene, the influence of amplitude is such as than amorphism plastics
ABS and polystyrene are much greater.This may be since the fusing and welding of crystalline plastic need more energy.
So the present invention collects voltage, current information, ultrasonic welding machine by voltage transformer and current sensor
Working power be 220V industrial-frequency alternating current.Voltage transformer and current transformer realize the real time monitoring of single phase alternating current power supply
And acquisition.The testing principle of AC supply voltage and electric current is exactly to pass through voltage transformer and current transformer for AC power source
High pressure high current be converted into ARM chip and can detecte the low-voltage of processing.Alternating voltage detection range is AC0V-AC400V.
As shown in figure 5, being the operating circuit schematic diagram of voltage transformer, as shown in figure 5, the alternating voltage signal of power supply is logical
The first side winding for crossing series limiting resistor input current type voltage transformer is exported through mutual inductor secondary side, output matching electricity
The current signal of output is converted to voltage signal by resistance, send ARM chip sampling processing.Series circuit has selected 1 150K Ω electricity
Resistance meets linear transformation range when input voltage is 0~400v.
It so, is the operating circuit schematic diagram of current sensor, as shown in figure 5, alternating current detection range is such as Fig. 6
AC0A-AC10A, the current signal of AC power source are directly accessed current sensor first side winding, and induced current is through sensor
Secondary side output exports build-out resistor for current signal and is converted to voltage signal, send ARM chip sampling processing.
The present invention collects barometric information by baroceptor, as shown in fig. 7, the voltage model of baroceptor output end
Enclosing is 0.5~4.5v, and the voltage of output is carried out analog-to-digital conversion, obtains atmospheric pressure value.
The present invention collects humidity data by humidity sensor, as shown in figure 14, the voltage of humidity sensor output end
Range is 0.5~4.5v, and the voltage of output is carried out analog-to-digital conversion, obtains humidity value.
The present invention collects amplitude data by vibrating sensor, as shown in figure 13, the voltage of vibrating sensor output end
Range is 0.5~4.5v, and the voltage of output is carried out analog-to-digital conversion, obtains amplitude.
The present invention by frequency and weld time observation circuit come collection frequency and weld time data, it is as shown in Figure 8
Circuit diagram, the frequency and ultrasonic drilling machine weld time of ultrasonic wave utilize the input capture function of ARM chip interior, timer
It is realized with counter.The frequency of ultrasonic wave can be calculated with correlation formula, and ultrasonic drilling machine weld time calculates hair ultrasonic wave
Origin And Destination obtains.
Wherein, product quality differentiates as shown in figure 9, the threshold values for the alarm parameters that personnel are arranged in computer terminal is sent to cloud
Server is simultaneously stored in database, and Cloud Server obtains the bound (threshold values) of setting data at this time.After monitor starting, judgement
Whether ultrasonic wave issues, if issuing without ultrasonic wave, monitor does not acquire data.If there is ultrasonic wave sending, monitor acquires number
According to and complete, send data to Cloud Server, Cloud Server judges according to threshold values, if there is one or more parameters super
Range out, is judged as defective products and alarms, and is otherwise judged as that non-defective unit is not alarmed.After data are stored in database by server,
Threshold values is returned to monitor, " voltage, electric current, air pressure, frequency, yield, weld time, amplitude, humidity " parameter bound is same
Monitor is walked, monitor is whether parameter when can determine whether processing goes out normal range (NR), if there are one or more parameters
It goes beyond the scope, be judged as defective products and alarm, be otherwise judged as that non-defective unit is not alarmed.
The realization specifically alarmed is as shown in Figure 10, and personnel are saved in server in the parameter that page end is arranged, and will " electricity
Pressure, electric current, air pressure, frequency, yield, weld time, amplitude, humidity " parameter bound Simultaneous Monitoring instrument, monitor can determine whether
Whether parameter when processing goes out normal range (NR), if the parameter of monitoring is all within the set range, by serial communication, informs rotating disc type
Non-defective unit is moved to inside non-defective unit case by ultrasonic welding machine main body without alarm, control manipulator.If have one or one with
Upper parameter goes beyond the scope, and by serial communication, informs that rotating disc type ultrasonic welding machine main body carries out audible alarm and prompts corresponding
Word alarm prompt (prompting certain parametic fault), defective products is moved to inside defective product box by control unloading manipulator.With this
Meanwhile monitor issues alarm signal to server, warning message is received in the TIMP system of page end, for example, air pressure is relatively low
When, it will call the police " the machine air pressure of the workshop C1 3 is 100kpa, and air pressure is lower than setting lower limit ".
The bound setting specifically alarmed
The method of 1 > citing " air pressure " bound setting.It is tested using the method for control variable, tests out air pressure report
Alert bound.In the case where keeping " voltage, electric current, frequency, weld time " constant, changes atmospheric pressure value one by one and does experiment,
Respectively with 100, the atmospheric pressure value of 150,200,250,300,400,500,600,700,750,800kpa etc., every group of atmospheric pressure value production
20 plastic cement parts, the plastic cement part produced carry out safety test and tensile test, test the non-defective unit that is considered as passed through, no
By being then defective products.If 200,250,300,400,500,600,700kpa is non-defective unit, and 100,150,750,800kpa
It is all defective products, then lower limit, between 150kpa and 200kpa, the upper limit is between 700kpa and 750kpa.Again with 160,170,
180,190kpa does experiment, 160,170,180kpa be all defective products, 190kpa is non-defective unit, then setting lower limit value to
190kpa.Upper limit value is similar, it is assumed that determines that upper limit value is 720kpa.Thus it is possible to which the TIMP system in page end is arranged
The threshold value of air pressure is less than 190kpa, is greater than 720kpa.The threshold value and air pressure of " voltage, electric current, frequency, weld time, amplitude "
It is similar.
The method of 2 > citing " weld time " bound setting
It is tested using the method for control variable, tests out the bound of " weld time " alarm.General product and
So, " weld time " is usually between 0.02s to 0.06s.In the case where keeping " voltage, electric current, frequency, air pressure " constant, by
One change weld time value is done experiment, respectively with 0.016s, 0.017s, 0.018s, 0.019s, 0.020s, 0.022s,
The weld time of 0.024s, 0.06s, 0.08s, 0.1s, 0.12s, 0.14s, 0.2s etc., every group of weld time produce 10 plastic cement
Part, the plastic cement part produced carry out safety test and tensile test, test the non-defective unit that is considered as passed through, not by being then
Defective products.If 0.020s, 0.022s, 0.024s are non-defective unit, and 0.016s, 0.017s, 0.018s, 0.019s are bad
Product, then setting 0.020s for lower limit value.Upper limit value is similar, it is assumed that determines that upper limit value is 0.2s.Thus it is possible in net
The threshold value of the TIMP system setting air pressure at page end is less than 0.02s, is greater than 0.2s.The threshold value of " voltage, electric current, frequency " is similar.
The bound threshold value of alarm, which can be set, is shown in Table 1,
Certainly, update is adjusted according to actual environment for upper and lower limit threshold value, and table 1 is an implementation in practical operation
Example.
The collected data of the present invention can be transmitted by Ethernet or wireless network.On the one hand, Ethernet is utilized
100Base-T4 interface realizes that data are transmitted by Ethernet by cable and interchanger Electricity Federation.Still further aspect uses
RTL8189 module is uploaded data by wifi, in actual use, it is only necessary to connect wireless router or wireless aps (i.e.
Access Point, that is, wireless access point), effectively realize the data interaction of monitor and database.Data
Library store a large amount of " voltage, electric current, air pressure, frequency, yield, weld time, amplitude, humidity " creation datas, so as to
After utilize.
The present invention carries out real-time analysis processing to the technological parameter of processing, and the automatic manipulator being furnished with can automatically take out production
Product will not measure product and be placed in defective region according to welding effect, and good product is placed in non-defective unit region, greatly reduces behaviour
To make the labor intensity of personnel, realizes that data creation data is information-based, production statistics is convenient, it is produced using big data technical optimization,
Realize a kind of rotating disc type ultrasonic welding machine with Process Quality Monitoring net.
The mode of networking of the present invention is connect using wired connection with wireless WIFI, reliability, and performance is stablized, flexibly.For
The workshop in big region, can be used wired connection, for the workshop of zonule, wireless WIFI connection can be used.Peach beautiful jade supersonic welding
The data that the monitor that picks is collected into are transferred to Cloud Server by interchanger by Ethernet chip and carry out in TIMP system
Data exchange.Rather than simple ZigBee is used to be wirelessly connected.ZigBee is although low in energy consumption, and flexibility is good, does not have to wiring, but
It is reliability and performance not as good as wired connection.
In addition, the data of present invention database and SD card record rotating disc type ultrasonic welding machine, convenient for post analysis number
According to, and be more than and only exist SD card in intelligent rotating disc type ultrasonic welding machine.This mode is welded than current turntable type ultrasonic wave
It picks more excellent by SD card storing data, not only convenient storage, but also capacity is big, shows more convenient with analysis data.
The present invention machines plastic toy and right, general skilled operator one day 8 for the ultrasonic bonding of single-station
10000 plastic toys can be processed in hour.Than general rotating disc type bonding machine, in fast state, speed promotes 20%, and one day 8
20000 plastic toys can be processed in hour.
Although the embodiments of the present invention have been disclosed as above, but its is not only in the description and the implementation listed
With it can be fully applied to various fields suitable for the present invention, for those skilled in the art, can be easily
Realize other modification, therefore without departing from the general concept defined in the claims and the equivalent scope, the present invention is simultaneously unlimited
In specific details and legend shown and described herein.
Claims (8)
1. a kind of product quality control method of device for ultrasonic welding, which comprises the following steps:
Acquire the subsequent parameter data in welding process；
The subsequent parameter data are compared with upper limit threshold and lower threshold, when the subsequent parameter data are greater than described
Upper limit threshold or be less than the lower threshold when, to device for ultrasonic welding send alarm signal so that the supersonic welding
Equipment is connect to remove defective products corresponding with the subsequent parameter data from the device for ultrasonic welding.
2. the product quality control method of device for ultrasonic welding as described in claim 1, which is characterized in that welded in acquisition
Before follow-up data in the process, further includes:
The first supplemental characteristic in welding process is acquired, and is sent to Cloud Server, so that Cloud Server is by first parameter
Data are compared with the upper limit threshold and the lower threshold；
Receive the upper limit threshold and lower threshold and/or alarm signal that the Cloud Server is sent, wherein the alarm signal
When number being greater than the upper limit threshold for first supplemental characteristic or be less than the lower threshold, the Cloud Server is sent
's；
It stores the upper limit threshold and lower threshold and the alarm signal is sent to the device for ultrasonic welding, so that institute
Device for ultrasonic welding is stated to remove defective products corresponding with first supplemental characteristic from the device for ultrasonic welding.
3. the product quality control method of device for ultrasonic welding as claimed in claim 2, which is characterized in that will be described subsequent
Before supplemental characteristic is compared with upper limit threshold and lower threshold, further includes:
When the upper limit threshold and the lower threshold update, receive and store that the Cloud Server sends it is new it is described on
Limit threshold value and the new lower threshold.
4. the product quality control method of device for ultrasonic welding as claimed in claim 2, which is characterized in that first ginseng
Number data and the subsequent parameter data include voltage, electric current, air pressure, amplitude, humidity, frequency and weld time, the voltage
It is acquired by voltage transformer, the electric current is acquired by current sensor, and the air pressure is adopted by baroceptor
Collection, the frequency and weld time are acquired by frequency and weld time observation circuit, and the amplitude passes through vibrating sensor
It acquires, the humidity acquired by humidity sensor；
Wherein, first supplemental characteristic being collected and the subsequent parameter data are sent to described super by serial ports UART
Sound wave welding equipment, meanwhile, the Cloud Server is sent to by interchanger by too steel wire rack piece.
5. the product quality control method of device for ultrasonic welding as described in claim 1, which is characterized in that the upper limit threshold
Value and lower threshold respectively include upper voltage limit threshold value and lower voltage limit threshold value, upper current limit threshold value and lower current limit threshold value, gas
Press the gentle pressure lower threshold of upper limit threshold, upper frequency limit threshold value and lower-frequency limit threshold value, when weld time upper limit threshold and welding
Between lower threshold.
6. the product quality control method of device for ultrasonic welding as described in claim 1, which is characterized in that the upper limit threshold
Value and the lower threshold are terminal setting, and are sent to the Cloud Server.
7. the product quality control method of device for ultrasonic welding as claimed in claim 5, which is characterized in that the terminal is
Computer or mobile terminal.
8. the product quality control method of device for ultrasonic welding as claimed in claim 5, which is characterized in that described to ultrasound
Wave welding equipment sends alarm signal, so that the device for ultrasonic welding will defective products corresponding with the subsequent parameter data
It is removed from the device for ultrasonic welding, comprising:
Alarm signal is sent to device for ultrasonic welding, so that the device for ultrasonic welding will be with the subsequent parameter data pair
The defective products answered is removed from the device for ultrasonic welding, meanwhile, Xiang Suoshu Cloud Server sends the alarm signal, so that
The Cloud Server sends the alarm signal to the terminal.
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| CN201811641889.6A CN109675824A (en) | 2018-12-29 | 2018-12-29 | The product quality control method of device for ultrasonic welding |
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| CN111863652A (en) * | 2020-07-31 | 2020-10-30 | 华天科技（西安）有限公司 | Production parameter optimization method for crater super-sensitive product |
| CN114193029A (en) * | 2020-09-18 | 2022-03-18 | 宝山钢铁股份有限公司 | Welding machine weld joint pre-evaluation method based on big data analysis model |
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