SU1665342A1 - Welding trainer - Google Patents

Abstract

The invention relates to tools for handling tools. The purpose of the invention is improving the didactic capabilities of the simulator. For this purpose, the welding simulator contains a welding torch with a welding electrode and the first and second measuring electrodes, a welding power source, a welder's helmet simulator and a recording unit for the spatial position of the welding electrode, including four amplifiers, the first adder, the first, second, third, and fourth comparators, the first , second, third and fourth setters of initial conditions, first differential amplifier, detector, first and second elements OR, first, second and third electronic switches, first, second the third counter, decoder and display. The introduction of the second, third, fourth and fifth elements of the OR, second and third differential amplifiers, the fifth, sixth, seventh, eighth, ninth and tenth amplifiers, the first and second voltage dividers into the unit for measuring the spatial position of the welding electrode the psychomotor skills of the trained welder to maintain regulatory requirements: the length of the arc gap, the angle of inclination of the welding electrode, its deviation from the center of cutting the edges of the welded parts during the test the actual welding process by electrode wire in shielding gas or by a non-consumable electrode. 3 il.

Description

The invention relates to the field of tool handling.

The aim of the invention is to increase the didactic capabilities of the simulator.

FIG. 1 shows the scheme of the proposed simulator; in fig. 2 - one of the possible constructive schemes for a welding torch with measuring electrodes; in fig. 3 is one of the possible schemes for the implementation of a high-voltage amplifier.

The welder simulator contains a welding power source 1, a welding torch.

2 with an electrode, unit 3 for recording the position of the welding electrode, simulator 4 of the welder's helmet, generators 5 and 6 pulses, amplifiers 7-10, adders 11-16, differential amplifiers 17-19, detector 20. amplifier 21. elements OR 22 -26, dividers 27 and 28 voltages, amplifiers 29-33, comparators 34-37, dials 38-41 of initial conditions, keys 42-47, counters 48-51, decoders 52-54 and indicators 55-57.

In addition, welding torch 2 contains 1 measuring electrodes 58-61.

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The simulator welder works as follows.

The trained welder includes a simulator and, using initial setting conditions 38-41, sets the allowable limits for the welding torch to deviate from the center of the edges, the allowable solid angle of inclination of the welding torch, and the lower and upper limits for the installation height of the welding torch above the edges. After that, the student takes a welding torch in his hand, brings it to the place of the start of welding and touches the cutting electrode. The main arc ignites, the electrode and shielding gas flow into the welding zone, the electrode, the parts being welded and the weld welded.

After switching on the simulator, the signals from the output of the generator 5 are fed to the inputs of high-voltage amplifiers 7-10, at the first outputs of which these signals have an amplitude of 15-20 kV. These high voltage signals are fed through high voltage cables to the measuring electrodes 58-61, which leads to the occurrence of a spark discharge between the measuring electrodes and the parts to be welded. In the secondary winding of the transformer 12 (Fig. 3) current begins to flow. A current also flows in the primary winding, and a voltage is generated across the resistor R3, which varies with the frequency of the first generator 5. The detected sign of which is removed from the resistor R2 and fed from the second outputs of the high-voltage amplifiers 7 and 8 to the corresponding inputs of the differential amplifier 17 and the adder 11 When the welding electrode is oriented strictly in the center of the joint, the measuring electrodes 58 and 59 are equally spaced from the cutting surface of the edges of the parts to be welded, the voltage taken from the second high-voltage outputs. Voltage amplifiers 7 and 8 are the same in size, and the output of the differential amplifier 17 is zero voltage. When the welding electrode is moved to the left or right of the butt center during the welding process, the measuring electrodes 58 and 59 are at different distances from the surface cutting the edges of the parts to be welded, which leads to an increase in the length of the spark gap between one measuring electrode and the edge of one of the parts being welded and a decrease in the same gap between the second measuring electr ode and edge of the second welded part.

As the length of the spark gap changes, the resistance of the spark gap changes.

gap, which leads to a change in the current of the secondary and, accordingly, the primary windings of the transformer T2. The second outputs of the high-voltage amplifiers 7 and 8 are set according to the voltage, which, entering the inputs of the differential amplifier 17, causes a voltage to appear at its output, the value of which indicates the deflection of the welding torch from the central position, and the sign direction of deviation. This voltage is fed to the input of the detector 20, the output of which is set to a unipolar voltage that is fed to the information input of the amplifier 21 with a variable gain, which eliminates the harmful influence of the length of the spark gap on the accuracy of determining the deviation of the welding electrode from the center of the groove. The output of the amplifier 21 is set to a voltage, the value of which depends only on the deviation of the welding electrode from the center of the groove and does not depend on

height of its installation. This can be achieved by controlling the gain of the amplifier 21 by the signal of the length of the spark gap, which is fed to its control input. From the output of the amplifier 21c

By varying the gain, this voltage is fed to the second input of the first comparator 34, where it is compared to the reference voltage that goes to its first input from the sensor 38 of the initial conditions.

When this voltage exceeds the value of the reference voltage, the first comparator 34 is activated and switches the key 42 to the open state. As a result, the feedback signal from one of the outputs of the counter 51 is transmitted through the key 42, the second element OR 23 and the amplifier 29 to the headphones of the welder’s helmet simulator, notifying the trained welder about the violation of the center position of the welding torch 2 in relation to the groove. The welder must set the welding torch 2 to the center position, after which the beep

The feedback in the headphones will disappear. The output signal of the comparator 34 is also fed to the control input of the key 47, opening it and thereby allowing the passage of second pulses from the output of the counter 51 to the input of the counter 50, which records the error time for the deflection of the welding torch 2 from the center of the edge preparation. Indicator 57 displays this time.

The simulator provides control of maintaining the height of installation of the welding electrode above the parts being welded. The signals from the second outputs of the high-voltage amplifiers 7-10 are also fed to the inputs of the adder 12, the output of which contains the sum of the input voltages. With a normal arc gap and correct setting of the arc gap lengths using initial setting conditions 39 and 40, the value of the output voltage of the adder 12 is in the gap between the reference voltages of the lower and upper limits of the arc gap length. In this state, the comparators 35 and 36 do not produce control signals that are fed through the OR element 22 to the control input of the key 43. With a fixed height of the electrode and its deviation from the central position or a change in the angle of inclination to the inputs of the adder 12, the signals They are larger or smaller in size, but their sum at the output of adder 12 remains constant in magnitude, which does not trigger the comparators 35 and 36 of the lower and upper limits of the arc gap length.

A change in the distance between the welding electrode and the parts being welded up or down from the normal position during the welding process leads to a significant change in the lengths of the spark gaps between the measuring electrodes and the parts being welded, which leads to a change in the magnitude of the signals at the second outputs of the high voltage amplifiers 7 -10 and their sum at the output of the adder 12. If the voltage value at the output of the adder 12 exceeds the reference voltage values set by the initial conditions 39 and 40, One of the comparators 35 or 36 of the lower or upper limit of the arc gap length (depending on how long the arc gap length is violated) is generated, producing a control signal that opens the key 43. The feedback sound signal comes from one of the outputs of the counter 51 through the key 43, the element OR 23 and the amplifier 29 to the headphones of the simulator 4 helmets, notifying the trained welder about his violation of the standard length of the arc gap. The welder must set the welding electrode to the normal position at the height of its installation. Its correct position is indicated by the disappearance of the audible alarm in the headset of the simulator 4 helmet. The time spent in the error state over the length of the arc gap is recorded by the counter 49 and indicated by the indicator 56.

The simulator also allows you to control the angle of inclination of the electrode of the welding torch 2 and generate an audible feedback signal, notifying the welder about his violation of the angle of inclination of the welding torch. This is done as follows.

Information about the angles of inclination of the welding electrode in two mutually perpendicular planes can be obtained by analyzing the output signals from the second outputs of high voltage amplifiers 7-10. These signals are inverted by amplifiers 30-33. Denote the signals at the outputs of the amplifiers 30-33, respectively, UD, UA. UB, Uc. In the case when the welding electrode is perpendicular to the surface of the parts to be welded, the output signals of the detectors are of the same size. When there is a deviation of the welding electrode relative to the normal position, the output signals of the detectors of high-voltage amplifiers 7-10 change upwards or downwards. Thus, this information can be used to determine the angles of inclination of the welding electrode in two mutually perpendicular planes whose intersection line passes through the central axis of the welding torch 2.

The output signals of the amplifiers 30-33 are fed to the adders 13-16, the outputs of which are respectively signals

UC + UD; UA + UB: UB + UC; UA + UD.

In differential amplifiers 18 and 19, the modulus of the signal difference is found:

I (UA + UBHUC + UD) I. KUA + UoHUB + Uc).

These differences are fed to voltage dividers 27 and 28, where they are divided into larger of the values (UA + UB) or (Uc + Uo) and (UA + UD) or (DB + UC). which are separated by the elements OR 24 and 25. At the outputs of the dividers 27 and 28, signals are obtained

l (UA-rU8) - (U: + UD) l to. max (UA + UB), (Uc + UD)} N

l (UA + UD) - (Lfe + Uc) l .K.tq.

rnax | (UA + UD), (J + Uc)}

Thus, the output signals of dividers 27 and 28 are proportional to the components of the angle of inclination: p. The accuracy of determining the angles of inclination of the welding electrode does not depend on the length of the arc gap. The OR element 26 selects a larger tilt angle output signal in two mutually perpendicular planes. This signal varies linearly with a change in the angle of inclination of the welding electrode and, most importantly, remains constant at a fixed angle of the welding electrode and a varying length of the arc gap.

When the welding electrode is tilted more than the standard value, the output of the element OR 26 produces a voltage that exceeds the value of the reference voltage set by the initial conditioner 41, which triggers the comparator 37, the comparator’s output opens the key 44, and the feedback signal communication comes from one of the outputs of the counter 51 through the key 44. the element OR 23 and the amplifier 29 to the input of the headphones of the simulator 4 of the welder’s helmet notify the trainee of their violation of the standard la tilt. The welder must set the welding electrode to a normal position along the angle of its inclination, the normal position of which is indicated by the disappearance of the audible alarm signal in the headphones. The time spent in the error state at the angle of inclination of the welding electrode is recorded by the counter 48 and indicated by the indicator 55.

Thus, the simulator provides the development of the correct psychomotor skills of the trained welder to maintain the regulatory requirements: arc length, welding electrode inclination angle, its deviation from the center of the edges of the welded parts when conducting a real welding process with an electrode wire in a protective gas or non-consumable electrode welding of bulk metal structures

Claims (1)

Invention Formula A welder simulator containing a welding torch, a welding power source, the output of which is connected to the first input of the welding torch, a welder’s helmet simulator and a recording unit for the welding electrode spatial position, containing two pulse generators, four amplifiers, the first adder, four comparators, four initial conditions adjusters, first differential amplifier, detector, two OR elements, three keys and three counters, a decoder and an indicator, with the first outputs of the first and second high-voltage amplifiers connected to the second and third inputs of the welding torch, the inputs are connected to the output of the first pulse generator, and the second outputs are connected respectively to the first and second inputs of the first adder and differential amplifier, the outputs of the first, second and third switches are connected to the inputs of the first OR element, the output of which is connected with the input of the third amplifier, the output of which is connected to the input 0 simulator helmet welder, the outputs of the first, second, third and fourth setpoint initial conditions are connected respectively with the first inputs of the first, second, third and fourth comparators, the outputs of the first and second comparators are connected to the inputs of the second element OR, the output of which is connected to the control input of the first key, the control inputs of the second and third keys are connected respectively to the outputs of the third and fourth comparators, the output of the first differential amplifier is connected to the input of the detector, output d is connected to the control input of the second amplifier chetverto5 having an information input coupled to an output of the first adder and an output connected to the second input of the third comparator, the outputs of the first, second and third counters are connected 0, respectively, with the inputs of the first, second, and third decoders, the outputs of which are connected to the inputs of the corresponding indicators, differing from the fact that the targets for the didactic capabilities of the simulator are inserted, the third, fourth, and fifth elements OR, two are entered into the recording unit of the spatial position of the electrode. voltage divider, fourth meter, fifth, sixth, seventh, eighth, ninth and tenth amplifiers, second, third, fourth, fifth and 0 the sixth adders, the fourth and fifth and sixth keys, and the second and third differentiating amplifiers, the first outputs of the fifth and sixth amplifiers are connected respectively to the fourth and fifth inputs of the welding torch, the inputs are connected to the output of the first pulse generator, the second outputs of the first, The second, fifth, and sixth amplifiers are connected respectively to the inputs of the seventh, eighth, ninth, and ninth amplifiers and the inputs of the first and second adders, the output of which is connected to the second inputs of the first and second comparators; mogo amplifier connected to the first inputs of the third and 5 fourth adders, the output of the eighth amplifier is connected to the second input of the third adder and the first input of the fifth adder, the output of which is connected to the first input of the third OR element, the second input of which is connected to the output of the fourth adder, and the output is connected to the information input of the first voltage divider, the control input of which is connected to the output of the second differentiating amplifier, whose inputs are connected respectively to the outputs of the fourth and fifth adders, the output of the ninth amplifier is connected to the second input of the fifth amplifier and the first input the sixth adder, the second input of which is connected to the second input of the fourth adder and the output of the tenth amplifier, and the output is connected to the first input of the fourth element OR. the second input of which is connected to the output of the third adder, and the output is connected to the information input of the second voltage divider, the control input of which is connected to the output of the third differentiating amplifier, whose inputs are connected 0 five 0 respectively, with the outputs of the third and sixth adders, the outputs of the voltage dividers are connected respectively to the inputs of the fifth OR element, the output of which is connected to the second input of the fourth comparator, the input of the fourth counter is connected to the output of the second pulse generator, the first, second and third outputs are connected respectively to the information inputs the first, second and third keys, and the fourth output is connected to the information inputs of the fourth, fifth and sixth keys, the outputs of which are connected respectively to the inputs the first, second and third counters, the control inputs of the fourth, fifth, and sixth keys are connected respectively to the output of the second OR element and the outputs of the third and fourth comparators. 1 FIG. 2 w WQl -f 7D