UN-150ZB钢轨闪光焊机的软件优化与完善
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摘要
根据铁路建设十二五规划,新修干线将会持续增加,投产新线总规模将会超过2万公里,因此在新线上建设中、既有线路维修中的钢轨闪光焊机越来越多,如何保证钢轨闪光焊机的质量可靠性与故障的快速检测将是一个非常严峻的问题。目前在国内大量应用的钢轨现场闪光焊机都是交流焊机,不管是国产焊机还是进口焊机都存在着对维修人员要求高、故障排查周期长等问题,且随着焊接接头数量增多,元器件的状态会发生改变,焊接质量很难保证,为此,本论文立题对成都艾格科技研发的UN-150ZB钢轨闪光焊机的计算机监控系统进行完善和优化。
本论文进行了如下的工作：(1)建立位移智能标定模块,实现上位机对位移标定自动化；(2)建立焊机的输入信号检测模块和焊机启动故障的自诊断模块,便于一线设备维护人员对设备的检验和维修；(3)建立上位机监控系统的电压、速度标定在线显示模块和对电压、速度标定的PLC控制软件进行完善；(4)建立焊接过程中故障诊断模块,对焊接过程中控制系统中的过渡阶段信号、油压、位移信号进行检测与保存,并在数据记录图像界面上予以显示；建立压力、阻抗及顶锻量的检测模块进行焊机状态的监控并实时提出检修建议以保证焊接质量；建立数目的提示模块,对接头数目进行提示。
经过现场实际运用表明：完善后的监控系统使焊机的整体性能得到提升、焊机的自动化水平得到提高；有良好的人机交互界面及良好的可操作性能,大大降低设备维护人员的难度,从而有力保证了施工进度。
According to the12th Five-Year Plan of the railway construction, the newly built railway lines will continue to increase and the total size of the production of new lines will be more than20,000km. Therefore, there are more and more rail flash butt welding machines in the new line construction and old lines maintenance. How to ensure the quality reliability and the fault rapid detection of rail flash butt welding machine will be a very serious problem. In the domestic, the site flash butt welding machines Widely used belongs to the AC welder at present, Both of domestic welder and imported welder have many problems, such as high requirements for maintenance personnel, long cycle of troubleshooting And with the increase in the number of welded joints, the status of components will change, welding quality is difficult to be ensured. To this end, how to improve and optimize the computer monitoring system of UN-150ZB rail flash butt welding machine which developed by Chengdu Iger technology is the purpose of this thesis.
The present paper had carried on following work:(1) the displacement of intelligent calibration module was established, which could achieve displacement calibration automation by host computer,(2) input signal detection module and welding machines boot failure diagnosis module were developed, which was easy for first-line maintenance personnel to inspect and maintain the equipment.(3) Voltage calibration and speed calibration line display module were developed on Computer Control System and the voltage, speed calibration of the PLC control software were improved:(4) pressure, impedance and the upset detection module was established to monitor the welder state and give Maintenance recommendations to personnel for the welding quality:joint number module was researched to Prompt number of joint.
The practical application shows that the welding machine's overall performance was enhanced and the level of automation welding machine was improved after the completion of the monitoring system, the good man-machine interface and good operation performance reduced maintenance personnel of difficulty greatly and insured the construction progress on the way.
本论文进行了如下的工作：(1)建立位移智能标定模块,实现上位机对位移标定自动化；(2)建立焊机的输入信号检测模块和焊机启动故障的自诊断模块,便于一线设备维护人员对设备的检验和维修；(3)建立上位机监控系统的电压、速度标定在线显示模块和对电压、速度标定的PLC控制软件进行完善；(4)建立焊接过程中故障诊断模块,对焊接过程中控制系统中的过渡阶段信号、油压、位移信号进行检测与保存,并在数据记录图像界面上予以显示；建立压力、阻抗及顶锻量的检测模块进行焊机状态的监控并实时提出检修建议以保证焊接质量；建立数目的提示模块,对接头数目进行提示。
经过现场实际运用表明：完善后的监控系统使焊机的整体性能得到提升、焊机的自动化水平得到提高；有良好的人机交互界面及良好的可操作性能,大大降低设备维护人员的难度,从而有力保证了施工进度。
According to the12th Five-Year Plan of the railway construction, the newly built railway lines will continue to increase and the total size of the production of new lines will be more than20,000km. Therefore, there are more and more rail flash butt welding machines in the new line construction and old lines maintenance. How to ensure the quality reliability and the fault rapid detection of rail flash butt welding machine will be a very serious problem. In the domestic, the site flash butt welding machines Widely used belongs to the AC welder at present, Both of domestic welder and imported welder have many problems, such as high requirements for maintenance personnel, long cycle of troubleshooting And with the increase in the number of welded joints, the status of components will change, welding quality is difficult to be ensured. To this end, how to improve and optimize the computer monitoring system of UN-150ZB rail flash butt welding machine which developed by Chengdu Iger technology is the purpose of this thesis.
The present paper had carried on following work:(1) the displacement of intelligent calibration module was established, which could achieve displacement calibration automation by host computer,(2) input signal detection module and welding machines boot failure diagnosis module were developed, which was easy for first-line maintenance personnel to inspect and maintain the equipment.(3) Voltage calibration and speed calibration line display module were developed on Computer Control System and the voltage, speed calibration of the PLC control software were improved:(4) pressure, impedance and the upset detection module was established to monitor the welder state and give Maintenance recommendations to personnel for the welding quality:joint number module was researched to Prompt number of joint.
The practical application shows that the welding machine's overall performance was enhanced and the level of automation welding machine was improved after the completion of the monitoring system, the good man-machine interface and good operation performance reduced maintenance personnel of difficulty greatly and insured the construction progress on the way.
引文
[1]吕其兵,吕振玉,谭克利,骆德阳等.基于VB6.0的钢轨闪光焊质量在线监控与管理.铁道建筑,2005(8)：61-63
[2董卫国,刘奇梅.钢轨无缝线路焊接技术现状.焊接,2000(3)：37～39
[3]钱晓龙.MicroLogix控制器应用实例.机械工业出版社,2003.4
[4]郭希烈,马纪龙.无缝线路长钢轨焊接及其发展(下).铁道建筑,1979年
[5]赵熹华,冯吉才.压焊方法及设备.机械工业出版社,2005.8
[6]钱晓龙,李鸿儒.智能电器与MicroLogix控制器.机械工业出版.2003.3
[7]盛花.K190nK钢轨交流闪光焊机控制系统改造及焊接工艺研究.硕士学位论文.成都：西南交通大学,2006年
[8]任德亮,李向国.无缝线路钢轨焊接技术.
[9]李江全,张丽,岑红蕾.Visual Basic串口通信与测控.人民邮电出版社,2007年
[10]谭洪涛.进口AMS60闪光焊机测控系统改造.硕士学位论文.成都：西南交通大学,2007年
[11]张翼英等.Visual Basic6.0课程设计.清华大学出版社,2008年
[12]任德亮,李向国.无缝线路钢轨焊接技术.焊接技术,2003(05)：4-5
[13]周奕.高速铁路无缝线路钢轨焊接技术的研究.上海铁道科技,2009(3)：15-17
[14]陈雪芬.K1000焊机计算机系统及控制软件的研发.硕士学位论文.成都：西南交通大学,2011年
[15]张华俊.进口K900钢轨闪光焊机监测系统界面汉化及脉冲工艺研究.硕士学位论文.成都：西南交通大学,2006年
[16]史清宇,陈志翔,王学东.先进焊接方法与技术.机械工业出版社.2010
[17]吴丰顺,熊晓红,万里.材料成型装备控制技术.机械工业出版社.2008
[18]李鸿吉.VisualBasic6.0编程方法详解[M]北京：科学出版社,2001
[19]Oster E. On-line welding CAQ in welding[J].Welding in the word, 1998, (1):60-67
[20]任德亮,李向国.无缝线路钢轨焊接技术.焊接技术.2003
[21]Zhao Dong-tian. Welding Technology of 250m Long Rail for Trans-section Seamlaess Railway Track. Journal of Shijiazhuang Railway Institute,2004, (S1).
[22]MINSUBISHI. FX-232AW接口单元通信手册[M].上海：2000
[23]Ward-smith, Les.RAIL FLASH-BUTT WELDING IN THE SATS.South African mechanical engineer.1985, vol 35(1):9-10
[24]Corvino, Lorenzo:Intrieri, Tonino. Electrical falsh-butt welding of rails in situ. Rail Engineering International,1989, vol.18(1):17-20
[25]Lv Qi-bing, Dai Hong,Luo De-yang, Tan Ke-li. Optimization of Flash Butt Welding Parameters for Welding of U75V Rails. Journal of Southwest Jiaotong University.2006 v 41(2):210-213
[26]PHILIPS Semiconductors. PCA82C250 CAN controller interface data sheet, 1997.
[27]Bosch. CAN specification. Robert Bosch GmbH. (Version2.0).1991.
[29](日)伊地知坚一,陈岳源.无缝线路作业.中国铁道出版社,1982.
[30]Fenn R, Lu Y. Real time welding quality control and assessment system. International Journal for the Joining of Materials,1997, Vol (9), No (3):94-98
[31]K. Etschberger. Controler Area Network (3rd edition).2002.
[32]李道华.传感器电路分析与设计.武汉大学出版社,2000.
[33]J. Wagner, C. Mitterer, M. Penoy, et al. The effect of deposition temperature on microstructure and properties of thermalCVDTiN coatings[J]. International Journal of Refractory Metals & Hard Materials,2008, 26:120-126.
[34]左演声.材料现代分析方法[M].北京：北京工业大学出版社,2005.
[35]高春燕,安剑,张逸微.Visual Basic程序开发范例宝典.人民邮电出版社.2008.
[36]王英.模拟电子技术基础.西南交通大学出版社.2000
[37]王英.数字电子技术基础.西南交通大学出版社.2000
[38]赵熹华编著.压力焊.机械工业出版社.1994年
[39]黄建平,戴虹,骆德阳.合金钢轨连续闪光焊过程特征与质量.西南交通大学材料 科学与工程学院.
[40]向朝.钢轨交流闪光焊质量检测与预测研究.西南交通大学硕士研究生论文.2006
[41]龚沛曾,陆慰民,杨志强.Visual Basic程序设计简明教程.高等教育出版社
[42]赵红光,何超,吕其兵.基于UN-150ZB钢轨闪光焊机的自诊断系统.现代焊接.
[43]李众.单片机与FX系列PLC通信协议应用研究.华东船舶工业学院学报.2001.5
[44]高键.FX系列PLC通信协议在调距桨改造中的实现.中国修船.1999
[45]华路光.PLC在多数据采集系统中的应用.新技术新工艺.2005
[46]Hongguang Zhao, Chao He, Xi Zhang, Qibing Lv. Fault Diagnosis System Based on UN-150ZB Mobile Rail Flash Butt Welding. International Conference on Manufacturing Scienc e and Engineering. 2012.
[47]何超,赵红光,吕其兵.钢轨精磨机砂轮对刀与磨削自动化[J].成都市机械学会焊接分会论文集,2011(12).
[2董卫国,刘奇梅.钢轨无缝线路焊接技术现状.焊接,2000(3)：37～39
[3]钱晓龙.MicroLogix控制器应用实例.机械工业出版社,2003.4
[4]郭希烈,马纪龙.无缝线路长钢轨焊接及其发展(下).铁道建筑,1979年
[5]赵熹华,冯吉才.压焊方法及设备.机械工业出版社,2005.8
[6]钱晓龙,李鸿儒.智能电器与MicroLogix控制器.机械工业出版.2003.3
[7]盛花.K190nK钢轨交流闪光焊机控制系统改造及焊接工艺研究.硕士学位论文.成都：西南交通大学,2006年
[8]任德亮,李向国.无缝线路钢轨焊接技术.
[9]李江全,张丽,岑红蕾.Visual Basic串口通信与测控.人民邮电出版社,2007年
[10]谭洪涛.进口AMS60闪光焊机测控系统改造.硕士学位论文.成都：西南交通大学,2007年
[11]张翼英等.Visual Basic6.0课程设计.清华大学出版社,2008年
[12]任德亮,李向国.无缝线路钢轨焊接技术.焊接技术,2003(05)：4-5
[13]周奕.高速铁路无缝线路钢轨焊接技术的研究.上海铁道科技,2009(3)：15-17
[14]陈雪芬.K1000焊机计算机系统及控制软件的研发.硕士学位论文.成都：西南交通大学,2011年
[15]张华俊.进口K900钢轨闪光焊机监测系统界面汉化及脉冲工艺研究.硕士学位论文.成都：西南交通大学,2006年
[16]史清宇,陈志翔,王学东.先进焊接方法与技术.机械工业出版社.2010
[17]吴丰顺,熊晓红,万里.材料成型装备控制技术.机械工业出版社.2008
[18]李鸿吉.VisualBasic6.0编程方法详解[M]北京：科学出版社,2001
[19]Oster E. On-line welding CAQ in welding[J].Welding in the word, 1998, (1):60-67
[20]任德亮,李向国.无缝线路钢轨焊接技术.焊接技术.2003
[21]Zhao Dong-tian. Welding Technology of 250m Long Rail for Trans-section Seamlaess Railway Track. Journal of Shijiazhuang Railway Institute,2004, (S1).
[22]MINSUBISHI. FX-232AW接口单元通信手册[M].上海：2000
[23]Ward-smith, Les.RAIL FLASH-BUTT WELDING IN THE SATS.South African mechanical engineer.1985, vol 35(1):9-10
[24]Corvino, Lorenzo:Intrieri, Tonino. Electrical falsh-butt welding of rails in situ. Rail Engineering International,1989, vol.18(1):17-20
[25]Lv Qi-bing, Dai Hong,Luo De-yang, Tan Ke-li. Optimization of Flash Butt Welding Parameters for Welding of U75V Rails. Journal of Southwest Jiaotong University.2006 v 41(2):210-213
[26]PHILIPS Semiconductors. PCA82C250 CAN controller interface data sheet, 1997.
[27]Bosch. CAN specification. Robert Bosch GmbH. (Version2.0).1991.
[29](日)伊地知坚一,陈岳源.无缝线路作业.中国铁道出版社,1982.
[30]Fenn R, Lu Y. Real time welding quality control and assessment system. International Journal for the Joining of Materials,1997, Vol (9), No (3):94-98
[31]K. Etschberger. Controler Area Network (3rd edition).2002.
[32]李道华.传感器电路分析与设计.武汉大学出版社,2000.
[33]J. Wagner, C. Mitterer, M. Penoy, et al. The effect of deposition temperature on microstructure and properties of thermalCVDTiN coatings[J]. International Journal of Refractory Metals & Hard Materials,2008, 26:120-126.
[34]左演声.材料现代分析方法[M].北京：北京工业大学出版社,2005.
[35]高春燕,安剑,张逸微.Visual Basic程序开发范例宝典.人民邮电出版社.2008.
[36]王英.模拟电子技术基础.西南交通大学出版社.2000
[37]王英.数字电子技术基础.西南交通大学出版社.2000
[38]赵熹华编著.压力焊.机械工业出版社.1994年
[39]黄建平,戴虹,骆德阳.合金钢轨连续闪光焊过程特征与质量.西南交通大学材料 科学与工程学院.
[40]向朝.钢轨交流闪光焊质量检测与预测研究.西南交通大学硕士研究生论文.2006
[41]龚沛曾,陆慰民,杨志强.Visual Basic程序设计简明教程.高等教育出版社
[42]赵红光,何超,吕其兵.基于UN-150ZB钢轨闪光焊机的自诊断系统.现代焊接.
[43]李众.单片机与FX系列PLC通信协议应用研究.华东船舶工业学院学报.2001.5
[44]高键.FX系列PLC通信协议在调距桨改造中的实现.中国修船.1999
[45]华路光.PLC在多数据采集系统中的应用.新技术新工艺.2005
[46]Hongguang Zhao, Chao He, Xi Zhang, Qibing Lv. Fault Diagnosis System Based on UN-150ZB Mobile Rail Flash Butt Welding. International Conference on Manufacturing Scienc e and Engineering. 2012.
[47]何超,赵红光,吕其兵.钢轨精磨机砂轮对刀与磨削自动化[J].成都市机械学会焊接分会论文集,2011(12).