焊接材料智能管理与设计专家系统研究
摘要
焊接材料，包括焊条、焊丝(实芯焊丝和药芯焊丝)、焊剂、焊带等，已广泛用于船舶、桥梁、车辆、压力容器、化工设备、工程机械、海洋设施及原子能工业等各个领域，在国民经济建设中起着十分重要的作用。但是我国目前在焊材的设计方法上仍然以手工设计为主，一般是凭借设计者的经验，参考典型配方，初步拟定各物质的含量，再通过实验加以调变，逐步完善或改造创新。在合金系统的设计和某些主要成分的用量上，辅以简单计算进行粗估，设计周期长、开发成本高。因此，焊材设计手段的更新至关重要。随着近几十年来计算机技术的飞速发展和广泛普及，计算机辅助技术已经在很多领域发挥了巨大的作用，将计算机技术应用于焊材设计与管理必将大大缩短开发周期、降低开发成本，提高设计质量水平，是本文要解决的重要课题。
焊接材料，品种繁多，如何对焊接材料进行系统的管理是我国焊材制造业及焊材应用业的一大课题。管理信息系统的引入已经成为当今焊材管理发展的新方向。
通过广泛的市场调研，在查阅大量文献资料的基础上，认为将管理信息系统及专家系统引入焊接材料管理与设计具有可行性和必要性。同时在对软件进行分析对比后认为Visual C++程序设计语言具有简单性、可扩展性、访问速度快及数据源友好的特点，而SQL Server2000数据库开发软件具有非常好的再造和重写特性，以其良好的稳定性、便于管理和易于开发等优势已经成为数据库领域中的重要产品。在此分析基础上本文选择Visual C++及SQL Server2000作为开发工具，以焊条作为设计样本，建立了具有实际使用价值的焊材数据库，并在此基础上建立了专家系统，实现了基于C／S的焊材计算机辅助智能管理与设计专家系统。
Welding material, including welding rod, welding stick (solid and medical welding stick), welding flux, welding belt and so on, are extensively used in all kinds of fields such as vessel, bridge, vehicle, pressure container, chemical facilities, industrial machinery, ocean facilities, as well as atomic energy industry, which plays such a key in our national economic development. However, up till the present moment, hand-design is still the main way of welding material's design. The design steps can be demonstrated in the following aspects. According to the designer's experience and consulting the typical formula, firstly, to determine tentative materials' contents, then to adjust them by experiments, to be improving step by step and to constantly bring forth new ideas in the design. As for the design of alloy system and the determination of the quantity of main contents, they rely on the approximate estimation after simply calculation, which result in longer development cycle, higher cost and worse accuracy. As a result, the development of national economy is restricted. So the way to design welding material should be brought up to date. With the development and the popularization of computer, ES has or is being used in all kinds of fields and takes positive effect to shorten the cycle, to reduce the price and to raise the design quality and management level. As a main task of the paper, in a word, ES is discussed in details in the following.
There are so many kinds of welding materials; therefore, how to manage the welding materials has become an extraordinary important task for the manufacturing and application industries. MIS has become a leader for the management of welding materials.
Under the conduction of my tutor, the author gathered the tutor's experience of many years' management and design of welding materials, surveyed widespread market and consulted a great quantity of reference books. The author argues that introduction MIS and ES to the management and design of welding
materials is practicable and necessary. Through the contrast of much software, Visual C++ and SQL Server 2000 are adopted to develop the MIS and ES of welding materials intelligent management and design for their fine performance. The whole steps of software development based on C/S edition will be described in details in following.
焊接材料，品种繁多，如何对焊接材料进行系统的管理是我国焊材制造业及焊材应用业的一大课题。管理信息系统的引入已经成为当今焊材管理发展的新方向。
通过广泛的市场调研，在查阅大量文献资料的基础上，认为将管理信息系统及专家系统引入焊接材料管理与设计具有可行性和必要性。同时在对软件进行分析对比后认为Visual C++程序设计语言具有简单性、可扩展性、访问速度快及数据源友好的特点，而SQL Server2000数据库开发软件具有非常好的再造和重写特性，以其良好的稳定性、便于管理和易于开发等优势已经成为数据库领域中的重要产品。在此分析基础上本文选择Visual C++及SQL Server2000作为开发工具，以焊条作为设计样本，建立了具有实际使用价值的焊材数据库，并在此基础上建立了专家系统，实现了基于C／S的焊材计算机辅助智能管理与设计专家系统。
Welding material, including welding rod, welding stick (solid and medical welding stick), welding flux, welding belt and so on, are extensively used in all kinds of fields such as vessel, bridge, vehicle, pressure container, chemical facilities, industrial machinery, ocean facilities, as well as atomic energy industry, which plays such a key in our national economic development. However, up till the present moment, hand-design is still the main way of welding material's design. The design steps can be demonstrated in the following aspects. According to the designer's experience and consulting the typical formula, firstly, to determine tentative materials' contents, then to adjust them by experiments, to be improving step by step and to constantly bring forth new ideas in the design. As for the design of alloy system and the determination of the quantity of main contents, they rely on the approximate estimation after simply calculation, which result in longer development cycle, higher cost and worse accuracy. As a result, the development of national economy is restricted. So the way to design welding material should be brought up to date. With the development and the popularization of computer, ES has or is being used in all kinds of fields and takes positive effect to shorten the cycle, to reduce the price and to raise the design quality and management level. As a main task of the paper, in a word, ES is discussed in details in the following.
There are so many kinds of welding materials; therefore, how to manage the welding materials has become an extraordinary important task for the manufacturing and application industries. MIS has become a leader for the management of welding materials.
Under the conduction of my tutor, the author gathered the tutor's experience of many years' management and design of welding materials, surveyed widespread market and consulted a great quantity of reference books. The author argues that introduction MIS and ES to the management and design of welding
materials is practicable and necessary. Through the contrast of much software, Visual C++ and SQL Server 2000 are adopted to develop the MIS and ES of welding materials intelligent management and design for their fine performance. The whole steps of software development based on C/S edition will be described in details in following.
引文
1 张文钺．21世纪我国焊接材料的发展前景．焊接技术，2000，4：38-41
2 陈丙森 主编．计算机辅助焊接技术．北京：机械工业出版社，1999：29
3 曹立明 陈石麟 周强．知识工程原理．江苏．中国矿业大学出版社：1995：122，35
4 吴信东 邹燕．专家系统技术．北京．电子工业出版社：1988
5 史济建 俞瑞钊．专家系统实现技术．浙江．浙江大学出版社：1995
6 赵熹华．专家系统在焊接中的应用及发展趋势．焊接，98(8)：2～6
7 彭金宁．焊接专家系统在我国的发展．焊接，1993(11)：2～6
8 马玉刚．国外焊接专家系统的发展．沈阳工业大学学报，97，19(4)：102～106
9 Bingsen, Chen; Jinning, Peng. Expert systems and their development. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:247～253
10 Bahashwan, A. A.; Garg, S.B.L. Review of the application of expert systems to welding. International Journal of Materials & Product Technology v 11 n 1-2 1996:89～97
11 林青松．计算机在我国焊接领域的应用概况．机械产品与科技，97(3)：6～9
12 Zhou, Zhaowei. Welding research in China. Welding Research Abroad v 42 n 3 Mar 1996:13～19
13 王国珍等．焊接缺陷诊断与咨询专家系统的设计．第八次全国焊接会议论文集(第三集)．北京：机械工业出版社，1997：545～548
14 魏艳红．焊接接头PPES机械性能预测专家系统．焊接学报，1993(12)：268～272
15 Dai, Shu-Ho. Methodology for the assessment of the safety of pressurized components containing welding defects and the related expert system, International Journal of Pressure Vessels and Piping v 60 n 2 1994:127～132
16 Dai, Shu-Ho. Life extension, reliability analysis and expert system for the assessment of fatigue damage in structures with welded defects-A study of applications of high technology in reliability analysis for pressure vessel technology, International Journal of Pressure Vessels and Piping v 56 n 2 1993:263-273
17 Li, Wushen; Dong, Jianming; Zhang, Bingfan. Welding cracking prediction and diagnosis expert system. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:373～380
18 邓连祥．焊接工艺管理专家系统．焊接,97(10)：15～18
19 石运伟．焊接工艺在线规划专家系统．机器人，98,20(1)：51～54
20 肖高华．焊接工艺制定专家系统在电力机车生产中的应用．铁道车辆，98，36(4)：77～78，88
21 张初冬．新型的弧焊工艺专家系统--DriAwpes 1.0．大连铁道学院学报，97，18(2)：59～64
22 胡小建．微机辅助弧焊工艺参数选择系统．焊接技术，2000，2：P15
23 杨运强 李俊岳 刘奇能 涂浩．计算机辅助焊接工艺设计．焊接技术，2000，4：3～4
24 胡小建．焊接数据库及焊接工艺评定系统．焊接技术，1998，3：39～40
25 魏艳红 高增福 杨松．焊接工艺规程数据库系统．焊接，1998，3：P12～14
26 Yanhong, Wei. Computer aided welding procedure qualification system, Welding Research Abroad v 41 n 2 Febr 1995:17～24
27 Yanhong, Wei. Expert system for generating welding procedures of boilers and pressure. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:381～388
28 Peng, Jinning; Chen, Bingsen. Development of an arc welding procedure expert system shell. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:365～372
29 刘顺红等．焊缝坡口设计与选择计算机系统．第八次全国焊接会议论文集(第三集)．北京：机械工业出版社，1997：610～612
30 Cho, Kyu-Kab Sun,Jung-Guy Oh, Jung-Soo. Automated welding operation planning system for block assembly in shipbuilding. International Journal of Production Economics v 60,1999: 203～209
31 Srinivasan, Sridhar; Kane, Russell D., Expert systems for material selection and analysis for the oil industry: an application-oriented perspective, Materials and Design Technology American Society of Mechanical Engineers, Petroleum Division (Publication) PD v 62 1994:ubl by ASME, New York, NY, USA:365～372
32 Kurozawa, Toshiro; Ogawa, Koichi; Takehara, Akinobu, Development of expert system for assisting process planning of friction welding (1st report, knowledge base and reasoning method of friction welding conditions), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 61 n 585 May 1995:2153～2158
33 Brown, J.D.; Rodd, M.G.; Williams, N.T. Application of artificial intelligence techniques to resistance spot welding. Ironmaking and Steelmaking v 25 n 3 1998:199～204
34 Suyoto.; Kurozawa, Toshiro; Ogawa, Koichi; Takehara, Akinobu. Development of expert system for assisting process planning of friction welding (2nd report, modifying system of candidate welding conditions using fuzzy reasoning). Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 62 n 594 Feb 1996:787～793
35 Fathi, Madjid; Lambrecht, Martin, EBFLATSY: a fuzzy logic system to calculate and optimize parameters for an electron beam welding machine, Fuzzy Sets and Systems v 69 n 1 Jan 13 1995:3～13
36 Murakami, Ri-ichi; Shimada, Yoshihiro; Ueda, Sai. Development of expert system for estimation of weld flaws by ultrasonic testing JSME International Journal, Series A: Mechanics and Material Engineering 37 4 Oct 1994:389～395
37 Kawahito,Akiyoshi, Fuzzy diagnostic expert system for ultrasonic testing (Construction of personal-computer-aided system and supplemental knowledge for parasitic echo), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 59 n 566 Oct 1993:3218～3223
38 Yoshimura, Toshio; Morimoto, Kazunori; Matsuura, Hiroshi; Kawahito, Akiyoshi, Fuzzy diagnostic expert system for ultrasonic testing (application of data processing for judging the shape of defect echo), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 61 n 582 Feb 1995:724～729
39 Dupuis, O. Kaftandjian, V. Babot, D. Zhu, Yue Min. Automatic detection and characterization of weld defects: Determination of confidence levels for data fusion of radioscopic and ultrasonic images.Insight:Non-DestructiveTesting and Condition Monitoring Marl999 (3): 170～172
40 Anon. Developments in intelligent control of arc welding power supplies. Welding and Metal Fabrication v 62 n 7 July 1994:3p
41 Lucas, W. Welding engineering expert system and multimedia computer programs. Welding Research Abroad v 42 n 8-9 Aug-Sept 1996:2～6
42 Siewert, T.A. Welding software aids engineers. Welding Design & Fabrication v 69 n 11 1996(11): 4pp
43 Martin, P.J., Artificial neural networks in welding, International Journal for the Joining of Materials v 6 n 2 Jun 1994:62～67
44 廖立乾 文花明 编著．焊条的设计、制造与使用．北京：机械工业出版社，1988
45 张子荣 李日升鹤 编著．电焊条．北京：机械工业出版社，1998
46 周振丰．焊接冶金与金属焊接性．第2版．北京．机械工业出版社：1992：32，78，5
47 吴今培 肖健华著．智能故障诊断与专家系统．北京：科学技术出版社，1997：37～41．112
48 史忠植．知识工程．北京：清华大学出版社，1988：35
49 焊接与切割(上)(下)中国机械工业标准汇编．中国标准出版社．1996
50 尹士科 朱明生 王移山 董连仁 合编．国内外焊条简明手册．北京：兵器工业出版社，1991
51 吴树雄．电焊条选用指南．第2版．北京．化学工业出版社：1996
52 尹士科．世界焊接材料手册．北京．中国标准出版社：1995
53 唐伯钢．低碳钢与低合金高强度钢焊接材料．北京．机械工业出版社：1987
54 天津大学焊接教研室主编．金属熔焊原理及工艺．北京．机械工业出版社：1979
2 陈丙森 主编．计算机辅助焊接技术．北京：机械工业出版社，1999：29
3 曹立明 陈石麟 周强．知识工程原理．江苏．中国矿业大学出版社：1995：122，35
4 吴信东 邹燕．专家系统技术．北京．电子工业出版社：1988
5 史济建 俞瑞钊．专家系统实现技术．浙江．浙江大学出版社：1995
6 赵熹华．专家系统在焊接中的应用及发展趋势．焊接，98(8)：2～6
7 彭金宁．焊接专家系统在我国的发展．焊接，1993(11)：2～6
8 马玉刚．国外焊接专家系统的发展．沈阳工业大学学报，97，19(4)：102～106
9 Bingsen, Chen; Jinning, Peng. Expert systems and their development. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:247～253
10 Bahashwan, A. A.; Garg, S.B.L. Review of the application of expert systems to welding. International Journal of Materials & Product Technology v 11 n 1-2 1996:89～97
11 林青松．计算机在我国焊接领域的应用概况．机械产品与科技，97(3)：6～9
12 Zhou, Zhaowei. Welding research in China. Welding Research Abroad v 42 n 3 Mar 1996:13～19
13 王国珍等．焊接缺陷诊断与咨询专家系统的设计．第八次全国焊接会议论文集(第三集)．北京：机械工业出版社，1997：545～548
14 魏艳红．焊接接头PPES机械性能预测专家系统．焊接学报，1993(12)：268～272
15 Dai, Shu-Ho. Methodology for the assessment of the safety of pressurized components containing welding defects and the related expert system, International Journal of Pressure Vessels and Piping v 60 n 2 1994:127～132
16 Dai, Shu-Ho. Life extension, reliability analysis and expert system for the assessment of fatigue damage in structures with welded defects-A study of applications of high technology in reliability analysis for pressure vessel technology, International Journal of Pressure Vessels and Piping v 56 n 2 1993:263-273
17 Li, Wushen; Dong, Jianming; Zhang, Bingfan. Welding cracking prediction and diagnosis expert system. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:373～380
18 邓连祥．焊接工艺管理专家系统．焊接,97(10)：15～18
19 石运伟．焊接工艺在线规划专家系统．机器人，98,20(1)：51～54
20 肖高华．焊接工艺制定专家系统在电力机车生产中的应用．铁道车辆，98，36(4)：77～78，88
21 张初冬．新型的弧焊工艺专家系统--DriAwpes 1.0．大连铁道学院学报，97，18(2)：59～64
22 胡小建．微机辅助弧焊工艺参数选择系统．焊接技术，2000，2：P15
23 杨运强 李俊岳 刘奇能 涂浩．计算机辅助焊接工艺设计．焊接技术，2000，4：3～4
24 胡小建．焊接数据库及焊接工艺评定系统．焊接技术，1998，3：39～40
25 魏艳红 高增福 杨松．焊接工艺规程数据库系统．焊接，1998，3：P12～14
26 Yanhong, Wei. Computer aided welding procedure qualification system, Welding Research Abroad v 41 n 2 Febr 1995:17～24
27 Yanhong, Wei. Expert system for generating welding procedures of boilers and pressure. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:381～388
28 Peng, Jinning; Chen, Bingsen. Development of an arc welding procedure expert system shell. Welding in the World, Le Soudage Dans Le Monde v 34 Sept 1994:365～372
29 刘顺红等．焊缝坡口设计与选择计算机系统．第八次全国焊接会议论文集(第三集)．北京：机械工业出版社，1997：610～612
30 Cho, Kyu-Kab Sun,Jung-Guy Oh, Jung-Soo. Automated welding operation planning system for block assembly in shipbuilding. International Journal of Production Economics v 60,1999: 203～209
31 Srinivasan, Sridhar; Kane, Russell D., Expert systems for material selection and analysis for the oil industry: an application-oriented perspective, Materials and Design Technology American Society of Mechanical Engineers, Petroleum Division (Publication) PD v 62 1994:ubl by ASME, New York, NY, USA:365～372
32 Kurozawa, Toshiro; Ogawa, Koichi; Takehara, Akinobu, Development of expert system for assisting process planning of friction welding (1st report, knowledge base and reasoning method of friction welding conditions), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 61 n 585 May 1995:2153～2158
33 Brown, J.D.; Rodd, M.G.; Williams, N.T. Application of artificial intelligence techniques to resistance spot welding. Ironmaking and Steelmaking v 25 n 3 1998:199～204
34 Suyoto.; Kurozawa, Toshiro; Ogawa, Koichi; Takehara, Akinobu. Development of expert system for assisting process planning of friction welding (2nd report, modifying system of candidate welding conditions using fuzzy reasoning). Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 62 n 594 Feb 1996:787～793
35 Fathi, Madjid; Lambrecht, Martin, EBFLATSY: a fuzzy logic system to calculate and optimize parameters for an electron beam welding machine, Fuzzy Sets and Systems v 69 n 1 Jan 13 1995:3～13
36 Murakami, Ri-ichi; Shimada, Yoshihiro; Ueda, Sai. Development of expert system for estimation of weld flaws by ultrasonic testing JSME International Journal, Series A: Mechanics and Material Engineering 37 4 Oct 1994:389～395
37 Kawahito,Akiyoshi, Fuzzy diagnostic expert system for ultrasonic testing (Construction of personal-computer-aided system and supplemental knowledge for parasitic echo), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 59 n 566 Oct 1993:3218～3223
38 Yoshimura, Toshio; Morimoto, Kazunori; Matsuura, Hiroshi; Kawahito, Akiyoshi, Fuzzy diagnostic expert system for ultrasonic testing (application of data processing for judging the shape of defect echo), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C v 61 n 582 Feb 1995:724～729
39 Dupuis, O. Kaftandjian, V. Babot, D. Zhu, Yue Min. Automatic detection and characterization of weld defects: Determination of confidence levels for data fusion of radioscopic and ultrasonic images.Insight:Non-DestructiveTesting and Condition Monitoring Marl999 (3): 170～172
40 Anon. Developments in intelligent control of arc welding power supplies. Welding and Metal Fabrication v 62 n 7 July 1994:3p
41 Lucas, W. Welding engineering expert system and multimedia computer programs. Welding Research Abroad v 42 n 8-9 Aug-Sept 1996:2～6
42 Siewert, T.A. Welding software aids engineers. Welding Design & Fabrication v 69 n 11 1996(11): 4pp
43 Martin, P.J., Artificial neural networks in welding, International Journal for the Joining of Materials v 6 n 2 Jun 1994:62～67
44 廖立乾 文花明 编著．焊条的设计、制造与使用．北京：机械工业出版社，1988
45 张子荣 李日升鹤 编著．电焊条．北京：机械工业出版社，1998
46 周振丰．焊接冶金与金属焊接性．第2版．北京．机械工业出版社：1992：32，78，5
47 吴今培 肖健华著．智能故障诊断与专家系统．北京：科学技术出版社，1997：37～41．112
48 史忠植．知识工程．北京：清华大学出版社，1988：35
49 焊接与切割(上)(下)中国机械工业标准汇编．中国标准出版社．1996
50 尹士科 朱明生 王移山 董连仁 合编．国内外焊条简明手册．北京：兵器工业出版社，1991
51 吴树雄．电焊条选用指南．第2版．北京．化学工业出版社：1996
52 尹士科．世界焊接材料手册．北京．中国标准出版社：1995
53 唐伯钢．低碳钢与低合金高强度钢焊接材料．北京．机械工业出版社：1987
54 天津大学焊接教研室主编．金属熔焊原理及工艺．北京．机械工业出版社：1979