4D激光焊接质量监控设备及软件培训资料

Training4DIngenieurgesellschaftfürTechnischeDienstleistungenmbHBurgwedelerStrasse79Tel:[phone]D-30916IsernhagenHBFax:[phone]WeldWatcher®–ProcesscontrolofLaserbeamweldingTraining_english_CV1000_complete.docPage2of20Tableofcontents1.General•WhycontrollingaweldingprocessbymeansoftheWeldWatcher®?-Thelaserpowerisadjustedandmonitoredbythelasercontroller.-Thecontrolofthelaserpowerisnotinfluencedregardlesswhetherthelaserbeamiscoupledintotheworkpieceorwhetherthecoverglassiscontaminatedordefect.-TheWeldWatcher®evaluatestheenergyenteredintothematerial.2.Measuringprinciple•Duringtheweldingprocessthemeltingandevaporationofthemetalcreateacharacteristicprocessradiation.•Theprocessradiationconductedbackthroughtheopticalfibreisdecoupled,opticallyfilteredandtransformedintoanelectricalsignalbymeansofasensor.•Thissignallevelisproportionaltotheradiationcapacityoftheprocessradiation.•TransmittedtotheWeldWatcherthesoftwareautomaticallyevaluatesthesignal.•Thequalityofthecurrentsignalisevaluatedonthebasisofpreviouslygeneratedreferencevaluesbymeansoftheenvelopingcurvetechnique.•TheresultofevaluationisdisplayedonthescreenandtransmittedtothePLCbyastandardisedbussystem.3.Hardware•Sensor•Sensorcable•Computer•ConnectiontothePLC4.Software/Operation•Structureoftheuserinterface•Operation•Creationofreferences•Adaptationofreferencesafterchangesofprocessparameterse.g.-Laserpower-Weldingfeedrates-Seamlength•CommunicationWeldWatcher-PLC5.Troubleshooting6.MaintenanceWeldWatcher®–ProcesscontrolofLaserbeamweldingTraining_english_CV1000_complete.docPage3of20SENSORANDSIGNALPROCESSINGTheprocessradiationreflectedbackthroughtheopticalfibreiseithermappedinthelaseroronthesensoroftheopticalequipment.Owingtothesystemconfiguration,therearenoadjustmentorsoilingproblemsastheyoccurwithconventionalexterior(off-axial)sensors.Thesensormountingissuppliedbythemanufacturerofthelasertogetherwiththelasersourceoradaptedinco-operationwithaservicetechnician.Whenthesensorheadisfastenedinthesensormountingandthesensorcableisconnected,theWeldWatcher®isreadyforoperation.OneWeldWatcher®systemisusedperlaser(evenwithseveralopticalfibres).Adefinedspectralrangeoftheprocessradiationconductedbackthroughtheopticalfibreisdecoupled,opticallyfilteredandtransformedintoanelectricsignalbymeansofadetector.Thissignalisproportionaltotheradiationcapacityoftheprocessradiation.Owingtotheuseofanelectricinterface(4-20mA),thesignalcanbetransmittedsafefrominterferencetotheWeldWatcher®systemovergreatdistancesbymeansofthespecialcablesupplied.Here,itisfedtothecomputerunitthroughanA/Dconverterafterpre-amplificationandfrequency-selectivefiltering.Finally,thesoftwareautomaticallyevaluatestheprocesssignal.PrincipleofaWeldWatcherG2SystemWeldWatcher®–ProcesscontrolofLaserbeamweldingTraining_english_CV1000_complete.docPage4of20WeldingsignalswithreferencesandenvelopingcurvesWeldWatcher®–ProcesscontrolofLaserbeamweldingTraining_english_CV1000_complete.docPage5of20ONLINEMONITOR(STANDARDINTERFACE)1.SIGNALGRAPHICSFIELD(thecurrentprocesssignal)2.MENUBAR(forcallingupfurthersub-programs)3.FUNCTIONKEYS(forcallingupfunctionsandcertainmenupoints)4.WELDINGRESULT(resultcounterforpastweldingresults)5.ADDITIONALINFORMATION(levelindicationofthe2additionalanalogueentries)6.STATUSDISPLAYS(forthesystemstatusandthemachineconnection)7.STATUSREPORTS(currentlayoverofthefaulthistory,eventdisplay)8.DEVIATIONS(forsignallevel,coverglassandlengthdifference)Functionkeys[F1]WWOKRESETResetoftheWeldWatcherafteraninternalfaultorcommunicationproblem[F2]TIMESCALE/PATHSCALEChangeoverfromtime[s]tolength[mm]orangle[°]andviceversaofthescaleinthemonitor[F3]LOGIN/LOGOUTChangeoftheuserlevel[F4]COVERGLASSCHANGEDResetofthecoverglasscompensation(compensationofcontamination),afterhavingchangedthecoverglass.[F5]FAULTHISTORY1000-lineand3-columnfaulthistoryoftheonlinemonitoronasecondwindow.[F6]RESETSTATISTICSResetofthecounterWeldWatcher®–ProcesscontrolofLaserbeamweldingTraining_english_CV1000_complete.docPage6of20[F7]AUTOREFERENCEIfyouselectthisfield,thefollowingselectionwindowisopened:Thismenuoffersthefollowingpossibilities:1.Creation/generationofnew(notexisting)references:IfyouselectAutomaticgenerationofreferencesonthebasisofonesamplereference(templatereference),thereferencesaregeneratedforallseamsandpartseamsreadinbythePLC.Thereferencesaregeneratedinonego.Anaveragingofseveralweldingoperationsisnotcarriedout.Forthisreason,itisrecommendedtocarryouttheautoreferencefortimeandthentheautoreferenceforallnewreferences,aftertheautomaticgeneration.Attention:Thenewautomaticallygeneratedreferencesadoptallessentialcriteriaofthesamplereference(e.g.faultlimits,filter...).Itisthereforerecommended(timesaving)toenterthecriteriatobeappliedforallreferencesinthesamplereferencebeforestartingthegeneration.2.Adaptationofexistingreferences:Ifthesignalamplitudeofthecurrentweldingapplicationischanged(e.g.asaresultofchangingthejointgaporthelaserpower),thereferencecurvemaybeautomaticallyadapted.AutoReference/Levelisactivatedforthispurposeandanewreferenceisforme