Introduction to the principle and functions of the nut error prevention monitoring system:

1. System functions

1.1 Nut welding error prevention function. The system is mainly used for the status detection of the nuts conveyed by the fixed resistance welding machine (spot welding machine) before welding (it can detect whether the nuts are placed upside down or not, and can also detect unqualified nuts, with a detection rate of 100%). It also has the function of electrode wear and positioning pin wear alarm to prompt the operator to deal with it in time.

1.2 Dot counting function. The system also has the technical production management of the dot count, production count, and regular electrode grinding of the fixed resistance welding machine (spot welding machine) and the hanging spot welding machine, which is suitable for on-site management of various production workshops.

The system can also be used for production counting management of stamping production lines, workstations of various automatic production lines, and workpieces.

2. Working principle

When welding nuts, first send the nuts to the positioning pins. During the period when the welding machine pressure head presses down and tightens the nuts (before discharge welding, the time is very short), the precision displacement sensor of this system measures the precise displacement change of the pressing nut stroke. The data is sampled to the MCU control center. According to the pressing amount, it is judged whether the nut placement direction is correct, so as to control whether the welding machine welds or outputs an error alarm, so as to achieve the purpose of nut HD-400B-all-rounds-comprehensive-welding-monitor.html">welding monitoring.

The dot counting function takes the welding current signal for welding counting, which is accurate and reliable.

3. Structural features

3.1 The control core adopts MCU and imported German high-reliability displacement sensor, and the display control adopts human-machine interface components, which are reliable, safe and stable; the operation interface is humanized, the operation method is simple and clear, and the parameter adjustment is simple and fast;

3.2 The displacement measurement system adopts German imported high-reliability displacement sensor to measure the displacement. The system can work reliably for more than 100 million times. The resolution of nut height detection is 0.025mm, which can effectively detect various abnormal nut conveying conditions;

3.3 The nut measurement parameters of this system can be automatically completed by the system. The workers can operate simply and with high accuracy, which is most suitable for factory use;

3.4 Parameter setting can be completed on the touch screen, and different measurement and allowable error values can be set according to different welding workpieces and electrode caps;

3.5 The system control unit MCU has a rich interface, which can easily communicate with the host computer or other controllers;

3.6 The counting signal can be provided by proximity switch, photoelectric switch, travel switch, micro switch, or relay, etc., and the system expansion is easy without distance limit;

3.7 Customized functions can be developed according to customer needs.

4. Special functions

4.1 Effectively detect abnormal nut conveying conditions

The system has a high-precision nut detection function with a resolution of 0.025mm. It can effectively detect nut reverse feeding, nut flying, unqualified nuts and abnormal conditions during equipment conveying. The detection rate is not 100%. Only when the nut is inspected and delivered qualified, the welding start signal is sent to the welding machine, and then the welding machine can discharge, which can effectively prevent the product from being scrapped;

4.2 Preventing the workpiece from being leaked or over-welded

By setting the number of welding points required for the workpiece, when the number of welding points reaches the set number of points, the counter outputs an alarm sound and a light signal to remind the worker that the welding number has been reached, thereby achieving the purpose of preventing leaked welding and over-welding and ensuring the welding quality of the workpiece;

4.3 Regular grinding management of the electrode cap (head)

By setting the service life cycle of the electrode cap for one grinding, when the service life of the electrode cap reaches the number of life times, an alarm prompts and forces the welding machine to stop, forcing the electrode to be ground. Only when the electrode is ground can the unlocking signal be confirmed to continue welding, and the welding quality is guaranteed by ensuring the shape of the electrode;

4.4 Production counting and shift task management function

By setting the target workpiece output for each shift, when the production count reaches the target output, an alarm sounds to remind the worker that the target output has been completed and production is stopped;

4.5 Repair welding free counting function

When it is found that some welding points do not meet the requirements, the dot counting switch on the touch screen can be turned to "Re-welding without counting" to perform re-welding without counting. After the re-welding is completed, it can be switched to "Normal counting" without affecting the setting of production number and electrode repair number;

4.6 Dot counting self-reset function

Through the "Operation Monitoring" screen, the dot counting reset method can be set to manual or automatic. When "Automatic" is selected, the dot counting output alarm is automatically reset, and the next workpiece can be welded immediately.