Automated generation of "leading" digital welding technology

2024-01-09

The rise of "new infrastructure" during this period has brought "digital technology" back into people's vision, among which high-speed trains are an essential component of a country. Nowadays, our "Fuxing" high-speed train is running at a speed of 350 kilometers per hour on the vast land of our motherland. So what "digital technology" was used in the manufacturing process of the "Fuxing" high-speed train? Below, the editor will take you to learn about digital welding.

Digital welding

Welding, as a key process in the manufacturing of high-speed train bodies, has tens of thousands of welds. On the production line of high-speed train body in the core research and development base of China's high-speed rail, an average of one set of welding data is uploaded to the welding management center every 0.5 seconds. Thisthe current scenario of a digital management system for vehicle body welding. So, in the face of such massive data, how should we control welding quality?

As is well known, traditional welding relies heavily on manual labor, requiring welders to perform self inspection, mutual inspection, and inspection after welding. It is time-consuming and labor-intensive, yet unable to monitor the welding process in real-time. Currently, China has established a digital management system for the welding process of high-speed trains through digital technology. Through data collection deployed on the welding machine, the welding management system can collect all welding parameters during the welding process in real time, such as welding voltage, current, etc., recorded every 0.5 seconds, and automatically compared with standard parameters. Once there is a deviation, an automatic alarm will be triggered.

The welding digital management system can monitor the welding process of the vehicle anytime and anywhere through real-time collection, automatic judgment, and automatic alarm of welding data, achieving "process control" of welding and better ensuring welding quality.

The Development and Prospects of Digital Welding

In recent years, the market size of digital welding management systems in China has been continuously expanding, and the market growth rate is growing day by day. According to reliable data, as of 2019, sales have exceeded 10 billion yuan, with an annual compound growth rate of over 15%. According to the editor's understanding, the types of products in the welding digital management system market have also kept pace with market demand in recent years, with a large number of robot products such as welding, arc welding, and laser welding entering the market. At the same time, many domestic enterprises have sprung up like mushrooms after rain, among which well-known companies such as Evergrande, Xinsong, and Beijing Times have significant competitiveness in the market.

However, the domestic market is also constantly being monopolized by foreign enterprises. According to statistics, foreign enterprises have occupied nearly 80% of China's market share, seriously leading to uneven development of Chinese enterprises. However, China's digital welding enterprises are indeed lagging behind foreign countries in terms of scientific research technology, enterprise scale, production standards, etc. They still have a foothold in China based on price advantages and geographical advantages, but it is difficult for them to compete with foreign enterprises outside the country. Digital welding machines are a product of the integration of computer technology and welding technology. Currently, most digital welding machines exist in the form of independent systems, but automated welding production is the true application of digital welding machines. So what are the development prospects for digital welding?

Firstly, digital welding machine systems will inevitably develop towards high precision, high speed, high quality, and high reliability. This has extremely high requirements for the information processing speed of the system's controller and core software, and requires each moving component and driving control of the system to have high-speed corresponding characteristics. This has a great driving force for the research and innovation capabilities of Chinese enterprises, and also encourages the cultivation of professional talents. The integration of digital welding machines in the robot welding system utilizes digital communication capabilities to achieve stable and excellent welding process performance of digital welding machines.

Secondly, the networked form of digital welding is gradually replacing the original form. Integrating digital welding machines into a network can effectively debug processes, monitor product quality, and achieve integrated and networked management. Digital welding machines combine many processes into one, and such welding processing systems with multiple programs have a certain degree of flexibility, which can meet the different needs of welding processes for different materials and workpieces to a certain extent.

Subsequently, artificial intelligence technology is naturally an indispensable and important factor in the development of digital welding, and artificial intelligence technology marked by fuzzy logic, artificial neural networks, and expert systems has become an important research direction in the field of control. In digital welding machines, fuzzy control should be applied to weld seam tracking, welding quality, and control of arc welding power and equipment in the future. The application of BP neural network in welding joint quality prediction and monitoring, welding process parameter design, weld seam forming control, weld seam tracking, and welding defect detection should be actively developed.

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