基于ZigBee技术的锅炉焊接参数监控系统

Boiler Welding Parameter Monitoring System Based on the ZigBee Technology

针对锅炉制造过程焊缝质量问题,设计并研制了一套基于ZigBee技术的锅炉焊接参数监控系统。采用红外测温传感器,测量由于旋转致使焊剂没有附在焊缝表面的筒体环缝焊接温度;采用四个热电偶,等间距吸附在锅炉纵缝筒体表面,测量筒体纵缝焊接温度,解决了传统方式中数据实时采集难的问题;借助于ZigBee无线网络传输技术,解决了焊件移动频繁、工厂有线通信布线难的问题。锅炉车间长期使用表明,系统设计合理、性能稳定,具有实时性和易扩展性,不但能实时采集焊机的焊接电压、电流、锅炉筒体的预热温度、层间温度和后热温度,而且能对现场违规操作进行合理控制,在一定程度上提高了公司效益,对整个制造行业的数字化生产起到了推动作用。由于工业现场焊机的类型较多,下一步将结合现场情况对焊接参数采集设备和网关进行智能化升级,以保证系统具有更好的适应性。

Aiming at the quality problem of welding seam in boiler manufacturing process,a boiler welding parameter monitoring system based on ZigBee technology is designed and developed.Infrared temperature sensor is used for measuring the circumferential weld temperature of the cylinder due to the rotation caused by the flux not attached to the surface of the weld.Four thermocouples are used,which are adsorbed on the surface of the longitudinal cylinder of the boiler at equal intervals,and the longitudinal welding temperature of the cylinder is measured,thus the problem of real-time data collection in the traditional way can be solved.With the help of ZigBee wireless network transmission technology,the problems that the weldment moves frequently and the difficulty of factory wired communication wirings are solved.The long-term operation in boiler workshop shows that the system design is reasonable,the performance is stable,and it features real-time performance and easy to expand.It can not only collect welding voltage,current,preheating temperature,interlayer temperature and post-heating temperature of the boiler cylinder in real time,but also control the illegal operation in the field,which improves the benefit of enterprise to a certain extent.It also plays a great role in promoting the digital production of the whole manufacturing industry.However,there are many types of welding machines in the industrial field;the intelligent upgrade of welding parameter acquisition equipment and gateway shall be carried out in next step to ensure the system has better adaptability.