1. An electrode cap batch replacement alarm method is characterized by comprising the following steps:

acquiring the maximum spot welding times of an electrode cap on each device in a production workshop;

acquiring a preset alarm ratio of each device;

determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm ratio;

collecting the current spot welding times of the electrode cap of each device in a production workshop;

when the current spot welding times of the electrode cap with the equipment in the production workshop reach an alarm threshold value, alarm information is sent, wherein the alarm threshold value is larger than the lower limit value of the alarm range of the equipment, and the alarm information comprises equipment information that the current spot welding times of the electrode cap falls into the alarm range.

2. The batch replacement alarm method for the electrode caps as claimed in claim 1, wherein the step of determining the alarm range of each device according to the maximum number of spot welding times of the electrode caps of each device and the preset alarm ratio comprises the steps of:

multiplying the maximum spot welding times of the electrode cap of each device by the preset alarm proportion of the device to obtain the lower limit value of the alarm range of the device;

taking the maximum spot welding times of the electrode cap of each device as the upper limit value of the alarm range of the device;

and determining the alarm range of the equipment according to the lower limit value of the alarm range of the equipment and the upper limit value of the alarm range of the equipment.

3. The batch replacement alarm method for electrode caps as claimed in claim 2, wherein the alarm threshold is equal to an upper limit value of an alarm range of the equipment.

4. The batch replacement alarm method for electrode caps as claimed in claim 1, wherein the preset alarm ratio of each piece of equipment in a production workshop is the same.

5. The electrode cap batch replacement alarm method according to claim 4, further comprising the steps of:

counting shutdown losses and electrode cap losses in the production plant based on historical data;

and updating the preset alarm proportion of the equipment according to the shutdown loss and the loss of the electrode cap.

6. The batch replacement alarm method for electrode caps as claimed in claim 5, wherein updating the preset alarm ratio of the equipment according to the shutdown loss and the electrode cap loss comprises the following steps:

determining the comprehensive loss according to the shutdown loss and the electrode cap loss;

establishing a relation between a preset alarm proportion of the equipment and the comprehensive loss based on historical data;

and calculating the value of the preset alarm ratio when the comprehensive loss is minimum as the updated preset alarm ratio of the equipment according to the relation between the preset alarm ratio of the equipment and the comprehensive loss.

7. The utility model provides an alarm device is changed in electrode cap batch which characterized in that includes:

a memory for storing a program;

a processor for executing the program to:

acquiring the maximum spot welding times of an electrode cap on each device in a production workshop;

acquiring a preset alarm ratio of each device;

determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm ratio;

collecting the current spot welding times of the electrode cap of each device in a production workshop;

and sending alarm information when the current spot welding times of the electrode cap with the equipment in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the equipment, and the alarm information comprises equipment information that the current spot welding times of the electrode cap falls into the alarm range.

8. The utility model provides an alarm system is changed in electrode cap batch which characterized in that includes:

the collector is used for collecting the current spot welding times of the electrode cap of each device in the production workshop;

the system comprises a server, a data processing unit and a data processing unit, wherein the server is used for acquiring the maximum spot welding times of an electrode cap on each device in a production workshop, acquiring a preset alarm proportion of each device, determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm proportion, and sending alarm information when the current spot welding times of the electrode cap with the device in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the device, and the alarm information comprises device information that the current spot welding times of the electrode cap fall into the alarm range;

and the terminal is used for receiving the alarm information sent by the server.

9. The electrode cap batch replacement alarm system of claim 8, wherein the terminal displays device position information of the electrode caps to be replaced and current spot welding number information of the electrode caps of the device according to the alarm information.

10. A computer storage medium in which a processor-executable program is stored, wherein the processor-executable program, when executed by the processor, is configured to implement the electrode cap batch replacement alarm method according to any one of claims 1 to 6.

Background

In the production process of a welding shop, spot welding is one of the most important processes of the welding process, and the consumption degree of an electrode cap for welding affects the quality of welding, so that the electrode cap needs to be replaced.

At present, the replacement of the electrode cap is mainly realized by giving a set value of the grinding times of the electrode cap in an electronic system (PLC) program of digital operation, and after the set value is reached, the PLC gives an alarm signal to remind a maintenance worker of the device to replace the electrode cap.

In addition, the electrode caps are replaced in one step before the equipment is turned on every time, the mode does not need to be stopped and replaced frequently, but the replaced electrode caps have few use times which are far less than the use times needing replacing, and great waste of the electrode caps is caused.

In the related technology, another method for replacing the electrode cap is to calculate the average number of the electrode cap per hour according to historical data, and obtain the maximum number of times of spot welding of the electrode cap and the early warning time of each device; calculating the product of the number of spot welding times of the equipment per hour and the early warning time of the equipment; and subtracting the product corresponding to each device from the maximum number of spot welding times of the electrode cap to obtain the alarm threshold value of each device, and performing alarm replacement according to the alarm threshold values. However, the method is large in calculation amount and complicated in parameter setting, and the average hit number per hour is calculated, so that continuous and stable production is required, and a factory with unstable production is not suitable for the method.

Disclosure of Invention

In order to solve at least one of the technical problems, the invention provides an electrode cap batch replacement alarm method, system, device and storage medium, which can balance the shutdown cap replacement loss and the electrode cap waste loss of a production workshop so as to reduce the comprehensive loss of the production workshop and are suitable for various production workshops.

In a first aspect, an embodiment of the present invention provides an alarm method for batch replacement of electrode caps, including the following steps:

acquiring the maximum spot welding times of an electrode cap on each device in a production workshop;

acquiring a preset alarm ratio of each device;

determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm ratio;

collecting the current spot welding times of the electrode cap of each device in a production workshop;

and sending alarm information when the current spot welding times of the electrode cap with the equipment in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the equipment, and the alarm information comprises equipment information that the current spot welding times of the electrode cap falls into the alarm range.

In some embodiments, the determining the alarm range of each device according to the maximum number of spot welding times of the electrode cap of each device and the preset alarm ratio comprises the following steps:

multiplying the maximum spot welding times of the electrode cap of each device by the preset alarm proportion of the device to obtain the lower limit value of the alarm range of the device;

taking the maximum spot welding times of the electrode cap of each device as the upper limit value of the alarm range of the device;

and determining the alarm range of the equipment according to the lower limit value of the alarm range of the equipment and the upper limit value of the alarm range of the equipment.

In some embodiments, the alarm threshold is equal to an upper alarm range limit of the device.

In some embodiments, the predetermined alarm rate for each of the devices in the production plant is the same.

In some embodiments, the electrode cap batch replacement warning method further includes the steps of:

counting shutdown losses and electrode cap losses in the production plant based on historical data;

and updating the preset alarm proportion of the equipment according to the shutdown loss and the loss of the electrode cap.

In some embodiments, updating the preset alarm rate of the device based on the shutdown loss and the electrode cap loss comprises:

determining the comprehensive loss according to the shutdown loss and the electrode cap loss;

establishing a relation between a preset alarm proportion of the equipment and the comprehensive loss based on historical data;

and calculating the value of the preset alarm ratio when the comprehensive loss is minimum as the updated preset alarm ratio of the equipment according to the relation between the preset alarm ratio of the equipment and the comprehensive loss.

In a second aspect, an embodiment of the present invention further provides an alarm device for batch replacement of electrode caps, including:

a memory for storing a program;

a processor for executing the program to:

acquiring the maximum spot welding times of an electrode cap on each device in a production workshop;

acquiring a preset alarm ratio of each device;

determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm ratio;

collecting the current spot welding times of the electrode cap of each device in a production workshop;

and sending alarm information when the current spot welding times of the electrode cap with the equipment in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the equipment, and the alarm information comprises equipment information that the current spot welding times of the electrode cap falls into the alarm range.

In a third aspect, an embodiment of the present invention further provides an electrode cap batch replacement alarm system, including:

the collector is used for collecting the current spot welding times of the electrode cap of each device in the production workshop;

the system comprises a server, a data processing unit and a data processing unit, wherein the server is used for acquiring the maximum spot welding times of an electrode cap on each device in a production workshop, acquiring a preset alarm proportion of each device, determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm proportion, and sending alarm information when the current spot welding times of the electrode cap with the device in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the device, and the alarm information comprises device information that the current spot welding times of the electrode cap fall into the alarm range;

and the terminal is used for receiving the alarm information sent by the server.

In some embodiments, the terminal displays the device position information of the electrode cap needing to be replaced and the current spot welding times information of the electrode cap of the device according to the alarm information.

In a fourth aspect, the embodiment of the present invention further provides a computer storage medium, in which a program executable by a processor is stored, and when the program executable by the processor is executed by the processor, the program is used to implement the electrode cap batch replacement alarm method according to the embodiment of the first aspect.

The technical scheme of the invention at least has one of the following advantages or beneficial effects: the method comprises the steps of obtaining the maximum spot welding times of an electrode cap of each device in a production workshop and the preset alarm proportion of each device, then determining the alarm range of each device according to the maximum spot welding times and the preset alarm proportion of each device, collecting the current spot welding times of the electrode cap of each device in the production workshop in real time in the working process of the production workshop, and sending alarm information when the current spot welding times of the electrode cap with the device in the production workshop are detected to reach the alarm threshold value. The alarm range of the electrode cap of each equipment is determined by setting the preset alarm proportion of the equipment, when the current spot welding frequency of the electrode cap of one equipment in a production workshop exceeds the lower limit value of the alarm range and reaches the alarm threshold value, the alarm information is sent to remind a worker to replace, the alarm information comprises other equipment information which falls into the alarm range but does not reach the alarm threshold value besides the equipment information which reaches the alarm threshold value, only the electrode cap of the equipment which falls into the alarm range needs to be replaced when the electrode cap is replaced, the electrode cap of all the equipment does not need to be replaced, and the loss of the electrode cap is reduced. Meanwhile, when the equipment reaches the alarm threshold value and the electrode cap of the equipment falling into the alarm range needs to be replaced, the electrode cap of the equipment which is about to reach the alarm threshold value can be replaced by the aid of the electrode cap replacement method, and therefore the times of shutdown replacement can be reduced. The method does not need to set the replacement alarm value according to the average spot welding times of the electrode cap, and can be suitable for workshops with unstable production.

Drawings

FIG. 1 is a flow chart of a method for alarming batch replacement of electrode caps according to an embodiment of the invention;

fig. 2 is a schematic diagram of an electrode cap batch replacement alarm system provided according to an embodiment of the invention.

Detailed Description

The embodiments described in the embodiments of the present application should not be construed as limiting the present application, and all other embodiments that can be obtained by a person skilled in the art without making any inventive step shall fall within the scope of protection of the present application.

In the following description, reference is made to "some embodiments" which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of the present application only and is not intended to be limiting of the application.

Before further detailed description of the embodiments of the present application, terms and expressions referred to in the embodiments of the present application will be described, and the terms and expressions referred to in the embodiments of the present application will be used for the following explanation.

PLC: programmable Logic controllers (programmable Logic controllers) are digital arithmetic-operating electronic systems designed specifically for use in industrial environments. It uses a programmable memory, in which the instructions for implementing logical operation, sequence control, timing, counting and arithmetic operation are stored, and utilizes digital or analog input and output to control various mechanical equipments or production processes.

Electrode caps: the electrode cap is used for welding resistance welding equipment, such as a fixed spot welder, a suspension type spot welder, a manipulator spot welder and the like, and is sleeved on an electrode connecting rod, so that the electrode cap is called. The material is mostly chromium zirconium copper, and also has dispersed copper. After welding for a certain number of times (generally 3000-.

Referring to fig. 1, the method of the embodiment of the present invention includes, but is not limited to, step S110, step S120, step S130, step S140, and step S150.

And step S110, acquiring the maximum spot welding times of the electrode cap on each device in the production workshop.

Specifically, each spot welding device in a production workshop records the number of spot welding times of a used electrode cap, and generally, each device records complete consumption data of at least one pair of electrode caps within one month, counts the data of the number of spot welding times of all the electrode caps within one month, and takes out the maximum value, thereby obtaining the maximum number of spot welding times of the electrode caps on the device. Of course, for equipment with lower electrode cap replacement frequency, electrode cap consumption data for a longer time can be counted, so that complete electrode cap consumption data can be obtained. And the electrode cap consumption data of each device can be stored in the respective device or can be stored in a database for convenient query and management.

And step S120, acquiring the preset alarm ratio of each device.

And S130, determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and the preset alarm ratio.

And step S140, collecting the current spot welding times of the electrode cap of each device in the production workshop.

Specifically, each device is provided with a collector, the collector can read welding data of the device, and data is recorded once every welding point, so that the current spot welding times of the electrode cap of each device can be counted in real time.

And S150, when the current spot welding times of the electrode cap of the equipment in the production workshop reach an alarm threshold value, sending alarm information, wherein the alarm threshold value is larger than the lower limit value of the alarm range of the equipment, and the alarm information comprises equipment information that the current spot welding times of the electrode cap falls into the alarm range.

In some embodiments, the preset alarm ratio of each device may be manually set, and for convenience of operation, the preset alarm ratios of all devices in the production plant may be uniformly set, for example, the preset alarm ratios of all devices are set to 90%. And determining the alarm range of each device according to the preset alarm proportion and the maximum number of spot welding times of the electrode cap of each device. Specifically, the preset alarm proportion of the device is 90%, the maximum dotting times of the electrode cap of the device counted from the historical data is 1000 times, and the lower limit value of the alarm range is the product of the preset alarm proportion of the device and the maximum dotting times of the electrode cap of the device, that is, 1000 × 90% — 900. The upper limit value of the alarm range can be determined by the alarm threshold value, the alarm threshold value can be manually set, generally, the alarm threshold value is larger than the lower limit value of the alarm range, for example, the alarm threshold value is set to be 98% of the maximum spot welding times of the electrode cap, then the alarm range of the equipment is determined to be 900-980, each equipment in a production workshop determines the alarm range according to the method, when the current spot welding times of the electrode cap of one equipment in the production workshop reach the alarm threshold value, the alarm information is sent, the content of the alarm information also comprises the equipment information that the current spot welding times of the electrode cap fall into the alarm range of the equipment in addition to the equipment information that reaches the alarm threshold value, after receiving the alarm information, a worker replaces the electrode cap of the equipment falling into the alarm range of the equipment according to the alarm information, and thereby realizing the batch replacement of the electrode caps which are about to reach the service life, and the welding quality is ensured. The method is adopted to replace the electrode caps in batches, the shutdown times can be properly reduced, the waste of the electrode caps can be properly reduced, meanwhile, the method is high in universality and simple to operate, and the alarm range of the equipment can be automatically calculated to automatically alarm only by setting the preset alarm proportion and the alarm threshold.

According to some specific embodiments of the invention, in order to reduce the waste of electrode caps in a production workshop and improve the automation degree, the maximum number of times of spot welding of the electrode caps of equipment can be directly used as an alarm threshold value, namely an upper limit value of an alarm range, the alarm threshold value is not required to be manually set, only the maximum number of times of spot welding of the electrode cap of each equipment is required to be automatically obtained from historical data, meanwhile, the maximum number of times of spot welding of the electrode caps of the equipment is used as the alarm threshold value, alarm information is triggered and sent, and at least one electrode cap reaches the use limit when the electrode caps of each batch are replaced, so that the waste of the electrode caps is reduced. For example, five devices are arranged in a production workshop, the maximum spot welding times of the electrode caps of the devices are respectively 1000, 1100, 1200, 1300 and 1400, the preset alarm proportion of the devices in the production workshop is 90%, the alarm range of each device is 900-1000, 990-1100, 1080-1200, 1170-1300, 1260-1400, the current spot welding times of the electrode caps of the devices obtained in real time from a collector are 1000, the devices in the alarm range of 900-1000 trigger alarm information to be sent to maintenance personnel, and meanwhile, the device information in the alarm range of 990-1100 is sent to the maintenance personnel together for electrode cap replacement, so that the electrode cap waste of the devices every day can be controlled within 10%.

According to some embodiments of the present invention, a self-learning method may be further adopted to optimize the preset alarm ratio of the device, and the batch replacement alarm method for electrode caps further includes step S210 and step S220.

And step S210, counting the shutdown loss and the electrode cap loss in the production workshop based on the historical data.

And step S220, updating the preset alarm ratio of the electrode cap according to the shutdown loss and the electrode cap loss.

In some embodiments, the replacement of the electrode cap in the production workshop has two opposite conflicting requirements of reducing the loss of the electrode cap and reducing the shutdown cap replacement times, the number of the replaced caps in each time needs to be increased when the shutdown cap replacement times are reduced, the preset alarm proportion needs to be set to be lower, and the alarm range is expanded. The waste of the electrode caps can be increased after the alarm range is expanded, and the alarm range is reduced in order to reduce the waste of the electrode caps, so that the times of halt and cap replacement can be increased, and the production yield is influenced. The preset alarm proportion of the equipment can be initialized to 90 percent or set manually, after long-time data collection, a more proper balance point between shutdown loss and electrode cap waste loss can be calculated by self-learning, and the balance point with the minimum final comprehensive loss is used as a final alarm range value.

Specifically, shutdown loss and electrode cap loss are respectively counted under the condition of different preset alarm proportions based on historical data, then comprehensive loss under the condition of different preset alarm proportions is determined according to the shutdown loss and the electrode cap loss, so that the relation between the preset alarm proportion of the equipment and the comprehensive loss is obtained, the preset alarm proportion of the equipment with the minimum comprehensive loss is calculated, and the preset alarm proportion is used for updating, so that the preset alarm proportion of each equipment can be automatically optimized, and the comprehensive loss of a production workshop is reduced.

Referring to fig. 2, an embodiment of the present invention further discloses an electrode cap batch replacement alarm system, including:

and the collector is used for collecting the current spot welding times of the electrode cap of each device in the production workshop. In the embodiment, the collector is connected with a PLC on the equipment, obtains the current spot welding times of the electrode cap of the equipment in real time, and sends the current spot welding times to the database for storage.

The server is used for acquiring the maximum spot welding times of the electrode cap of each device in the production workshop from the database, acquiring a preset alarm proportion of each device, determining the alarm range of each device according to the maximum spot welding times and the preset alarm proportion of the electrode cap of each device, and sending alarm information when the current spot welding times of the electrode cap with the device in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the device, and the alarm information comprises device information that the current spot welding times of the electrode cap fall into the alarm range;

and the terminal is used for receiving the alarm information sent by the server through the gateway.

Specifically, the terminal displays the equipment position information of the electrode cap needing to be replaced and the current spot welding times information of the electrode cap of the equipment according to the alarm information, so that the equipment can be conveniently replaced to a specified place by a worker, and the worker can conveniently inquire the current spot welding times of the electrode cap of the equipment.

The embodiment of the invention also discloses an electrode cap batch replacement alarm device, which comprises:

a memory for storing a program;

a processor for executing the program to:

acquiring the maximum spot welding times of an electrode cap on each device in a production workshop;

acquiring a preset alarm ratio of each device;

determining the alarm range of each device according to the maximum spot welding times of the electrode cap of each device and a preset alarm ratio;

collecting the current spot welding times of the electrode cap of each device in a production workshop;

and sending alarm information when the current spot welding frequency of the electrode cap with equipment in the production workshop reaches an alarm threshold value, wherein the alarm threshold value is greater than the lower limit value of the alarm range of the equipment, and the alarm information comprises equipment information that the current spot welding frequency of the electrode cap falls into the alarm range.

An embodiment of the present invention also discloses a computer-readable storage medium storing computer-executable instructions for execution by one or more control processors, e.g., to perform the steps described in the above embodiments.

One of ordinary skill in the art will appreciate that all or some of the steps, systems, and methods disclosed above may be implemented as software, firmware, hardware, and suitable combinations thereof. Some or all of the physical components may be implemented as software executed by a processor, such as a central processing unit, digital signal processor, or microprocessor, or as hardware, or as an integrated circuit, such as an application specific integrated circuit. Such software may be distributed on computer readable media, which may include computer storage media (or non-transitory media) and communication media (or transitory media). The term computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data, as is well known to those of ordinary skill in the art. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by a computer. In addition, communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media as known to those skilled in the art.

While the preferred embodiments of the present invention have been described in detail, it will be understood by those skilled in the art that the foregoing and various other changes, omissions and deviations in the form and detail thereof may be made without departing from the scope of this invention.