Detailed Explanation and Operation Guide of the Intelligent Control System of the Double-head T-shaped Welding Machine

2025-02-28

In modern manufacturing, as a key process link, the quality and efficiency of welding technology directly affect the performance of products and the production cycle. The intelligent control system of the double-head T-shaped welding machine has emerged as the times require, bringing revolutionary changes to the field of welding. This article will deeply analyze this advanced system, reveal its core secrets for you, and provide practical operation suggestions.

I. The Core Composition of the Intelligent Control System
(1) Data Acquisition Module

Diverse Applications of Sensors: To accurately capture various parameters during the welding process, the system is equipped with a variety of sensors. Current sensors, such as Hall effect current sensors or Rogowski coil current sensors, are precisely selected according to the current range of the welding machine and installed in the output circuit of the welding machine to monitor the welding current in real time. Voltage sensors, using resistive voltage division or isolated types, are connected to the output terminal of the welding machine to accurately measure the welding voltage. Temperature sensors, near the key heating parts of the welding machine, such as the transformer and power components, install thermocouples or thermistor temperature sensors to collect temperature data in real time. Wire feeding speed sensors install photoelectric encoders or Hall sensors on the wire feeding mechanism and calculate the wire feeding speed by measuring the rotation speed of the wire feeding wheel.
Coordinated Operation of Data Acquisition Equipment: The data acquisition card, with the characteristics of multi-channel, high sampling rate, and high precision, converts the analog signals output by the sensors into digital signals, making it convenient for computer processing. The Programmable Logic Controller (PLC), with its powerful logic control and data processing capabilities, receives the sensor signals, conducts preliminary data processing and storage, and communicates with the upper computer.
(2) Intelligent Control Unit
The Central Role of PLC: The PLC acts as the "brain" in the intelligent control system. Take the Siemens S7-1200 series PLC as an example, which has excellent reliability and stability. During the welding process, the current magnitude of the welding machine is precisely regulated through the analog output module, and the appropriate current value is set according to the material and thickness. Using the timer function, accurately control the welding sequence, including the preheating, main welding, filling, and arc extinguishing stages. Read the thermocouple temperature value through the analog input module to monitor the temperature in real time and prevent abnormal temperature from affecting the welding quality. For complex welding paths, control the stepper motor or servo motor to achieve precise motion control.
Deep Empowerment of Intelligent Algorithms: The introduction of machine learning and deep learning algorithms enables the system to have self-learning and adaptive capabilities. Through in-depth analysis of a large amount of historical welding data, the system can automatically optimize the welding parameters to adapt to the needs of different welding tasks. For example, the image recognition technology based on deep learning can automatically detect the welding joint, identify welding defects such as cracks and pores, and adjust the welding strategy in a timely manner to avoid the occurrence of defects.
(3) Communication and Network Module
Stable Guarantee of Wired Communication: The RS485 bus, using the RS485 communication protocol, connects the data acquisition equipment to the upper computer or monitoring system through twisted pair wires to achieve multi-point communication, which is suitable for the workshop scene with a short distance and a stable environment. Ethernet, using the Ethernet interface and the TCP/IP protocol, connects the data acquisition equipment to the enterprise local area network to ensure high-speed and stable data transmission, which is convenient for remote monitoring and data sharing.
Convenient Expansion of Wireless Communication: The Wi-Fi module is installed near the welding machine and transmits the collected data to the monitoring center or mobile terminal through the Wi-Fi network, especially suitable for workshops with inconvenient wiring or temporary workplaces. The 4G/5G communication module enables the data to be sent to the remote server or cloud platform, breaking through the distance and geographical limitations, realizing remote real-time monitoring, and meeting the needs of distributed welding operations or remote operation and maintenance.
(4) Human-Machine Interaction Interface
Design for Operational Convenience: The display screen of the handheld controller uses a high-resolution color screen, such as a 320*240 resolution, with a full Chinese operation interface. The operation process is simple and easy to understand, reducing the learning cost of operators and improving work efficiency.
Data Visualization Presentation: Real-time display of welding parameters, such as current, voltage, wire feeding speed, temperature, etc., is presented in the form of intuitive charts, which is convenient for operators to grasp the welding status in real time. At the same time, it has an alarm function. When the parameters exceed the preset threshold, the system will automatically send out sound and light alarm signals to remind the operator to deal with it in a timely manner.

II. Significant Advantages of the Intelligent Control System
(1) Excellent Improvement of Welding Quality

Real-time Monitoring and Adjustment of Parameters: Through real-time monitoring of key parameters such as welding current, voltage, and wire feeding speed, the system can detect parameter fluctuations and abnormalities in a timely manner. During the automatic welding process, if the current fluctuates suddenly, it may lead to defects such as lack of penetration and pores in the weld seam. The intelligent control system can quickly adjust the parameters to ensure the stability of the welding process and improve the uniformity and consistency of the weld seam.
Defect Prevention and Quality Traceability: Use intelligent algorithms to conduct real-time analysis of the welding process and give early warnings of possible welding defects. When welding high-strength steel, if the monitoring system finds that the cooling speed is too fast, which may lead to cold cracks in the weld seam, it will promptly remind the operator to adjust the welding process and effectively prevent the occurrence of defects. At the same time, the system records the welding parameters in real time, establishes a detailed parameter file for each welding joint. When there are welding quality problems, it can quickly trace back to the specific welding time, equipment, operator, and the welding parameters at that time, which is convenient for accurately analyzing the causes of quality problems and taking targeted improvement measures.
(2) Great Increase in Production Efficiency
Process Optimization and Process Coordination: The large amount of welding parameter data collected by the system provides a powerful basis for the optimization of the welding process. By analyzing the welding effects under different parameter combinations, the optimal welding parameter range can be determined, the welding time can be shortened, the welding defects can be reduced, and the welding efficiency can be improved. Real-time monitoring and recording of welding parameters provide rich data support for production management. Enterprises can reasonably arrange production plans, optimize welding processes, and improve the coordination and continuity of the production process based on this. By analyzing the welding parameters and production times of different products, rationally allocate equipment and human resources, and shorten the product production cycle.
Automated Operation Reduces Manual Intervention: The intelligent control system realizes the automation of the welding process, reduces the manual operation links, and reduces the occurrence rate of manual fatigue and human errors. The operator only needs to input information such as the material grade, plate thickness, groove form, welding wire grade and diameter, flux or shielding gas type, etc. on the human-machine interface, and the welding process parameters can be automatically generated or the corresponding parameters can be called to complete the fully automatic welding, greatly improving the production efficiency.
(3) Intelligent Upgrade of Equipment Management
Fault Diagnosis and Predictive Maintenance: Establish a fault diagnosis model based on artificial intelligence algorithms, such as neural networks and support vector machines, etc. Through learning and analysis of a large amount of historical data and fault cases, realize the automatic diagnosis and location of the faults of the welding machine. The system monitors the operation status of the equipment in real time, predicts potential faults, arranges maintenance in advance, reduces the equipment downtime, and improves the equipment utilization rate and maintenance efficiency.
Centralized Data Management and Analysis: Realize centralized data management. Managers can use data visualization tools to understand information such as the operation status of the equipment and the production progress in real time, discover and solve potential problems in a timely manner, and provide data support for enterprise decision-making. In-depth analysis of historical data helps to tap potential value and further optimize the production process and equipment management strategy.

III. Operation Suggestions and Precautions
(1) Preliminary Preparation Work

Equipment Inspection and Debugging: Before using the double-head T-shaped welding machine, be sure to carefully check whether the connections of all parts of the equipment are firm, whether the sensors are installed correctly, and whether the communication lines are unobstructed. Conduct a comprehensive debugging of the welding machine to ensure that the welding power source, wire feeding mechanism, cooling system, etc. are operating normally.
Parameter Setting and Process Planning: According to the actual situation such as the welding material, thickness, and groove form, accurately set the welding parameters, such as current, voltage, wire feeding speed, welding speed, etc. on the human-machine interface. Formulate a reasonable welding process plan, including the welding sequence, the number of welding layers, preheating and post-heating requirements, etc.
(2) Operation During the Welding Process
Real-time Monitoring and Parameter Fine-tuning: During the welding process, the operator needs to pay close attention to the welding parameters and the operation status of the equipment displayed on the human-machine interface. If abnormal parameter fluctuations or abnormal noises, odors, etc. of the equipment are found, stop the welding immediately, check the cause and make adjustments. According to the actual welding effect, the welding parameters can be fine-tuned within the allowable range to obtain the best welding quality.
Safety Protection Measures: Strictly abide by the welding safety operation procedures and wear protective equipment, such as a welding mask, protective gloves, work clothes, etc. Ensure that the welding area is well ventilated to prevent the accumulation of harmful gases. During the operation of the equipment, it is strictly prohibited to touch the welding parts and moving parts to avoid accidents such as scalding and mechanical injury.
(3) Post-maintenance
Equipment Cleaning and Maintenance: After the welding work is completed, promptly clean the welding spatter, dust, and other impurities on the surface and inside of the welding machine to keep the equipment clean. Regularly lubricate and maintain the mechanical transmission components of the welding machine, such as the wire feeding wheel, guide rail, and lead screw, to ensure the smooth operation of the equipment.
Data Backup and System Update: Regularly back up the welding parameter data and equipment operation logs to prevent data loss. Pay attention to the system software update information and update the intelligent control system in a timely manner to obtain better performance and functions and improve the stability and safety of the equipment.

The intelligent control system of the double-head T-shaped welding machine integrates advanced sensing technology, intelligent control algorithms, communication technology, and human-machine interaction design, bringing a high-quality, high-efficiency, and intelligent production solution to the welding industry. By reasonably using this system and following the above operation suggestions, enterprises can significantly improve the welding production level and gain an advantage in the fierce market competition.