|
The Weldwize 2000 is an automatic system that not only controls the flashing cycle on a Flash Butt Welding machine, but also stores the many flashing parameters required for
welding various grades and gauges of materials (and their combinations), permits manual weld set-ups, displays weld set-up and performance data, displays machine diagnostics, and communicates to line PLC's or higher
level computers. The entire system is easy to use and is intended to make the entry of new set-ups or the changing of any parameter a straight forward procedure. Security levels can be set to permit access only by
authorized personnel so that parameters can be reviewed by anyone, but only those who have the access code can make modifications. Optional features (such as printers) can be added to the basic system to allow
permanent records to be kept of each weld set-up and the corresponding machine performance (or this information can be communicated to another computer for later analysis). The system can be adapted to new or
existing welders.
Equipment
The Weldwize 2000 works in conjunction with a PLC and is housed in a two-door, NEMA 12, free standing enclosure. Inside of the enclosure are mounted the electronic flashing
curve circuitry, power supplies, servo amplifier, and ancillary electronics for flashing and upset control. Input/ Output modules for PLC interfacing are also mounted inside. A sloping front stainless steel operator
panel is affixed to the door. On this panel is an operator interface which consists of a fourteen inch color display (CRT), control function pushbuttons and a numeric keypad. Flashing time, start of upset, platen
position digital meters and a secondary voltmeter are also included on this panel.
Capacity
In its normal configuration the Weldwize 2000 is programmed with a 14 x 14 size matrix of exit vs. entry
grades. Each grade combination has a provision of 13 gauges for a possible total of 14 x 14 x 13 complete weld schedules, or 2548 schedules. Larger memory matrix arrays are available by expanding the memory capacity
and modifying the software, but 2548 possible schedules far exceeds most users requirements.
Operation
The Weldwize 2000 performs the following functions in conjunction with a programmable controller: An
empirically developed set of welding variables (schedule) can be directly entered into the PLC memory by keypad entry. A Password must be used so that only authorized personnel can enter or modify data. The weld
schedule is entered based on entry and exit steel grade and gauge. Weld parameters, which correspond to the grade and gauge data, consist of space bar step, gauge bar step, upset dimension, flashing time, flashing
curve, upset current time, upset heat percent, 8-step and high low tap switch positions, and high or low upset voltage selection. If the above data is valid or in range, schedule entry occurs. If invalid data entry
is attempted, a fault message alerts the operator and schedule entry does not occur. Any schedule in memory can be read without the use of the password.
The welding parameters stored in memory are retrieved
and used to setup the welder in the automatic or semi-automatic modes. The automatic mode is provided only if the user intends to download the grade and gauge information to the welder from a higher level computer
or PLC. This is accomplished serially or on a data highway.
The system utilizes Taylor-Winfield's unique Electro/Mechanical Flashing System to provide precise welder platen motion. The servo valve and its
corresponding cylinder use ultra clean fluid for long component life. The follower valve and upset cylinders retain operation via oil supplied by the machine pumping service.
Automatic Mode
In the
automatic mode, entry grade, gauge, width and punching data are downloaded to the welder PLC. This information is transferred to the Weldwize 2000 and if the data is valid, a unique schedule is retrieved from the
PLC memory and is displayed on the color monitor. The machine then automatically sets up to the retrieved parameters. Width information is used to select the number of damping cylinders (if required). If a notcher
is incorporated in the machine, notching is performed when the entry width is greater than the exit width. If the machine is equipped with the Oxygen Depletion option, its use is selected by the operator entry. If
not selected, the retrieved flashing time is decreased by 13% and the voltage is increased by one transformer tap setting.
Semi-Automatic Mode
In the semi-automatic mode, entry and exit grades and gauges
are entered via the numeric keypad. The operator then presses the schedule set-up button which causes the machine to setup to the retrieved schedule as outlined above.
Manual Mode
In the manual mode,
weld parameters (space bar step, gauge bar step, etc.) are individually entered via the numeric keypad. If all parameters are within range, pressing of the schedule set-up button will cause the machine to setup. The
Weldwize 2000 reviews all data entered to make certain that it is within proper range before allowing the machine to setup. Values out of range will be displayed on the operator's interface panel for his review
Selectable help pages on the CRT describe the various modes and schedule entry procedure. A fault page, with the detected fault, automatically appears when any schedule retrieval or entry fault occurs. Faults
consist of entered or retrieved parameters being out of range and incorrect space bar/gauge bar combinations. After weld completion, the welding results screen is automatically displayed.
Actual weld
parameters (initial die, final die, upset dimension, flashing time, flashing curve, upset time, upset current, tap switch settings, high or low upset voltage, and gas, punch and notch results) are displayed. If the
user has a data link compatible with the welder PLC, weld results and weld presets can be written to the higher level. If the user desires, he can archive the weld results.
|
