CN101628358B - Magnetic control resistance spot welding system - Google Patents
Magnetic control resistance spot welding system Download PDFInfo
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- CN101628358B CN101628358B CN2009100563335A CN200910056333A CN101628358B CN 101628358 B CN101628358 B CN 101628358B CN 2009100563335 A CN2009100563335 A CN 2009100563335A CN 200910056333 A CN200910056333 A CN 200910056333A CN 101628358 B CN101628358 B CN 101628358B
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Abstract
The invention relates to a magnetic control resistance spot welding system in the technical field of electromagnetic welding. The system comprises a synchronous system, an electric power conversion device, a lower excitation coil, an upper excitation coil, a spot-welding gun and an electric current sensor, wherein, the input end of the synchronous system is respectively connected with the resistance spot-welding gun and the excitation coils by the electric current sensor, the output terminal of the synchronous system is connected with the input terminal of the electric power conversion device so as to transmit an electromagnetic stirring synchronous control signal and an excitation coil protection signal, the lower excitation coil and the upper excitation coil are respectively fixedly arranged on the resistance spot-welding gun, and the driving input terminals and the earth terminals of the lower excitation coil and the upper excitation coil are respectively connected in parallel with the output terminal of the electric power conversion device. The invention greatly increases the power factor of the system, reduces exhaustion and harmonic waves generated on a power grid, and the system is energy-saving and environmentally friendly; and the full digitalization design of the entire control system is realized, the reliability and the flexibility of the system are greatly increased, and the difficulty of system maintenance is reduced.
Description
Technical field
What the present invention relates to is a kind of device of welding technology field, and what be specifically related to is a kind of magnetic control resistance spot welding system.
Background technology
Electromagnetic agitation has been successfully applied to fields such as arc welding, casting as a kind of effective ways that improve metal solidification process primary solidification structure.Its principle is that the noncontact effect by electromagnetic field makes the high-temperature metal magnetic fluid that flow at high speed clocklike take place, thus influence and change the deposite metal one time of crystallization.As far back as the seventies in last century, The former Russian scholar M.A.Abralov (Automatic Welding, Vol.30, No.5,52-55,1977) just studied the influence of external magnetic field, found the primary solidification structure that the effect of external magnetic field can the refinement weld metal and improve strength of joint tungsten electrode argon-arc welding seam metallic crystal tissue and mechanical performance.The broad research of magnetic control arc solder technology has fully proved the validity of external magnetic field refined crystalline strengthening welding point comprehensive mechanical property.But resistance spot welding and arc welding exist than big-difference, it belongs to the fixed position welding procedure, whole welding process is divided precompressed, welding, maintenance three phases, material for routine, usually have only the welding stage to have electric current, crystallisation by cooling process electric current subsequently then can turn-off, thereby the external magnetic field can't play a role, and this makes this method can't effectively control the crystallization process of nugget.
Find through retrieval prior art, number of patent application 200320109642.2 has been put down in writing a kind of " ac seam welding machine magnetic control means ", this technology adopts four permanent magnets that the formation of electric-resistance seam-welding process centre joint plumb joint is controlled, effectively refinement crystal grain, improved joint and drawn and cut intensity.Though resistance spot welding and electric-resistance seam-welding belong to resistance-welding process together, but electric-resistance seam-welding belongs to continuous welding process, electric current exists all the time in the whole welding process, and because the existence of shunting, still there is electric current to flow through in the metal of roller rear side ot-yet-hardened, make the external magnetic field still can act on this zone, thus can the crystallization control process.Resistance spot welding process nugget electric current when solidification and crystallization turn-offs, and magnetic control means can't work.Secondly, the weld seam of electric-resistance seam-welding is all more straight usually, the magnetic control means easy arrangement, but the resistance spot welding operating mode is then very complicated, magnetic control system oversize then easily and welded piece interfere.In addition, this magnetic control system adopts permanent magnet as magnetic field sources, and have following limitation: the magnetic field size depends on the distance between permanent magnet and the workpiece, and adjusting difficulty and precision are low; Can only produce the stationary magnetic field, magnetic field model is single; Magnetic field intensity can't change according to demand in the welding process; The permanent magnet volume is big, spacing is little, easy and bodywork parts and frock clamp generation interference; Continuous welding process environment temperature height, and permanent magnet will obviously be decayed above 80 degrees centigrade of magnetic.
Find by retrieval again, people such as Zhang Zhongdian have studied influence (the ten once national welding proceeding of permanent magnet to high-strength steel joint for resistance spot welding microstructure state and mechanical property by experiment, first: 406-409,2005), discovery is welded nuclear diameter and is obviously increased under the permanent magnet effect, the comprehensive mechanical property of joint also further improves.But still there is following defective in this magnetic control system: the magnetic field that (1) permanent magnet produces is the stationary magnetic field, and control model is single; (2) the magnetic field size is regulated by the spacing of dual permanent-magnet, and it is low to regulate difficulty and degree of regulation; (3) the permanent magnet volume is big, spacing is little, easy and bodywork parts and frock clamp generation interference; (4) permanent magnet fragility is big, and shock resistance and vibration ability are poor.
Summary of the invention
The present invention is directed to the prior art above shortcomings, a kind of magnetic control resistance spot welding system is provided.The present invention increases a controlled electromagnetic stirring system on the basis of basic resistance spot welding equipment, energising heating and postwelding at resistance spot welding process keep the stage, this system carries out function composite by electromagnetic stirring by the noncontact mode to the liquid metal in the nugget formation in resistance spot welding, realize increasing welding spot size, crystallization of refinement crystal grain, eliminate solidification cracking, evening chemical composition, and finally improve the purpose of joint for resistance spot welding comprehensive mechanical performance.
The present invention is achieved by the following technical solutions; the present invention includes: synchro system; power-converting device; following magnetizing coil; last magnetizing coil; spot-welding gun; first current sensor and second current sensor; wherein: the input of synchro system is by first current sensor; second current sensor is connected with magnetizing coil with the resistance spot welding welding gun respectively; the output of synchro system is connected with the input of power-converting device with transmission electromagnetic agitation synchronous control signal and magnetizing coil guard signal; following magnetizing coil and last magnetizing coil are fixedly set in respectively on the resistance spot welding welding gun, and the driving input of following magnetizing coil and last magnetizing coil and earth terminal are in parallel with the output of power-converting device respectively.
Described power-converting device comprises: AC/DC convertor, excitatory control driver and global controller, wherein: global controller is connected with synchro system is corresponding, the control input end of excitatory control driver is connected with global controller, excitatory control output end of driver and driving switch pipe are in series, the driving switch pipe is connected with last magnetizing coil with following magnetizing coil respectively, following magnetizing coil and last magnetizing coil all are connected to AC-DC converter main circuit output, the control input end of AC/DC convertor is connected with global controller, and the main circuit input of AC/DC convertor then directly is connected with AC network.
Described synchro system detects the job initiation electric current of spot-welding gun, for function composite by electromagnetic stirring provides synchronous control signal;
Described synchro system detects the magnetizing coil operating current, for power-converting device provides magnetizing coil overcurrent protection signal, realizes defencive function with the driving output of blocking power-converting device.
Described power-converting device is used for electric power adjustment and conversion, obtains the exciting curent of different sizes, and exciting curent operating frequency and dutycycle are adjusted and controlled.
The architectural feature of described magnetizing coil down and last magnetizing coil is: this coil is the solenoid solenoid that has iron core, for function composite by electromagnetic stirring provides suitable alternating magnetic field.
Described spot-welding gun is used to realize workpiece pressing and suitable spot-welded on electric current is provided.
The present invention carries out work in the following manner: the resistance spot welding welding gun carries out work according to spot welding parameter.When basic spot welding system started, synchro system began to detect the welding current in the welding gun, just started regularly when detecting welding current, and when reaching the stirring start-up time that configures in advance, power-converting device is just started working.The course of work of power-converting device is: at first, AC/DC convertor in the power-converting device will exchange input and be transformed to direct current output Ud, Ud is as the driving voltage source of magnetic stirrer (magnetizing coil), and Ud is adjustable continuously, can obtain the exciting current of different sizes like this, just obtain the operate outside magnetic field of different magnetic field intensity.The adjustment of Ud is undertaken by AC/DC convertor, and AC/DC convertor adopts TI 2407A DSP to realize the PWM control of rectification.After obtaining excitation voltage source Ud, then by with the DRV101 chip serve as control core excitatory control driver the power drive element of magnetic stirrer (magnetizing coil) is controlled, obtain the square-wave excitation electric current of certain frequency and dutycycle, described excitatory control driver can change and adjust the frequency and the dutycycle of exciting curent, and then obtains required alternating magnetic field.The adjustment in operate outside magnetic field both can be adjusted according to the difference of the required stirring action of different materials, can realize the real-time adjustment of excitatory intensity and excitatory alternative frequency and dutycycle as required in pinpoint welding procedure again.Described excitatory driving governor also includes the holding circuit part, and to prevent that magnetizing coil from being burnt, the time-delay control module can satisfy the special requirement of different electromagnetic agitation technologies.
Compared with prior art, magnetic control system of the present invention is independent of the resistance spot welding system, and its application will not be subjected to the restriction of spot welding controller type (exchanging or direct current); The magnetic control parameter is online adjustable, be that exciting current size, frequency and dutycycle can be adjusted arbitrarily and control, can obtain the alternating magnetic field of different exciting pattern and intensity, under the constant condition of control module, can also carry out dilatation by changing power component, to adapt to the requirement of different spot-welding technologies and welding material; Because magnetic control system adopts the frequency conversion mode, make the magnetic control system volume of design little, reliability is high, and magnetic field binding mode and intensity adjustable accuracy are higher; Simultaneously, can improve the system power factor greatly, reduce loss and, energy saving of system, environmental protection the harmonic wave that electrical network produced; The whole control system realizes the total digitalization design, has improved reliability, the flexibility of system greatly, and has reduced the difficulty of system maintenance.
Description of drawings
Fig. 1 is a structural representation of the present invention.
Fig. 2 is an alternating current-direct current rectifier converter structural representation.
Fig. 3 is excitatory control activation configuration schematic diagram.
Fig. 4 is an embodiment effect schematic diagram;
Wherein: a) exciting curent 2.1A/300Hz, b) exciting curent 2.1A/100Hz, c) exciting curent 2.1A/50Hz, d) exciting curent 2.1A/10Hz, e) exciting curent 900mA/10Hz, f) exciting curent 900mA/50Hz.
The specific embodiment
Below in conjunction with accompanying drawing embodiments of the invention are elaborated: present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
As shown in Figure 1, present embodiment comprises: synchro system 1, power-converting device 2, time magnetizing coil 8, last magnetizing coil 10, spot-welding gun 11, first current sensor 12 and second current sensor 13.Wherein: the input of synchro system 1 by first current sensor 12 and second current sensor 13 respectively with resistance spot welding welding gun 11 and following magnetizing coil 8; last magnetizing coil 10 is connected; the output of synchro system 1 is connected with the input of power-converting device 2 with transmission electromagnetic agitation synchronous control signal and magnetizing coil guard signal; following magnetizing coil 8 and last magnetizing coil 10 are fixedly set in respectively on the bottom electrode 7 and top electrode 9 of resistance spot welding welding gun 11, and the driving input of following magnetizing coil 8 and last magnetizing coil 10 and earth terminal are in parallel with the output of power-converting device 2 respectively.
Described synchro system 1 detects the operating current of the job initiation electric current of spot-welding gun 11, following magnetizing coil 8, last magnetizing coil 10 successively; for function composite by electromagnetic stirring provides synchronous control signal and for power-converting device 2 provides magnetizing coil overcurrent protection signal, realizes defencive function with the driving output of blocking power-converting device 2.
Described power-converting device 2 is used for electric power adjustment and conversion, obtains the exciting curent of different sizes, and exciting curent operating frequency and dutycycle are adjusted and controlled.
Described magnetizing coil 8 down and last magnetizing coil 10 are for having the solenoid solenoid of iron core, for function composite by electromagnetic stirring provides suitable alternating magnetic field.
Described spot-welding gun 11 is used to realize workpiece pressing and suitable spot-welded on electric current is provided.
As shown in figures 1 and 3, described power-converting device 2 comprises: global controller 3, AC/DC convertor 4 and excitatory control driver 6, wherein: global controller 3 is connected by synchro system 1 output signal line is corresponding with synchro system 1, the control input end of excitatory control driver 6 is connected with global controller 3 by the control signal wire that global controller 3 provides, the output of excitatory control driver 6 is connected with last magnetizing coil 10 with following magnetizing coil 8 respectively by driving switch pipe 24, following magnetizing coil 8 is connected with AC/DC convertor 4 main circuit outputs by lead with last magnetizing coil 10, the control input end of AC/DC convertor 4 is connected with global controller 3, and the main circuit input of AC/DC convertor 4 then directly is connected with AC network 5.
As shown in Figures 2 and 3, described AC/DC convertor 4 comprises: PWM Drive and Control Circuit 14 and rectifier bridge main circuit 15.Wherein: the input of PWM Drive and Control Circuit 14 is connected with global controller 3, output is connected with rectifier bridge main circuit 15, the input of rectifier bridge main circuit 15 is connected with AC network, and output is connected with the binding post 23 of following magnetizing coil 8 and last magnetizing coil 10.
As shown in Figure 3, described excitatory control driver 6 comprises: holding circuit unit 16, logic control element 17, protective emblem end 18, output control unit 19, PWM control module 20, delay unit 21.Wherein: the input of holding circuit unit 16 is connected with external protection input terminal; the protection output of holding circuit unit 16 is connected with protection output identification end 18 by switching tube Q; the input of logic control element 17 is connected with global controller 3 output control signal wires with the logic output signal line of holding circuit unit 16 respectively; the output signal line of logic control element 17 is connected with the input of PWM control module 20; the output signal line of PWM control module 20 is connected with output control unit 19; the input of delay unit 21 is connected with global controller 3 output control signal wires; the output of delay unit 21 is connected with output control unit 19, and the output of output control unit 19 is connected with last magnetizing coil 10 with following magnetizing coil 8 respectively after 24 series connection of power drive pipe.
Mash welder carries out work according to the spot welding parameter of setting in advance in the present embodiment.When basic spot-welding gun 11 starts, synchro system 1 in the present embodiment begins to detect the welding current in the welding gun, when detecting welding current, just start regularly, when reaching the stirring start-up time that configures in advance, synchro system 1 sends to power-converting device 2 and stirs enabled instruction, and power-converting device 2 is just started working.The course of work of power-converting device 2 is:
As shown in Figure 2, at first the AC/DC convertor 4 in the power-converting device 2 will exchange input and be transformed to direct current output Ud, Ud is as magnetic stirrer, it is the driving voltage source of magnetizing coil 8 and magnetizing coil 10, and Ud is adjustable continuously, can obtain the exciting current of different sizes like this, just obtain the operate outside magnetic field of different magnetic field intensity.The adjustment of Ud is undertaken by AC/DC convertor 4, and AC/DC convertor 4 adopts TI 2407A DSP to realize the PWM control of rectification.
As shown in Figure 3, after obtaining excitation voltage source Ud, by serving as that the control 6 pairs of magnetizing coils 8 of excitatory control driver of core and the power drive element 24 of magnetizing coil 10 are controlled with the DRV101 chip, obtain the square-wave excitation electric current of certain frequency and dutycycle, by changing power drive element 24, can also carry out the dilatation of drive current easily.Described excitatory control driver 6 can change and adjust the frequency and the dutycycle of exciting curent, and then obtains required alternating magnetic field.The adjustment in operate outside magnetic field both can be adjusted according to the difference of the required stirring action of different materials, can realize the real-time adjustment of excitatory intensity and excitatory alternative frequency and dutycycle as required in pinpoint welding procedure again.Described excitatory control driver 6 also includes the holding circuit part; be the holding circuit unit 16 among Fig. 3, to prevent that magnetizing coil from being burnt, the time-delay control module; be the time-delay control module 21 among Fig. 3, can satisfy the special requirement of different weldering electromagnetic agitation technologies.
Present embodiment method by experiment verifies that verification environment is: single phase ac mash welder (380V/120kW), basic spot welding system is the single phase ac mash welder.As shown in Figure 4, be the foregoing description test result, among the figure, CH1 is the control input signal of excitatory control driver 6, and CH2 is the magnetizing coil current signal.Present embodiment can increase the diameter of weldering nuclear in resistance spot welding welding stage of switching on, and eliminates composition segregation and solidification cracking, raising equiax crystal quantity, crystal grain thinning in the crystallisation by cooling stage.Owing in pinpoint welding procedure,, therefore,, can realize adopting less relatively welding current to produce the effect of onesize metal nugget, and improve the comprehensive mechanical performance of solder joint by present embodiment to the abundant stirring action of metal nugget.If be applied to car body welding producing line, not only can improve the bonding strength of body of a motor car, can also saves energy consumption.
Claims (5)
1. magnetic control resistance spot welding system; it is characterized in that; comprise: synchro system; power-converting device; following magnetizing coil; last magnetizing coil; spot-welding gun; first current sensor and second current sensor; wherein: the input of synchro system is connected with the resistance spot welding welding gun by first current sensor; be connected with last magnetizing coil with following magnetizing coil by second current sensor; the output of synchro system is connected with the input of power-converting device with transmission electromagnetic agitation synchronous control signal and magnetizing coil guard signal; following magnetizing coil and last magnetizing coil are fixedly set in respectively on the resistance spot welding welding gun, and the driving input of following magnetizing coil and last magnetizing coil and earth terminal are in parallel with the output of power-converting device respectively.
2. magnetic control resistance spot welding system according to claim 1, it is characterized in that, described power-converting device comprises: AC-DC converter, excitatory control driver and global controller, wherein: global controller is connected with synchro system is corresponding, the control input end of excitatory control driver is connected with global controller, excitatory control output end of driver and driving switch pipe are in series, the driving switch pipe is connected with last magnetizing coil with following magnetizing coil respectively, following magnetizing coil and last magnetizing coil all are connected to AC-DC converter main circuit output, the control input end of AC-DC converter is connected with global controller, and the main circuit input of AC-DC converter then directly is connected with AC network.
3. magnetic control resistance spot welding system according to claim 2, it is characterized in that, described AC-DC converter comprises: PWM Drive and Control Circuit and rectifier bridge main circuit, wherein: the input of PWM Drive and Control Circuit is connected with global controller, the output of PWM Drive and Control Circuit is connected with the rectifier bridge main circuit, the input of rectifier bridge main circuit is connected with AC network, and the output of rectifier bridge main circuit is connected with last magnetizing coil with following magnetizing coil respectively.
4. magnetic control resistance spot welding system according to claim 2; it is characterized in that; described excitatory control driver comprises: the holding circuit unit; logic control element; the protective emblem end; output control unit; PWM control module and delay unit; wherein: the input of holding circuit unit is connected with external protection input terminal; the protection output of holding circuit unit is connected with the protective emblem end; the input of logic control element is connected with global controller output control signal wire with the logic output signal line of holding circuit unit respectively; the output signal line of logic control element is connected with the input of PWM control module; the output signal line of PWM control module is connected with output control unit; the input of delay unit is connected with global controller output control signal wire; the output of delay unit is connected with output control unit, and the output of output control unit is connected with last magnetizing coil with following magnetizing coil respectively after described driving switch pipe series connection.
5. magnetic control resistance spot welding system according to claim 1 is characterized in that, described magnetizing coil down and last magnetizing coil are the solenoid solenoid that has iron core, for function composite by electromagnetic stirring provides suitable alternating magnetic field.
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Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102267002B (en) * | 2011-07-25 | 2013-07-10 | 上海交通大学 | Magnetic control resistance spot-welding method |
| CN102500901B (en) * | 2011-11-16 | 2014-04-16 | 上海交通大学 | Composite pulsation spot welding process and system |
| CN102513681A (en) * | 2011-12-15 | 2012-06-27 | 哈尔滨工业大学 | Workshop welding clamp resistance measurement method for adaptive control of dynamic resistance property |
| CN103170725A (en) * | 2013-04-09 | 2013-06-26 | 上海电机学院 | Electromagnetic friction stir spot welding device and method thereof |
| CN105636736B (en) * | 2014-01-31 | 2018-10-26 | 新日铁住金株式会社 | Tack-weld and spot welding method |
| CN105081545A (en) * | 2015-09-15 | 2015-11-25 | 上海交通大学 | Welding nuclear deviation control device and method for resistance spot welding |
| CN105081546B (en) * | 2015-09-15 | 2017-05-24 | 上海交通大学 | Position-adjustable resistance spot welding magnetic control device |
| CN109894729B (en) * | 2019-04-04 | 2020-11-06 | 成都理工大学 | Spot welder electrode holding rod automatic temperature control device without external power supply |
| CN112122758A (en) * | 2020-09-22 | 2020-12-25 | 哈尔滨工业大学（威海） | Ni element-regulated magnetic field-assisted resistance unit welding method for aluminum alloy and steel |
| CN114043055B (en) * | 2021-07-01 | 2024-01-09 | 北京工业大学 | Magnetic field array auxiliary resistance spot welding device and method for sheet metal material |
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