CN103223541A - A protection control method of a welding source - Google Patents
A protection control method of a welding source Download PDFInfo
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- CN103223541A CN103223541A CN2013100110967A CN201310011096A CN103223541A CN 103223541 A CN103223541 A CN 103223541A CN 2013100110967 A CN2013100110967 A CN 2013100110967A CN 201310011096 A CN201310011096 A CN 201310011096A CN 103223541 A CN103223541 A CN 103223541A
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Abstract
The invention provides a protection control method of a welding source. Operation is performed through the protection and control of the usage rate of the welding source in order to prevent welding from being interrupted and production efficiency from reducing. The average value (Si) of the square of welding current in the past ten minutes is calculated moment by moment. If the average value (Si) reaches a predetermined reference value (St), welding current (Iw) is cut off. In the above protection control method of the welding source, when the average value (Si) reaches the reference value (St) after given time, alarm (Ar) generated by sound of over usage rate in the ** second is given. A welding operator receives the alarm and may stop welding before in the state of over usage rate by executing a countermeasure of keeping welding while changing welding conditions. Therefore, production efficiency can be stopped from reducing.
Description
Technical field
The present invention relates to be used for the protection control method of the source of welding current of the protection source of welding current when welding above specified utilization rate.
Background technology
At the source of welding current of the arc welding that is used for sacrificial electrode arc welding, non-consumable electrode arc welding, plasma-arc welding etc., stipulate specified utilization rate.For example the source of welding current at the relative rated welding current 350A of regulation is that establishing during 10 minutes was 1 cycle under the situation of 60% specified utilization rate, and the welding of 350A amounts to be carried out 6 minutes, and remaining 4 minutes needs are ended to weld.If welding current becomes 300A, then allow utilization rate=(350/300)
2* 60=82%.If welding current becomes 271A, allow that then utilization rate becomes 100%, can continuous welding.The source of welding current stipulates that the reason of specified utilization rate is, surpasses specified utilization rate then is heated if be arranged at semiconductor element, transformer and the reactor of the transistor, diode etc. of the inside of the source of welding current, can produce to burn or the reduction of durability.
In the prior art; in order to prevent to surpass utilization rate, the welding current in the past during 10 minutes square mean value surpassed rated welding current square with specified utilization rate long-pending the time (when source of welding current temperature inside rising value has surpassed temperature rising value when being used with specified utilization rate) cut off the energising of welding current and stop to weld to protect the source of welding current.Below, will prevent that the control that surpasses utilization rate is called protection control (reference example such as patent documentation 1 etc.).
Patent documentation 1:JP spy opens flat 11-259149 communique
Summary of the invention
The welding operator is under the situation that slabs such as reinforcing bar, bridge are welded, and the situation that feeding big electric current in long-time continuous ground welds is more.In this case, also can produce the state that surpasses specified utilization rate that is in.If surpass specified utilization rate, then as described above, interrupt welding forcibly in order to protect the source of welding current.The workpiece that welding is interrupted midway or discarded or weld once more from interruptions.All expend man-hour under any situation, production efficiency reduces.
At this, the objective of the invention is to, provide a kind of in arc welding, when having surpassed specified utilization rate, seek the protection of the source of welding current, and can suppress the protection control method of the source of welding current of production efficiency reduction.
In order to solve above-mentioned problem; the protection control method of the source of welding current of the invention of technical scheme 1; welding current in all the time calculating over during 10 minutes square mean value; when having reached predetermined reference value, this mean value cuts off the energising of welding current; the protection control method of this source of welding current is characterised in that; when being estimated as above-mentioned mean value and reaching the said reference value at the appointed time, give the alarm.
The protection control method of the source of welding current of the invention of technical scheme 2 is characterised in that, is assumed to the value that former state is kept the above-mentioned welding current under the current point in time, carries out above-mentioned inferring like this.
The protection control method of the source of welding current of the invention of technical scheme 3 is characterised in that, carries out above-mentioned alarm by sound.
According to the present invention, the welding current in being estimated as over during 10 minutes square mean value when reaching predetermined reference value at the appointed time, send the alarm that the sound etc. of " in back * * second be in above utilization rate " and so on is produced.Therefore the welding operator was predicted before being in above utilization rate, received this alarm on one side and continued to weld and carry out the change of welding condition, even workpiece welded the state that also can not be in above utilization rate till terminal.In addition, therefore the welding operator can successfully restart welding restarting to weld part interruption welding easily after making source of welding current termination.Therefore, can not cut off the energising of welding current forcibly and welding is interrupted suddenly owing to surpassing utilization rate.Therefore, can prevent discarded workpiece or the situation that when restarting to weld, expends more man-hour, thereby, can suppress production efficiency and reduce beginning to protect on the basis of the source of welding current from surpassing utilization rate.
Description of drawings
Fig. 1 is the sequential chart of the protection control method of the expression source of welding current relevant with embodiments of the present invention.
Fig. 2 is the block diagram of the source of welding current that is used to implement the protection control method of the source of welding current relevant with embodiments of the present invention.
The specific embodiment
Below, with reference to accompanying drawing embodiments of the present invention are described.
Below the protection controlling party ratio juris of the source of welding current relevant with embodiments of the present invention is described.Set rated welding current It (A) and specified utilization rate α (%).And, by following formula definition datum value St.
St=(It)
2α ... (1) formula
At this, a reference value St is the relevant value of source of welding current temperature inside rising value when having carried out welding with the specified utilization rate α energising of employing rated welding current It.Also above-mentioned α can be set at value than the little setting of specified utilization rate.
Setting constant is period T=600 second (10 minutes), detects welding current Iw (A), by following formula calculate over interior welding current during 10 minutes square mean value Si.
Si=(1/T) ∫ (Iw)
2Dt... (2) formula
Integration carried out during the past 600 seconds of distance current point in time (10 minutes).
At this, carry out the A/D conversion if welding electric current I w is sampled, and detect and be welding current digital value Id (n), then following formula and following formula equivalence by the sampling period Ts (second) of each regulation.
Si (n)=(D (n-k-1)+...+D (n))/k ... (3) formula
Wherein, D (n)=Id (n) Id (n), the data number of k for during 10 minutes, being sampled, k=600/Ts.Welding current in can calculating during 10 minutes by each sampling period Ts by this formula square mean value Si.
Sampling period Ts was set to for example 1 second.In this case, k=600.If sampling period Ts high speed till 100 μ s degree, then can correctly be detected welding current waveform.But, in this case, if data number k=600 ten thousand then becomes the googol order, therefore need to use the CPU of energy high-speed computation processing, thereby become high price.In order to prevent this situation, by welding current Iw being detected by low pass filter (cut-off frequency 1～10Hz degree) and carry out smoothing, thereby, sampling period Ts also can correctly carry out the computing of following formula even postponing 1 second degree.
Set duration T d (second).Be assumed to and infer mean value Ss by the following formula computing when lighting the value Id (n) that during this duration T d, keeps the welding current Iw under the current point in time from the current time.
Ss=(D (n-k+m)+...+D (n)+D (n) m)/k ... (4) formula
Wherein, the data number of m in duration T d, being sampled, m=Td/Ts.Duration T d is used to determine for example be set at 30～180 seconds degree from being in the constant above utilization rate after what seconds current point in time begins.Come computing to infer mean value Ss by following formula by each sampling period Ts.
The protection control method of the source of welding current that embodiments of the present invention are relevant is undertaken by following step.
Step 1: set rated welding current It and specified utilization rate α, come computing and set a reference value St by above-mentioned (1) formula.
Step 2: by each sampling period Ts welding electric current I w being sampled and detects is digital value.If the n time welding current digital value is Id (n).
Step 3: by above-mentioned (3) formula, by welding current interior during 10 minutes of each sampling period Ts computing the n time square mean value Si (n), (Si (n) 〉=St) when the n time mean value Si (n) has reached a reference value St, make energising shutoff signal As be changed to high level, cut off the energising of welding current Iw and stop welding.When being in high level, energising shutoff signal As do not carry out the processing of step 4.
Step 4: by above-mentioned (4) formula by each sampling period Ts computing the n time infer mean value Ss (n), (Ss (n) 〉=St) makes alarm signal Ar be changed to high level and gives the alarm when this n time infers mean value Ss (n) and reached a reference value St.Alarm is undertaken by the sound of " back 60 seconds surpass utilization rate " etc., while discern so that the welding operator can weld.Became above-mentioned duration T d in 60 seconds.In addition, the handle portion of welding torch is vibrated gives the alarm.Also can be also with the abnormal show lamp is lighted.Even alarm signal Ar be changed to high level also only give the alarm and continue the welding.
Fig. 1 is the sequential chart of the protection control method of the expression source of welding current relevant with embodiments of the present invention.This figure (A) expression welding current Iw, the welding current of this figure (B) expression in during 10 minutes square mean value Si, this figure (C) expression alarm signal Ar, this figure (D) expression energising shutoff signal As.This figure is the situation that becomes Ss 〉=St in above-mentioned step 4.Below, describe with reference to this figure.
Such shown in this figure (A), the weld period of switching on for welding current I1 during moment t1～t2, constantly t2～t3 during be the cold termination of welding current Iw during, the weld period of switching on for welding current I1 during moment t3～t4, constantly t4～t5 during for during ending, constantly t5～t6 during be the fixed weld period that gives of welding current I2 energising, constantly t6～t7 during for during the termination.At this, I1＜I2.If be the sacrificial electrode arc welding, then the welding current value changes along with the feed speed of welding wire, if be the non-consumable electrode arc welding, then the welding current value changes by constant current control.During ending, each weld period and each be respectively identical time span.And, during the aggregate values during weld period and the termination became 10 minutes.
Like that, during before the moment t5, welding current I1 switches on identical utilization rate, so mean value Si becomes fixed value Si1 shown in this figure (B).Carry out the processing of above-mentioned step 3, Si1 becomes Si1=I1I1 (utilization rate) according to above-mentioned (2) formula or (3) formula.This Si1 is less than a reference value St shown in the dotted line.Therefore, like that, energising shutoff signal As is in low level shown in this figure (D).In addition, carry out the processing of above-mentioned step 4, constantly before the t5 during, the mean value Ss that infers by above-mentioned (4) formula computing is in state less than a reference value St.Therefore, like that, alarm signal Ar is in low level shown in this figure (C).
Like that, because variation has taken place the welding current setting value, therefore the welding current since moment t5 is increased to I2 from I1 shown in this figure (A).Therefore, like that, mean value Si increases gradually since moment t5 shown in this figure (B).And, the moment t51 before the moment t6 that welding finishes, mean value Si is in the state less than a reference value St shown in the dotted line.On the other hand, at moment t51, inferring mean value Ss becomes more than a reference value St, and therefore such shown in this figure (C), alarm signal Ar is changed to the short time high level, sends the audible alarm of " being in above utilization rate at back 60 seconds " and so on.At this, illustration the situation of duration T d=60.
Can the welding operator receive this alarm and judge and weld till terminal in duration T d (second), if possible then do not change welding condition and continue to weld.Be judged as can not the time, embodiment countermeasure as described below on the basis of having considered welding quality.
1) quicken the speed (speed of welding) of mobile welding torch, and can be to weld till terminal less than the time of duration T d.
2) by reducing the value of welding current Iw, prolong the time till becoming Si 〉=St, and can weld till terminal.
3) restarting to weld part interruption welding till having passed through duration T d easily.And, after the source of welding current is ended, welding is successfully begun once more from this.
This figure is that the welding operator receives alarm, is judged as at duration T d can not weld till terminal with interior, has implemented above-mentioned 1 at moment t51) shown in the situation of countermeasure of acceleration speed of welding.Therefore, shown in this figure (A), finishing the more forward welding of moment t52 end till terminal of predetermined instant t6 than original welding, so the energising of welding current I2 finishes at moment t52.Being the time shorter than duration T d during moment t51～t52, is the time longer than duration T d during moment t51～t6.Like that, mean value Si increases till moment t52 from moment t5 shown in this figure (B), reduces till moment t6 after this, keeps this value in during the termination of moment t6～t7.Like that, energising shutoff signal As is in low level state during all shown in this figure (D).Even if receiving alarm at moment t51, also keep welding current I2 and under the situation about not proceeding to weld with not quickening speed of welding, moment t52 and constantly between the t6 energising shutoff signal As be changed to high level, then the energising of welding current Iw is cut off.
Fig. 2 is the block diagram of the source of welding current that is used to implement the protection control method of the relevant source of welding current of above-mentioned embodiments of the present invention.This figure is that arc-welding process is the situation of sacrificial electrode arc-welding process.Below, with reference to this figure each module is described.
Electric power main circuit PM imports the source power supply (diagram is omitted) of 3 phase 200V etc., carries out the output control of inverter control etc. and output output voltage E and welding current Iw according to driving signal Dv described later.This electric power main circuit PM omits diagram, but possess to source power supply carry out No. 1 rectification circuit of rectification, to being carried out level and smooth capacitor by the direct current with pulsation (ripple) of rectification, being driven and smoothed DC converting is the inverter circuit of high-frequency ac, is to be suitable for the high frequency transformer of the magnitude of voltage of arc welding and to carried out No. 2 rectification circuits of rectification by the high-frequency ac of step-down with the high-frequency ac step-down by above-mentioned driving signal Dv.Direct current reactor DCL carries out smoothly above-mentioned output voltage E.Welding wire 1 is because the rotation of the feed rolls 5 that is coupled with feed motor WM and by being fed in the welding torch 4, and mother metal 2 between produce electric arc 3.Welding torch 4 is controlled by the welding operator.Between welding wire 1 and mother metal 2, apply weldingvoltage Vw, energising welding current Iw.
Torch switch ON is set in the welding torch 4, becomes the welding of high level commencing signal On if be in connection then export when the welding operator begins to weld.
A reference value initialization circuit SR is input to above-mentioned (1) formula and output reference value setting signal Str with predetermined rated welding current value It and predetermined specified utilization rate α.This circuit carries out the processing of above-mentioned step 1.
Welding current testing circuit IWD detects above-mentioned welding current Iw and exports welding current detection signal Iwd by low pass filter.Electric current A/D translation circuit ID carries out the A/D conversion by each predetermined sampling period Ts to this welding current detection signal Iwd, and output welding current data signal Id.This circuit carries out the processing of above-mentioned step 2.
Mean value operating circuit SIC with above-mentioned welding current data signal Id as input, by each above-mentioned sampling period Ts by above-mentioned (3) formula come the welding current of computing in during 10 minutes square mean value, and export as mean value computing signal Sic.Energising cut off judging circuit AS with this mean value computing signal Sic and above-mentioned a reference value setting signal Str as input, (time point of Sic 〉=Str), output becomes the energising shutoff signal As of high level to have reached the value of a reference value setting signal Str in the value of mean value computing signal Sic.These circuit carry out the processing of the first half of above-mentioned step 3.
Duration initialization circuit TDR output predetermined time duration setting signal Tdr.Infer mean value operating circuit SSC with this duration setting signal Tdr and above-mentioned welding current data signal Id as input, infer mean value by each above-mentioned sampling period Ts by above-mentioned (4) formula computing, and as inferring mean value computing signal Ssc output.Alarm judging circuit AR infers mean value computing signal Ssc and above-mentioned a reference value setting signal Str as input with this, two values is compared, at the alarm signal Ar of time point output the becoming short time high level that is changed to Ssc 〉=Str.Circuit for alarming KH as input, if alarm signal Ar is changed to high level, then sends this alarm signal Ar the alarm that sound produced of " in back * * second be in above utilization rate " and so on.This circuit for alarming KH is set in the source of welding current, wire feed unit (omitting diagram), the welding torch 4 etc.In addition, as described above, also can give the alarm by vibration, abnormal show lamp etc.These circuit carry out the processing of above-mentioned step 4.
The predetermined output voltage setting signal Er of output voltage initialization circuit ER output.Output voltage detecting circuit ED detects the primary side of high frequency transformer is exported the pulse-like voltage that has carried out rectification is output voltage E (by the voltage before the direct current reactor DCL), this detected value is fed low pass filter (cut-off frequency 1～10Hz degree), and export as voltage sense signal Ed.Error amplifying circuit EA amplifies the error between above-mentioned output voltage setting signal Er and this voltage sense signal Ed, and output error amplifying signal Ea.Become the power supply of constant-voltage characteristic by this error amplifying circuit EA.Drive circuit DV with this error amplification signal Ea, above-mentioned welding commencing signal On and above-mentioned energising shutoff signal As input, On is a high level at the welding commencing signal, and when being low level, energising shutoff signal As carries out pulse width modulation control according to error amplification signal Ea, output is used to drive the driving signal Dv of the inverter circuit in the above-mentioned electric power main circuit PM based on this result, is low level or energising shutoff signal As output drive signal Dv not when being high level at welding commencing signal On.This circuit carries out the processing of Hou half part of above-mentioned step 3.By this circuit, if energising shutoff signal As is in high level, then the output owing to the source of welding current is stopped, so the energising of welding current is cut off.
The predetermined feed speed setting signal Fr of feed speed initialization circuit FR output.Feeding control circuit FC with this feed speed setting signal Fr, above-mentioned welding commencing signal On and above-mentioned energising shutoff signal As input, at welding commencing signal On is that high level and energising shutoff signal As will be used for during for low level outputing to above-mentioned feed motor WM with the feeding control signal Fc of the feed speed feeding welding wire 1 of the value that is equivalent to this feed speed setting signal Fr, welding commencing signal On be low level or energising shutoff signal As during for high level output be used for the feeding control signal Fc of feed-disabling.This circuit carries out the processing of the latter half of above-mentioned step 3.By this circuit, when energising shutoff signal As is high level, stop the feeding of welding wire 1.
According to above-mentioned embodiment, welding current in being estimated as over during 10 minutes square mean value when after predetermined time duration, reaching predetermined reference value, send the alarm that the sound etc. of " back * * second be in above utilization rate " and so on is produced.Therefore the welding operator was predicted before being in above utilization rate, received this alarm on one side and continued to weld and carry out the change of welding condition, even workpiece welded the state that also can not can till terminal be in above utilization rate.In addition, therefore the welding operator can successfully begin welding once more restarting to weld part interruption welding easily after making source of welding current termination.Therefore, can not cut off the energising of welding current forcibly and welding is interrupted suddenly owing to surpassing utilization rate.Therefore, can prevent discarded workpiece or the situation that when restarting to weld, expends more man-hour, thereby, can suppress production efficiency and reduce beginning to protect on the basis of the source of welding current from surpassing utilization rate.
In the above-described embodiment, be that the situation of sacrificial electrode arc welding is illustrated to arc welding, but the present invention also can be applicable in non-consumable electrode arc welding, the plasma-arc welding etc.
Symbol description:
1 welding wire
2 mother metals
3 electric arcs
4 welding torches
5 feed rolls
AR alarm judging circuit
The Ar alarm signal
Judging circuit is cut off in the AS energising
The As shutoff signal of switching on
The DCL direct current reactor
The DV drive circuit
Dv drives signal
The E output voltage
The EA error amplifying circuit
The Ea error amplification signal
The ED output voltage detecting circuit
The Ed voltage sense signal
ER output voltage initialization circuit
Er output voltage setting signal
FC feeding control circuit
Fc feeding control signal
FR feed speed initialization circuit
Fr feed speed setting signal
I1, I2 welding current
ID electric current A/D translation circuit
Id welding current numeral (value/signal)
The It rated welding current
The Iw welding current
IWD welding current testing circuit
Iwd welding current detection signal
K, m data number
The KH circuit for alarming
ON torch switch
On welds commencing signal
The PM electric power main circuit
Si (welding current in during past 10 minutes square) mean value
The SIC mean value operating circuit
Sic mean value computing signal
SR a reference value initialization circuit
Ss infers mean value
SSC infers mean value operating circuit
Ssc infers mean value computing signal
The St a reference value
Str a reference value setting signal
The T cycle
The Td duration
TDR duration initialization circuit
Tdr duration setting signal
The Ts sampling period
The Vw weldingvoltage
The WM feed motor
The specified utilization rate of α
Claims (3)
1. the protection control method of a source of welding current; welding current in all the time calculating over during 10 minutes square mean value; cut off the energising of welding current when this mean value has reached predetermined reference value, the protection control method of this source of welding current is characterised in that
When being estimated as above-mentioned mean value and reaching the said reference value at the appointed time, give the alarm.
2. the protection control method of the source of welding current according to claim 1 is characterized in that,
Be assumed to former state and keep the value of the above-mentioned welding current under the current point in time, carry out above-mentioned inferring like this.
3. the protection control method of the source of welding current according to claim 1 and 2 is characterized in that,
Carry out above-mentioned alarm by sound.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2012012547A JP2013151000A (en) | 2012-01-25 | 2012-01-25 | Protection control method for welding power source |
| JP2012-012547 | 2012-01-25 |
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| Publication Number | Publication Date |
|---|---|
| CN103223541A true CN103223541A (en) | 2013-07-31 |
| CN103223541B CN103223541B (en) | 2016-04-27 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201310011096.7A Active CN103223541B (en) | 2012-01-25 | 2013-01-11 | The protecting control method of the source of welding current |
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| Country | Link |
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| JP (1) | JP2013151000A (en) |
| CN (1) | CN103223541B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105682844A (en) * | 2013-12-25 | 2016-06-15 | 株式会社达谊恒 | Arc welding control method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10385967B2 (en) | 2015-11-09 | 2019-08-20 | GM Global Technology Operations LLC | Method and apparatus to control a continuously variable transmission |
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| JP2745166B2 (en) * | 1991-05-24 | 1998-04-28 | 三菱電機株式会社 | Drive control device for servo amplifier and servo motor |
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| CN86103901A (en) * | 1985-06-10 | 1986-12-10 | 通用电气公司 | The root-mean-square value counting circuit of digital circuit cutout |
| JP2745166B2 (en) * | 1991-05-24 | 1998-04-28 | 三菱電機株式会社 | Drive control device for servo amplifier and servo motor |
| JPH0993795A (en) * | 1995-09-21 | 1997-04-04 | Fanuc Ltd | Overload supervising of servo motor |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105682844B (en) * | 2013-12-25 | 2019-06-07 | 株式会社达谊恒 | Arc welding control method |
Also Published As
| Publication number | Publication date |
|---|---|
| CN103223541B (en) | 2016-04-27 |
| JP2013151000A (en) | 2013-08-08 |
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