CN103506762A - Electric arc striking control system and method used for Plasma-MIG composite welding gun - Google Patents
Electric arc striking control system and method used for Plasma-MIG composite welding gun Download PDFInfo
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- CN103506762A CN103506762A CN201310470994.9A CN201310470994A CN103506762A CN 103506762 A CN103506762 A CN 103506762A CN 201310470994 A CN201310470994 A CN 201310470994A CN 103506762 A CN103506762 A CN 103506762A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
- B23K9/067—Starting the arc
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
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Abstract
The invention discloses an electric arc striking control system used for a Plasma-MIG composite welding gun. The electric arc striking control system comprises a PLC module, an interface circuit module and a program control module, wherein the PLC module is connected with the program control module, and the PLC module and the program control module are connected with the welding gun through the interface circuit module. Meanwhile, the invention further discloses an electric arc striking control method used for the Plasma-MIG composite welding gun. According to the electric arc striking control system and method used for the Plasma-MIG composite welding gun, output of an MIG welding machine and output of a plasma welding machine are controlled in the arc striking process, the output of the welding machines are controlled in a self-designed control mode, and the problem that under different welding parameters and different welding materials, Plasma-MIG composite electric arcs are difficult to strike or can not be struck is solved by calling the set arc striking control mode and a self-designed arc striking control program.
Description
Technical field
The present invention relates to Control Welding Process technical field, specifically a kind of electric arc striking control system and control method for the compound welding gun of Plasma-MIG.
Background technology
Adopting composite heat power supply is a kind of effective way that realizes high efficiency welding.Composite arc is not simple thermal source stack, but carries out the complementary integration process of excellent difference on the basis of every kind of thermal source feature of profound understanding and mechanism, can improve welding quality and efficiency simultaneously.
Plasma-MIG Combined Welding is the composite heat power supply welding procedure of carrying out system research both at home and abroad at present; this solder technology is the combination that plasma-arc and welding (MIG) connect method; uniqueness due to its welding gun structure; stem elongation is large; and the plasma arc central temperature after compression is very high, it is fast that welding wire melts speed.Plasma arc and MIG electric arc are coupled in space, it is inner that welding wire bottom, molten drop and MIG electric arc are also all enclosed in red-hot plasma arc, all there are great changes in molten drop is stressed, consumable electrode current trend etc., a series of features of this process have been produced thus, be that welding wire melting rate is fast, nothing is splashed, welding process is stable, pore is few, crystal grain is little, joint quality is high.Being applicable to the deep penetration welding of slab and the High Speed Welding of thin plate, is a kind of efficient welding procedure.
The crucial stable coupling that is to realize plasma arc and MIG electric arc of Plasma-MIG composite arc welding.Yet in composite arc Igniting pattern, conventionally employing is first ignited and is excited the mode of plasma-arc after MIG electric arc, under different welding parameters, the ionization atmosphere that MIG electric arc produces there are differences, existence cannot be set up the problem of plasma-arc, causes Plasma-MIG composite arc starting the arc difficulty or problem that cannot the starting the arc.
Summary of the invention
The present invention is directed to above shortcomings in prior art, a kind of electric arc striking control system and control method for the compound welding gun of Plasma-MIG is provided.
The present invention is achieved by the following technical solutions.
A kind of electric arc striking control system for the compound welding gun of Plasma-MIG, comprise PLC control module, interface module and program controling module, wherein, described PLC control module is connected with program controling module, and described PLC control module is connected with welding machine by interface module with program controling module
Described PLC control module comprises: CPU submodule, digital quantity I/O submodule, analog input/output sub-module and data communication module, described CPU submodule is control core, and respectively with the consumable electrode source of welding current of welding gun, the kinematic system of PLASMA ARC WELDING power supply and arc welding robot is connected, described digital quantity I/O submodule is connected with CPU submodule with analog input/output sub-module, for technological parameter, read and transmit, described CPU submodule, digital quantity I/O submodule is connected with interface circuit by data communication module with analog input/output sub-module, realize weld information exchange.
Described interface module comprises: source of welding current communication submodule, arc welding robot communication submodule and master controller communication submodule; Described source of welding current communication submodule connects the consumable electrode source of welding current and the PLASMA ARC WELDING power supply of welding gun; Described arc welding robot communication submodule connects arc welding robot and the positioner of welding gun; Described master controller communication submodule connects the display terminal of PLC control module and welding gun; Described source of welding current communication submodule, arc welding robot communication submodule and master controller communication submodule carry out data connection by RS-232 or CAN bus respectively, realize PLC control module the coordination of Plasma-MIG composite welding process is controlled.
Described program controling module comprises: starting the arc control program submodule and welding process monitoring facilities submodule, and the converting unit that described starting the arc control program submodule comprises starting the arc parameter and welding parameter, and be connected with PLC control module; Described welding process monitoring facilities submodule is connected with the arc welding robot of welding gun and the source of welding current of welding gun, realizes the coordination of the monitoring of welding process conditions at the arc and welding gun motion, the consumable electrode source of welding current and PLASMA ARC WELDING power supply.
The electric arc striking control system of the compound welding gun of Plasma-MIG and a control method for control method, comprise the following steps:
Described control program is specially: after welding starts, utilize short-circuit process to set up after MIG electric arc, Trig control signal is high level output simultaneously; PLC calls in starting the arc control model, and the controlled melting utmost point source of welding current and PLASMA ARC WELDING power supply output starting the arc parameter, under starting the arc control model, ignite when breakdown voltage is less than PLASMA ARC WELDING power supply floating voltage post plasma arc, electric arc combined success.
Described starting the arc control model is specially: in arc process, the output voltage of the consumable electrode source of welding current is linear increases, the electric current of the corresponding consumable electrode source of welding current adopts linear attenuation with it, cause burn-off rate to be greater than wire feed rate, make the electric arc of the consumable electrode source of welding current increase, reduce and puncture air required voltage gradually, increase electric arc combined success rate.
When described starting the arc control model adopts linear increasing, export consumable electrode source of welding current voltage and advance the speed as 10V/s-40V/s, described consumable electrode source of welding current current attenuation speed is 10A/s-50A/s.
Control system and control method thereof for the striking of Plasma-MIG composite arc provided by the invention, at Igniting pattern, output to MIG welding machine and plasma welding machine is controlled, adopt the control model of designed, designed to control welding machine output, by calling the starting the arc control program of starting the arc control model and the autonomous Design of setting, solved under various welding parameters and welding material, the difficult starting the arc of Plasma-MIG composite arc or problem that cannot the starting the arc, improved electric arc combined success rate.
Accompanying drawing explanation
By reading the detailed description of non-limiting example being done with reference to the following drawings, it is more obvious that other features, objects and advantages of the present invention will become:
Fig. 1 is the program flow diagram of control method of the present invention;
Fig. 2 is the welding machine output control model transfer principle figure of control system of the present invention;
Fig. 3 is the compound welding gun structural representation of Plasma-MIG;
In figure: 1 is ion-gas, 2 is protection gas, and 3 is plasma-arc, and 4 is MIG electric arc, and 5 is workpiece, and 6 is water-cooled nozzle, and 7 is annular plasma anode, and 8 is MIG ignition tip, gas centered by 9.
The specific embodiment
Below embodiments of the invention are elaborated: the present embodiment is implemented take technical solution of the present invention under prerequisite, has provided detailed embodiment and concrete operating process.It should be pointed out that to those skilled in the art, without departing from the inventive concept of the premise, can also make some distortion and improvement, these all belong to protection scope of the present invention.
The present embodiment provides a kind of electric arc striking control system for the compound welding gun of Plasma-MIG, comprise PLC control module, interface module and program controling module, wherein, described PLC control module is connected with program controling module, and described PLC control module is connected with welding machine by interface module with program controling module
Further, described PLC control module comprises: CPU submodule, digital quantity I/O submodule, analog input/output sub-module and data communication module, described CPU submodule is control core, and respectively with the consumable electrode source of welding current of welding gun, the kinematic system of PLASMA ARC WELDING power supply and arc welding robot is connected, described digital quantity I/O submodule is connected with CPU submodule with analog input/output sub-module, for technological parameter, read and transmit, described CPU submodule, digital quantity I/O submodule is connected with interface circuit by data communication module with analog input/output sub-module, realize weld information exchange.
Further, described interface module comprises: source of welding current communication submodule, arc welding robot communication submodule and master controller communication submodule; Described source of welding current communication submodule connects the consumable electrode source of welding current and the PLASMA ARC WELDING power supply of welding gun; Described arc welding robot communication submodule connects arc welding robot and the positioner of welding gun; Described master controller communication submodule connects the display terminal of PLC control module and welding gun; Described source of welding current communication submodule, arc welding robot communication submodule and master controller communication submodule carry out data connection by RS-232 or CAN bus respectively, realize PLC control module the coordination of Plasma-MIG composite welding process is controlled.
Further, described program controling module comprises: starting the arc control program submodule and welding process monitoring facilities submodule, and the converting unit that described starting the arc control program submodule comprises starting the arc parameter and welding parameter, and be connected with PLC control module; Described welding process monitoring facilities submodule is connected with the arc welding robot of welding gun and the source of welding current of welding gun, realizes the coordination of the monitoring of welding process conditions at the arc and welding gun motion, the consumable electrode source of welding current and PLASMA ARC WELDING power supply.
Be specially:
Described PLC control module is composite welding control system core, comprises following submodule: CPU module, digital quantity and analog input and output module and data communication module.Described CPU module is control program core, according to realizing the welding SECO source of welding current output state of setting and the coordination of robot system, realizes the smooth combustion of two electric arcs; Digital quantity and analog input and output module complete reading and transmitting of arc burning state parameter and default technological parameter in welding process, for CPU control program provides judgment basis; Data communication module realizes the information exchange of the source of welding current, welding robot and display terminal.
Described interface module comprises following submodule: source of welding current communication module, arc welding robot communication module, master controller communication module.Wherein source of welding current communication module connects respectively the consumable electrode source of welding current and PLASMA ARC WELDING power supply, realizes technological parameter output and control and state-detection in welding process; Arc welding robot communication module connects robot and positioner, completes the coordination of welding machine output state and welding gun motion; Master controller communication module connects the display terminals such as PLC controller and touch-screen, completes the monitoring of whole welding process.Each submodule of interface circuit connects by communication modes such as RS-232 or CAN buses.
Described program controling module comprises following submodule: starting the arc control program submodule and welding process monitoring facilities submodule, the conversion that described starting the arc control program submodule comprises starting the arc parameter and welding parameter; Described welding process monitoring facilities submodule is realized the coordination of the monitoring of welding process conditions at the arc and welding gun motion and the source of welding current.
The electric arc striking control system for the compound welding gun of Plasma-MIG that the present embodiment provides, its control method comprises the following steps:
Further, described control program is specially: after welding starts, utilize short-circuit process to set up after MIG electric arc, Trig control signal is high level output simultaneously; PLC calls in starting the arc control model, and the controlled melting utmost point source of welding current and PLASMA ARC WELDING power supply output starting the arc parameter, under starting the arc control model, ignite when breakdown voltage is less than PLASMA ARC WELDING power supply floating voltage post plasma arc, electric arc combined success.
Further, described starting the arc control model is specially: in arc process, the output voltage of the consumable electrode source of welding current is linear increases, the electric current of the corresponding consumable electrode source of welding current adopts linear attenuation with it, cause burn-off rate to be greater than wire feed rate, make the electric arc of the consumable electrode source of welding current increase, reduce and puncture air required voltage gradually, increase electric arc combined success rate.
Further, export consumable electrode source of welding current voltage and advance the speed as 10V/s-40V/s when described starting the arc control model adopts linear increasing, described consumable electrode source of welding current current attenuation speed is 10A/s-50A/s.
Be specially:
As shown in Figure 1, design Plasma-MIG composite arc starting the arc control program flow chart, first set the output parameter of MIG welding machine and plasma welding machine, secondly, the control program in initialize routine control module.
Utilize the short-circuit process of the consumable electrode source of welding current to set up MIG electric arc, then control the source of welding current and change output state, the length of MIG electric arc is increased, thereby reduce the breakdown voltage of plasma-arc, produce composite arc, then control welding output and realize the technological parameter setting, start welding.Consumable electrode electric current in welding process in cycle detection welding circuit and the output valve of arc-plasma current, and adjust in real time, realize composite welding.
The striking parameters such as the initial value that described starting the arc control model according to welding gun height setting MIG voltage, MIG electric current and wire feed rate was before welding starts and increment size, welding starts according to arc burning state, to control the source of welding current and export according to parameter preset afterwards, impel MIG arc length to increase, reduce the breakdown voltage of air-gap, thereby set up plasma-arc, realize recombination process, after electric arc combined success, export predefined technological parameter, start welding process.
After starting, welding sends welding wire to according to setting speed, gathering magnitude of voltage substitution control program between welding wire end and workpiece judges, if be now floating voltage scope, in loop being detected, occur after corresponding MIG electric current, triggering short circuit current Signal control signal is high level output.Decision signal using Signal signal as PLC control program, thus the starting the arc control model program shown in Fig. 2 is called in PLC control module, make MIG welding machine keep arcing voltage and electric current output as shown in Figure 2.The process striking that is short-circuited of MIG welding wire contact workpiece, MIG electric arc is shorter, cannot puncture air between annular copper-base and the MIG electric arc plasma arc that ignites.Take control program that MIG voltage is raise, thereby strengthen the breakdown voltage between the plasma utmost point and MIG electric arc.In the time of rising MIG voltage, reduce MIG electric current (reduction wire feed rate), make MIG electric arc and upwards climb because of the reduction of wire feed rate, thereby MIG electric arc height H reduces, air between annular copper-base (the Plasma utmost point) and MIG electric arc is breakdown, thereby ignite plasma arc, realize composite arc coupling.
After starting the arc program is called in welding machine by PLC control module, detect the plasma current of composite arc, at the output voltage of welding machine, reach after higher limit, if the plasma current I of feedback
p=0, illustrate that plasma-arc does not ignite, two electric arc combined failures, reinitialize control program, call starting the arc control model.If I now
p=1 explanation plasma arc successfully ignites, and sets up composite arc.Now, welding machine can feed back to triggering signal of PLC, thereby trigger PLC control module, calls welding parameter default in welding machine; When welding machine is exported according to the welding parameter of initial setting, PLC control module and robot communication, according to default speed of welding and the walking of teaching track, thereby order completes P l asma-MI G composite welding.
Physical principle design dual power supply output timing diagram according to arc through air, adopts and first sets up MIG electric arc, the rear two electric arcs of process implementation of setting up plasma-arc compound.As shown in Figure 3, by controlling the fired state of electric arc, regulate MIG electric arc and plasma anode surface distance H, before welding starts according to striking parameters such as the initial value of welding gun height setting MIG voltage, MIG electric current and wire feed rate and increment sizes, welding starts according to arc burning state, to control the source of welding current and export according to parameter preset afterwards, impel MIG arc length to increase, H reduces, thereby sets up plasma-arc.
Welding is set up MIG electric arc by short-circuit process after starting, and now MIG electric arc is shorter, and H is larger, punctures the output voltage that air required voltage is greater than PLASMA ARC WELDING power supply, so method punctures air between annular copper-base and the MIG electric arc plasma arc that ignites; Under starting the arc control model, the output voltage of MIG power supply adopts linear increase mode to export, and the burn-off rate of welding wire is increased; Control the source of welding current simultaneously and reduce MIG electric current in linear attenuation mode, thereby feed rate of welding wire is reduced, under both effects, MIG electric arc accelerates to climb, and the distance H between MIG electric arc and plasma anode reduces, and punctures air required voltage and reduces.
When puncturing air required voltage, be less than after the floating voltage of plasma power supply welding circuit Plasma Arc electric current I
pfor nonzero value, illustrate that plasma-arc ignites, realize coupling with the MIG electric arc having existed, form composite arc, can start welding process.
After the MIG voltage of linearity increase reaches preset upper limit value, compound failure is described, wire feeder is sent welding wire, repetition control program again to.
In described arc process, MIG voltage is 10-20V, and described MIG electric current is 80-280A, and MIG voltage is advanced the speed as 10V/s-40V/s, and described MIG current attenuation speed is 10A/s-50A/s.
Claims (8)
1. the electric arc striking control system for the compound welding gun of Plasma-MIG, it is characterized in that, comprise PLC control module, interface module and program controling module, wherein, described PLC control module is connected with program controling module, and described PLC control module is connected with welding gun by interface module with program controling module.
2. the electric arc striking control system for the compound welding gun of Plasma-MIG according to claim 1, it is characterized in that, described PLC control module comprises: CPU submodule, digital quantity I/O submodule, analog input/output sub-module and data communication module, described CPU submodule is control core, and respectively with the consumable electrode source of welding current of welding gun, the kinematic system of PLASMA ARC WELDING power supply and arc welding robot is connected, described digital quantity I/O submodule is connected with CPU submodule with analog input/output sub-module, for technological parameter, read and transmit, described CPU submodule, digital quantity I/O submodule is connected with interface circuit by data communication module with analog input/output sub-module, realize weld information exchange.
3. the electric arc striking control system for the compound welding gun of Plasma-MIG according to claim 1, is characterized in that, described interface module comprises: source of welding current communication submodule, arc welding robot communication submodule and master controller communication submodule; Described source of welding current communication submodule connects the consumable electrode source of welding current and the PLASMA ARC WELDING power supply of welding gun; Described arc welding robot communication submodule connects arc welding robot and the positioner of welding gun; Described master controller communication submodule connects the display terminal of PLC control module and welding gun; Described source of welding current communication submodule, arc welding robot communication submodule and master controller communication submodule carry out data connection by RS-232 or CAN bus respectively, realize PLC control module the coordination of Plasma-MIG composite welding process is controlled.
4. the electric arc striking control system for the compound welding gun of Plasma-MIG according to claim 1, it is characterized in that, described program controling module comprises: starting the arc control program submodule and welding process monitoring facilities submodule, the converting unit that described starting the arc control program submodule comprises starting the arc parameter and welding parameter, and be connected with PLC control module; Described welding process monitoring facilities submodule is connected with the arc welding robot of welding gun and the source of welding current of welding gun, realizes the coordination of the monitoring of welding process conditions at the arc and welding gun motion, the consumable electrode source of welding current and PLASMA ARC WELDING power supply.
5. a control method for the electric arc striking control system for the compound welding gun of Plasma-MIG described in any one in claim 1 to 4, is characterized in that, comprises the following steps:
Step 1, the welding parameter of the setting consumable electrode source of welding current and PLASMA ARC WELDING power supply welding process, the then control program in initialize routine control module;
Step 2, calls starting the arc control model after welding starts, and controls the combustion process of electric arc by changing the output state of the consumable electrode source of welding current and PLASMA ARC WELDING power supply, realizes the stable coupling of electric arc;
Step 3, electric arc proceeds to normal bond pattern after being coupled successfully, control welding robot according to the orbiting motion of setting, monitor the output state of the consumable electrode source of welding current and PLASMA ARC WELDING power supply in welding process, after current interruption phenomenon appears in composite arc, repeating step two.
6. the control method of the electric arc striking control system for the compound welding gun of Plasma-MIG according to claim 5, it is characterized in that, described control program is specially: after welding starts, utilize short-circuit process to set up after MIG electric arc, Trig control signal is high level output simultaneously; PLC calls in starting the arc control model, and the controlled melting utmost point source of welding current and PLASMA ARC WELDING power supply output starting the arc parameter, under starting the arc control model, ignite when breakdown voltage is less than PLASMA ARC WELDING power supply floating voltage post plasma arc, electric arc combined success.
7. the control method of the electric arc striking control system for the compound welding gun of Plasma-MIG according to claim 5, it is characterized in that, described starting the arc control model is specially: in arc process, the output voltage of the consumable electrode source of welding current is linear increases, the electric current of the corresponding consumable electrode source of welding current adopts linear attenuation with it, cause burn-off rate to be greater than wire feed rate, make the electric arc of the consumable electrode source of welding current increase, reduce and puncture air required voltage gradually, increase electric arc combined success rate.
8. the control method of the electric arc striking control system for the compound welding gun of Plasma-MIG according to claim 7, it is characterized in that, when described starting the arc control model adopts linear increasing, export consumable electrode source of welding current voltage and advance the speed as 10V/s-40V/s, described consumable electrode source of welding current current attenuation speed is 10A/s-50A/s.
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| CN104801866A (en) * | 2015-04-24 | 2015-07-29 | 哈尔滨工业大学 | Plasma and gas metal arc welding composite welding device with simple structure |
| CN107138831A (en) * | 2017-05-13 | 2017-09-08 | 上乘精密科技（苏州）有限公司 | A kind of argon arc welding board self-checking device control system |
| WO2018145543A1 (en) * | 2017-02-07 | 2018-08-16 | 王长春 | Dual heat source hybrid welding torch and welding method |
| CN108608126A (en) * | 2018-04-03 | 2018-10-02 | 哈尔滨工程大学 | Plasma shunts consumable electrode arc welding connection device and welding method |
| CN110026665A (en) * | 2019-05-07 | 2019-07-19 | 吴忠市黄河电焊机有限公司 | A kind of digital multifunctional power supply based on plasma arc technology |
| CN113695709A (en) * | 2021-09-06 | 2021-11-26 | 上海航天精密机械研究所 | Aerospace force-bearing structure arc fuse additive path planning method for designing tail stock |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104801866A (en) * | 2015-04-24 | 2015-07-29 | 哈尔滨工业大学 | Plasma and gas metal arc welding composite welding device with simple structure |
| WO2018145543A1 (en) * | 2017-02-07 | 2018-08-16 | 王长春 | Dual heat source hybrid welding torch and welding method |
| CN107138831A (en) * | 2017-05-13 | 2017-09-08 | 上乘精密科技（苏州）有限公司 | A kind of argon arc welding board self-checking device control system |
| CN107138831B (en) * | 2017-05-13 | 2019-06-11 | 上乘精密科技（苏州）有限公司 | A kind of argon arc welding board self-checking device control system |
| CN108608126A (en) * | 2018-04-03 | 2018-10-02 | 哈尔滨工程大学 | Plasma shunts consumable electrode arc welding connection device and welding method |
| CN108608126B (en) * | 2018-04-03 | 2021-01-05 | 哈尔滨工程大学 | Plasma shunting consumable electrode arc welding device and welding method |
| CN110026665A (en) * | 2019-05-07 | 2019-07-19 | 吴忠市黄河电焊机有限公司 | A kind of digital multifunctional power supply based on plasma arc technology |
| CN113695709A (en) * | 2021-09-06 | 2021-11-26 | 上海航天精密机械研究所 | Aerospace force-bearing structure arc fuse additive path planning method for designing tail stock |
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| CN103506762B (en) | 2015-09-30 |
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