CN111001908B - Consumable electrode pulse welding method, consumable electrode pulse welding system and consumable electrode pulse welding machine - Google Patents
Consumable electrode pulse welding method, consumable electrode pulse welding system and consumable electrode pulse welding machine Download PDFInfo
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- CN111001908B CN111001908B CN201911368700.5A CN201911368700A CN111001908B CN 111001908 B CN111001908 B CN 111001908B CN 201911368700 A CN201911368700 A CN 201911368700A CN 111001908 B CN111001908 B CN 111001908B
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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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
- B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
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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
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Abstract
The present disclosure relates to a consumable electrode pulse welding method, a pulse welding system and a welding machine, wherein the consumable electrode pulse welding method comprises: detecting whether the short circuit of the current pulse period is over or reaches a preset period or not; if yes, judging the short circuit is abnormal, and detecting whether the short circuit time exceeds a preset time; if so, compensating the peak time and the falling slope time of the next two pulse periods according to the peak time and the falling slope time of the current pulse period and the short-circuit time so as to increase the arc length of the next two pulse periods. The consumable electrode pulse welding method provided by the disclosure can reduce the generation of large-particle splashing.
Description
Technical Field
The disclosure relates to the technical field of welding, in particular to a consumable electrode pulse welding method, a consumable electrode pulse welding system and a welding machine.
Background
With the continuous improvement of scientific technology, the requirements of people on welding quality are also continuously improved. Most of the carbon steel workpieces are welded in the prior art by adopting carbon dioxide as shielding gas and adopting a short-circuit welding mode for processing, so that although the cost is low, the welding spatters are large and the forming is poor. With the development of welding technology, pulse welding appears, and has the characteristics of large welding heat input, small welding spatter and attractive weld forming, and most production enterprises gradually switch the welding process into pulse welding in order to pursue higher product added value.
However, when a welding wire having a high viscosity is used in the pulse welding process, the drop of the welding wire is not properly removed, which causes a large amount of welding spatter, and large particles of welding spatter adhere to the surface of the weld and the adjacent base material region, which causes poor weld formation and poor appearance, and even requires post-weld cleaning and polishing, which is time-consuming and labor-consuming and increases welding costs.
It is to be noted that the information disclosed in the above background section is only for enhancement of understanding of the background of the present disclosure, and thus may include information that does not constitute prior art known to those of ordinary skill in the art.
Disclosure of Invention
The purpose of the present disclosure is to provide a consumable electrode pulse welding method, a pulse welding system, and a welding machine, which can reduce the generation of large-particle spatters.
According to an aspect of the present disclosure, there is provided a consumable electrode pulse welding method including:
detecting whether the short circuit of the current pulse period is over or reaches a preset period or not;
if yes, judging the short circuit is abnormal, and detecting whether the short circuit time exceeds a preset time;
if so, compensating the peak time and the falling slope time of the next two pulse periods according to the peak time and the falling slope time of the current pulse period and the short-circuit time so as to increase the arc length of the next two pulse periods.
In an exemplary embodiment of the present disclosure, compensating for a peak time and a falling slope time of next two pulse periods according to the peak time and the falling slope time of a current pulse period and a short circuit time includes:
t2＝T2+K1·T0+C1
t3＝T3+K2·T0+C2
t21＝t2+C3
t31＝T3
wherein, T0For short-circuit time, T2For the peak time of the current pulse period, T3Lower of the current pulse periodTime of falling slope, t2Is the peak time, t, of the next pulse period3Is the falling slope time, t, of the next pulse period21Is the peak time of the next pulse period, t31Is the falling slope time of the next pulse period, K1、K2、C1、C2And C3Is a preset coefficient.
In an exemplary embodiment of the present disclosure, the pulse welding method further includes:
and if the short-circuit time does not exceed the preset time, compensating the peak time of the next pulse period according to the peak time of the current pulse period and the short-circuit time so as to increase the arc length of the next pulse period.
In an exemplary embodiment of the present disclosure, compensating for a peak time of a next pulse period according to a peak time of a current pulse period and a short circuit time includes:
t2＝T2+K1·T0+C1
wherein, T0For short-circuit time, T2Is the peak time, t, of the current pulse period2Is the peak time of the next pulse period, K1、C1Is a preset coefficient.
In an exemplary embodiment of the present disclosure, the K1The range of (A) is-50 to 50, and K2The range of (a) is-50 to 50.
In an exemplary embodiment of the present disclosure, the C1In the range of-100 to 100, C2In the range of-100 to 100, C3The range of (A) is-100 to 100.
In an exemplary embodiment of the present disclosure, the pulse welding method further includes:
and if the short circuit does not reach the preset period when the current pulse period is detected to be short-circuited, judging that the short circuit is normal short circuit.
In an exemplary embodiment of the present disclosure, the preset time ranges from 0.1ms to 0.5 ms.
According to another aspect of the present disclosure, there is also provided a consumable electrode pulse welding system, including: storage circuitry, processing circuitry and executable instructions stored in the storage circuitry and executable in the processing circuitry, the processing circuitry upon executing the executable instructions implements a consumable electrode pulse welding method as described above.
According to yet another aspect of the present disclosure, there is also provided a welder including the consumable electrode pulse welding system described above.
The consumable electrode pulse welding method provided by the disclosure has the advantages that when the short circuit is detected to occur at the end of the pulse basic value and the short circuit time T is short-circuited0When the preset time T is exceeded, the parameters of the next two output pulses can be adjusted according to the peak time and the falling slope time of the current pulse period, so that the pulse energy of the next two periods is increased, the molten drop has enough arc space transition, the generation of large-particle splashing is reduced, and the influence on the quality of a welding seam is avoided.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and together with the description, serve to explain the principles of the disclosure. It is to be understood that the drawings in the following description are merely exemplary of the disclosure, and that other drawings may be derived from those drawings by one of ordinary skill in the art without the exercise of inventive faculty.
FIG. 1 is a flow chart of a consumable electrode pulse welding method provided by one embodiment of the present disclosure;
FIG. 2 is a schematic diagram of voltage versus time for a pulse waveform suitable for droplet shedding timing provided by the present disclosure;
FIG. 3 is a schematic diagram of the current versus time variation of a pulse waveform suitable for droplet shedding timing provided by the present disclosure;
FIG. 4 is a graphical illustration of the voltage versus time of a conventional pulse waveform with a short circuit occurring at the end of the pulse base provided by the present disclosure;
FIG. 5 is a graphical illustration of the current versus time for a conventional pulse shape with a short circuit occurring at the end of the pulse base provided by the present disclosure;
FIG. 6 is a schematic diagram of voltage variation with time of a pulse waveform generating an abnormal short circuit and having a time exceeding T according to an embodiment of the present disclosure;
FIG. 7 is a schematic diagram of the variation of the current of the pulse waveform over time, which generates an abnormal short circuit and exceeds T in time according to an embodiment of the present disclosure;
FIG. 8 is a schematic diagram of voltage variation with time of a pulse waveform generating an abnormal short circuit and having a time not exceeding T according to an embodiment of the present disclosure;
fig. 9 is a schematic diagram of the current variation with time of the pulse waveform generating the abnormal short circuit and the time not exceeding T according to an embodiment of the disclosure.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the disclosure. One skilled in the relevant art will recognize, however, that the subject matter of the present disclosure can be practiced without one or more of the specific details, or with other methods, steps, etc. In other instances, well-known technical solutions have not been shown or described in detail to avoid obscuring aspects of the present disclosure.
The terms "a," "an," "the," and "said" are used to indicate the presence of one or more elements/components/etc.; the terms "comprising" and "having" are intended to be inclusive and mean that there may be additional elements/components/etc. other than the listed elements/components/etc.
The applicant finds that in the pulse actual welding process, ideal pulse droplet falling is a pulse-droplet transition mode, the droplet falling time is at the corner of the falling edge of a pulse waveform, as shown in fig. 2 and 3, the droplet falling time is proper, the electric arc is stable, the splashing is low, and the welding seam quality is excellent.
However, in actual welding production, due to the fact that the viscosity of the welding wire is high, or due to reasons such as swinging of a welding gun, unsmooth wire feeding and the like, molten drops fall off improperly, electric arcs are unstable, splashing is increased, and welding quality is affected. If the molten drop falls later, the molten drop occurs at the end of the basic value, the electric arc is short, the molten drop does not have enough space to fall off, and if a corresponding treatment mode is not available, large particles are easy to splash. Thereby affecting the quality of the weld.
Fig. 4 and 5 are schematic diagrams illustrating conventional waveform processing when a short circuit occurs at the end of a basic value, wherein when the short circuit occurs at the end of the basic value, the short circuit continues until the rising edge of a pulse, and when the short circuit is finished, the initial current value of an arc is large, and the force of blasting is also large, so that large particles are splashed, and the quality of a welding seam is seriously affected.
The present embodiment first discloses a consumable electrode pulse welding method, as shown in fig. 1, the pulse welding method including:
step S100, detecting whether the short circuit of the current pulse period exceeds or reaches a preset period or not;
step S200, if yes, judging that the short circuit is abnormal, and detecting whether the short circuit time exceeds a preset time;
and step S300, if so, compensating the peak time and the falling slope time of the next two pulse periods according to the peak time and the falling slope time of the current pulse period and the short-circuit time so as to increase the arc length of the next two pulse periods.
The pulse welding method provided by the disclosure is characterized in that when the short circuit is detected to occur at the end of the pulse basic value and the short circuit time T is short-circuited0When the preset time T is exceeded, the parameters of the next two output pulses are calculated according to the peak time and the falling slope time of the current pulse periodThe pulse energy of the next two periods is increased, the molten drop has enough arc space transition, the generation of large-particle splashing is reduced, and the quality of a welding seam is prevented from being influenced.
Next, each step of the consumable electrode pulse welding method in the present exemplary embodiment will be further described.
In step S100, it is detected whether a predetermined period is exceeded or reached at the end of the short circuit of the current pulse period.
Specifically, a welding gun switch is turned on, when a welding time sequence enters a welding state, a system reads pulse parameters in the welding process, updates variable parameters and monitors the occurrence of short circuit in real time, and when the feedback voltage of the current pulse period is detected to be lower than a short circuit judgment threshold value, the short circuit is considered to occur; on the contrary, when the feedback voltage of the current pulse period is detected to be larger than the short circuit judgment threshold value, the short circuit is not considered to occur.
When the short circuit is considered to occur, detecting that the short circuit of the current pulse period exceeds or reaches a preset period when the short circuit of the current pulse period is ended, namely the short circuit generated in the current pulse period lasts to the next pulse period, and judging that the short circuit generated in the current pulse period is at the end stage of the pulse base value stage; and if the short circuit generated in the current pulse period does not continue to the next pulse period, judging that the short circuit generated in the current pulse period is not at the end of the pulse base value stage.
In step S200, if yes, it is determined as an abnormal short, and it is detected whether the short time exceeds a preset time.
Specifically, if the short circuit generated in the current pulse period lasts until the next pulse period, it is determined whether the short circuit time exceeds a preset time T. Wherein the preset time T is 0.1 ms-0.5 ms.
If the end of the short circuit of the current pulse period is detected and the preset period is not reached, namely the current pulse period is considered not to generate the short circuit at the end of the pulse base value stage, and the short circuit time is not detected if the current pulse period is judged to be the normal short circuit.
In step S300, if yes, it is determined as an abnormal short circuit, and the peak time and the falling slope time of the next two pulse periods are compensated according to the peak time and the falling slope time of the current pulse period, so that the arc length of the next two pulse periods is increased.
Specifically, as shown in fig. 6 and 7, if the short circuit generated in the current pulse period continues to the next pulse period and the short circuit time exceeds the preset time T, the peak time and the falling slope time of the next two pulse periods are compensated according to the peak time and the falling slope time of the current pulse period, and the compensation calculation is performed according to the following formula:
t2＝T2+K1·T0+C1
t3＝T3+K2·T0+C2
t21＝t2+C3
t31＝T3
wherein, T2For the peak time of the current pulse period, T3Falling slope time of current pulse period, t2Is the peak time, t, of the next pulse period3Is the falling slope time, t, of the next pulse period21Is the peak time of the next pulse period, t31Is the falling slope time of the next pulse period, K1、K2、C1、C2And C3Is a preset coefficient.
Wherein, t2Size and T0Is positively correlated with the magnitude of (a), t3Size and T0Is inversely related.
Wherein, K1In the range of-50 to 50, K2In the range of-50 to 50, C1In the range of-100 to 100, C2In the range of-100 to 100, C3The range of (A) is-100 to 100. Can be determined by welding parent metal, welding material and gas pair coefficient K1、K2、C1、C2And C3Is adjusted.
As shown in fig. 8 and 9, if the short-circuit time does not exceed the preset time, the peak time of the next pulse period is compensated according to the peak time of the current pulse period and the short-circuit time, so that the arc length of the next pulse period is increased, and compensation calculation is performed according to the following formula:
t2＝T2+K1·T0+C1
it should be noted that although in the above detailed description several modules or units of the device for action execution are mentioned, such a division is not mandatory. Indeed, the features and functionality of two or more modules or units described above may be embodied in one module or unit, according to embodiments of the present disclosure. Conversely, the features and functions of one module or unit described above may be further divided into embodiments by a plurality of modules or units.
Moreover, although the steps of the methods of the present disclosure are depicted in the drawings in a particular order, this does not require or imply that the steps must be performed in this particular order, or that all of the depicted steps must be performed, to achieve desirable results. Additionally or alternatively, certain steps may be omitted, multiple steps combined into one step execution, and/or one step broken down into multiple step executions, etc.
The present disclosure also provides a consumable electrode pulse welding system, comprising: the pulse welding system comprises a storage circuit, a processing circuit and executable instructions stored in the storage circuit and operable in the processing circuit, wherein the processing circuit executes the executable instructions to implement the pulse welding method.
Through the above description of the embodiments, those skilled in the art will readily understand that the exemplary embodiments described herein may be implemented by software, or by software in combination with necessary hardware. Therefore, the technical solution according to the embodiments of the present disclosure may be embodied in the form of a software product, which may be stored in a non-volatile storage medium (which may be a CD-ROM, a usb disk, a removable hard disk, etc.) or on a network, and includes several instructions to enable a computing device (which may be a personal computer, a server, a mobile terminal, or a network device, etc.) to execute the method according to the embodiments of the present disclosure.
The present disclosure also provides a welder comprising the consumable electrode pulse welding system described above. For example, the welder may be a robotic welder.
Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. This application is intended to cover any variations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.
Claims (8)
1. A method of pulse welding a consumable electrode, comprising:
detecting whether the short circuit of the current pulse period is over or reaches a preset period or not;
if yes, judging the short circuit is abnormal, and detecting whether the short circuit time exceeds a preset time;
if so, compensating the peak time and the falling slope time of the next two pulse periods according to the peak time and the falling slope time of the current pulse period and the short-circuit time so as to increase the arc length of the next two pulse periods;
if the short circuit time does not exceed the preset time, compensating the peak time of the next pulse period according to the peak time of the current pulse period and the short circuit time so as to increase the arc length of the next pulse period;
and if the short circuit does not reach the preset period when the current pulse period is detected to be short-circuited, judging that the short circuit is normal short circuit.
2. The consumable electrode pulse welding method of claim 1, wherein compensating for the peak time and the falling slope time of the next two pulse periods based on the peak time and the falling slope time of the current pulse period and the short circuit time comprises:
t2＝T2+K1·T0+C1
t3＝T3+K2·T0+C2
t21＝t2+C3
t31＝T3
wherein, T0For short-circuit time, T2For the peak time of the current pulse period, T3Is the falling slope time, t, of the current pulse period2Is the peak time, t, of the next pulse period3Is the falling slope time, t, of the next pulse period21Is the peak time of the next pulse period, t31Is the falling slope time of the next pulse period, K1、K2、C1、C2And C3Is a preset coefficient.
3. The consumable electrode pulse welding method of claim 1, wherein compensating for a peak time of a next pulse period based on a peak time of a current pulse period and a short circuit time comprises:
t2＝T2+K1·T0+C1
wherein, T0For short-circuit time, T2Is the peak time, t, of the current pulse period2Is the peak time of the next pulse period, K1、C1Is a preset coefficient.
4. The consumable electrode pulse welding method of claim 2, wherein the K is1The range of (A) is-50 to 50, and K2The range of (a) is-50 to 50.
5. The consumable electrode pulse welding method of claim 2, wherein C is1In the range of-100 to 100, C2In the range of-100 to 100, C3The range of (A) is-100 to 100.
6. The consumable electrode pulse welding method of claim 1, wherein the preset time is in a range of 0.1ms to 0.5 ms.
7. A consumable electrode pulse welding system, comprising: storage circuitry, processing circuitry and executable instructions stored in the storage circuitry and operable in the processing circuitry, the executable instructions when executed by the processing circuitry effecting the consumable electrode pulse welding method of any one of claims 1 to 6.
8. A welder, characterized by comprising the consumable electrode pulse welding system of claim 7.
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| CN111545875B (en) * | 2020-05-15 | 2021-11-09 | 唐山松下产业机器有限公司 | Consumable electrode pulse gas shielded welding machine, energy control device and energy control method |
| CN113145996B (en) * | 2021-05-21 | 2022-09-23 | 唐山松下产业机器有限公司 | Gas metal arc welding control method, system, device and storage medium |
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