CN116329716A - Consumable electrode gas shielded welding system, control method thereof, controller and medium - Google Patents
Consumable electrode gas shielded welding system, control method thereof, controller and medium Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 168
- 238000000034 method Methods 0.000 title claims abstract description 56
- 238000010891 electric arc Methods 0.000 claims abstract description 94
- 239000002184 metal Substances 0.000 claims abstract description 15
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- 238000003860 storage Methods 0.000 claims description 10
- 230000003247 decreasing effect Effects 0.000 claims description 6
- 238000002844 melting Methods 0.000 abstract description 13
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- 239000012080 ambient air Substances 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
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- 238000010438 heat treatment Methods 0.000 description 1
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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
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
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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
- B23K9/095—Monitoring or automatic control of welding parameters
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
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Abstract
The application discloses a gas metal arc welding system of a melting electrode, a control method, a controller and a medium thereof. The control method of the gas metal arc welding system of the melting electrode comprises the following steps: acquiring electric signal information of an electric arc; the electrical signal information includes a voltage signal and a current signal; based on the electric signal information of the electric arc, judging the state of the electric arc, and generating a first current value according to the state of the electric arc; regulating the current of the electric arc in an arcing state, and generating a second current value to control the average voltage of the electric arc to be in a constant voltage state; accumulating the first current value and the second current value to obtain a target current value, and outputting a current driving signal related to the target current value to a welding power supply; setting a corresponding wire feeding direction and amplitude according to the arc state of the arc, generating a first wire feeding speed, and outputting a corresponding wire feeding driving signal to a wire feeding device. By the scheme, the performance of the gas shielded welding system of the melting electrode can be improved.
Description
Technical Field
The application relates to the technical field of welding, in particular to a gas shielded welding system for a melting electrode, a control method, a controller and a medium thereof.
Background
In order to expand the application range of gas shielded welding of a melting electrode, particularly reduce heat input and welding spatter, improve welding speed and welding forming, a scheme for promoting droplet transition by utilizing surface tension between a droplet and a molten pool is proposed. According to the scheme, constant-speed wire feeding is abandoned, constant-voltage or quasi-constant-voltage control of a power supply is abandoned at the same time, constant-current control is adopted at each stage of droplet transition, single droplet energy is better controlled, but the self-regulating action of an electric arc is weakened, so that the scheme realizes lower heat input and lower welding spatter, meanwhile, the self-regulating action of the electric arc is weakened, the adaptation range of the electric arc is also reduced, lower heat input and better penetration cannot be realized, and the application scene of the scheme is macroscopically limited.
Disclosure of Invention
The technical problem that this application mainly solves is to provide a melting electrode gas shielded welding system and control method, controller, medium thereof, can guarantee that melting electrode gas shielded welding system obtains more stable molten drop transition, lower welding heat input, more controllable welding penetration in the welding process, promotes welding performance, has wider range of application.
In order to solve the above-mentioned problems, a first aspect of the present application provides a control method of a consumable electrode gas shielded welding system, the control method comprising: acquiring electric signal information of an electric arc; the electrical signal information includes a voltage signal and a current signal; based on the electric signal information of the electric arc, judging the state of the electric arc, and generating a first current value according to the state of the electric arc; adjusting the current of the electric arc in an arcing state, and generating a second current value to control the average voltage of the electric arc to be in a constant voltage state; accumulating the first current value and the second current value to obtain a target current value, and outputting a current driving signal related to the target current value to a welding power supply; and setting a corresponding wire feeding direction and amplitude according to the arc state of the arc, generating a first wire feeding speed, and outputting a corresponding wire feeding driving signal to a wire feeding device.
Wherein the adjusting the current when the arc is in an arcing state, generating a second current value to control the average voltage of the arc to be in a constant voltage state, comprises: when the arc is in an arcing state, if the arc length of the arc is shortened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be increased, and if the arc length of the arc is lengthened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be decreased.
Wherein the control method further comprises: and judging the time of the electric arc in the droplet necking stage based on the electric signal information of the electric arc, and starting a chopping absorption module before the electric arc is in the droplet necking stage so as to limit the target current value of the welding power supply corresponding to the time of the electric arc in the droplet necking stage to a preset threshold value.
Wherein, to the wire feed unit output corresponding wire feed drive signal, include: collecting the wire feeding speed of the wire feeding device in real time, and generating a second wire feeding speed according to the historical wire feeding speed of the wire feeding device so as to adjust the average wire feeding speed of the wire feeding device to be in a constant-speed wire feeding state; and accumulating the first wire feeding speed and the second wire feeding speed to obtain a target wire feeding speed, and outputting a wire feeding driving signal related to the target wire feeding speed to the wire feeding device.
To solve the above-described problems, a second aspect of the present application provides a controller for use in a consumable electrode gas shielded welding system including a welding power source and a wire feeder, the controller comprising: the electric signal sampling module is connected with the welding power supply and used for acquiring electric signal information of the electric arc; the electrical signal information includes a voltage signal and a current signal; the electric arc state judging module is connected with the electric signal sampling module and is used for judging the electric arc state of the electric arc based on the electric signal information of the electric arc and generating a first current value according to the electric arc state of the electric arc; the arc length control module is connected with the electric signal sampling module and is used for adjusting the current when the electric arc is in an arcing state and generating a second current value so as to control the average voltage of the electric arc to be in a constant voltage state; the power supply driving module is respectively connected with the arc state judging module and the arc length control module, and is used for accumulating the first current value and the second current value to obtain a target current value and outputting a current driving signal related to the target current value to a welding power supply; the wire feeding reciprocating control module is connected with the electric arc state judging module and is used for setting a corresponding wire feeding direction and amplitude according to the electric arc state of the electric arc to generate a first wire feeding speed; and the wire feeding driving module is respectively connected with the wire feeding reciprocating control module and the wire feeding device and is used for generating and outputting a corresponding wire feeding driving signal to the wire feeding device based on the first wire feeding speed.
The arc length control module executes the step of adjusting the current when the arc is in an arcing state and generating a second current value to control the average voltage of the arc to be in a constant voltage state, and specifically comprises the following steps: when the arc is in an arcing state, if the arc length of the arc is shortened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be increased, and if the arc length of the arc is lengthened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be decreased.
Wherein the welding power supply comprises a chopper absorption module; the controller also comprises a droplet necking judging module and a chopping driving module, wherein the droplet necking judging module is respectively connected with the electric signal sampling module and the chopping driving module, and the chopping driving module is connected with the chopping absorbing module; the droplet necking judgment module is used for judging the time of the electric arc in a droplet necking stage based on the electric signal information of the electric arc, and controlling the chopping driving module to start the chopping absorption module before the electric arc is in the droplet necking stage so as to limit the target current value of the welding power supply corresponding to the electric arc in the droplet necking stage to a preset threshold value; the chopper driving module is used for starting or closing the chopper absorbing module.
The controller also comprises a wire feeding speed sampling module and an average wire feeding speed control module, wherein the wire feeding speed sampling module is respectively connected with the average wire feeding speed control module and the wire feeding device, and the average wire feeding speed control module is connected with the wire feeding device; the wire feeding speed sampling module is used for collecting the wire feeding speed of the wire feeding device in real time; the average wire feeding speed control module is used for generating a second wire feeding speed according to the historical wire feeding speed of the wire feeding device so as to adjust the average wire feeding speed of the wire feeding device to be in a constant-speed wire feeding state; the wire feeding driving module executes the step of generating and outputting a corresponding wire feeding driving signal to the wire feeding device based on the first wire feeding speed, and specifically includes: and accumulating the first wire feeding speed and the second wire feeding speed to obtain a target wire feeding speed, and outputting a wire feeding driving signal related to the target wire feeding speed to the wire feeding device.
To solve the above problems, a third aspect of the present application provides a controller, including a processor and a memory that are connected to each other; wherein the memory stores program instructions, and the processor retrieves the program instructions from the memory to execute the method for controlling the consumable electrode gas shielded welding system according to the first aspect.
In order to solve the above problems, a fourth aspect of the present application provides a consumable electrode gas shielded welding system, which includes a welding power source, a wire feeder, and a controller, the controller being connected to the welding power source and the wire feeder, respectively, and the controller being the controller of the second aspect or the third aspect.
To solve the above-described problems, a fifth aspect of the present application provides a computer-readable storage medium having stored thereon program instructions which, when executed by a processor, implement the control method of the consumable electrode gas shielded welding system of the first aspect described above.
The beneficial effects of the invention are as follows: in the control method of the consumable electrode gas shielded welding system, the electric signal information of the electric arc is obtained, wherein the electric signal information comprises a voltage signal and a current signal, so that the state of the electric arc can be judged based on the electric signal information of the electric arc, a first current value is generated according to the state of the electric arc, and meanwhile, the current when the electric arc is in an arcing state is regulated, and a second current value is generated to control the average voltage of the electric arc to be in a constant voltage state; then, the first current value and the second current value can be accumulated to obtain a target current value, and a current driving signal related to the target current value is output to the welding power supply; and setting the corresponding wire feeding direction and amplitude according to the arc state of the arc, generating a first wire feeding speed, and outputting a corresponding wire feeding driving signal to the wire feeding device. The arc state of the arc can be judged based on the electric signal information of the arc, and a first current value is generated according to the arc state of the arc, namely the welding power supply has the functions of short circuit, arcing judgment and current waveform control, the corresponding wire feeding direction and amplitude can be set according to the arc state of the arc, the first wire feeding speed is generated, and the corresponding wire feeding driving signal is output to the wire feeding device, so that the consumable electrode gas shielded welding system can control through the current waveform of the welding power supply, and simultaneously assist in the back-drawing control of the welding wire in the short circuit, so that the stability of droplet transition in the welding process is commonly promoted, and the consistency of the droplet is maintained in a large range; on the other hand, the second current value is generated by adjusting the current when the arc is in an arcing state so as to control the average voltage of the arc to be in a constant voltage state, namely, the welding power source works in a constant voltage or quasi-constant voltage control mode macroscopically, so that the anti-interference capability of the arc is further improved, the application range of gas shielded welding of a melting electrode is indirectly improved, the heat input of welding is further reduced, and thinner metal can be welded; deeper penetration can be realized, and the problem that only thin plates can be welded due to shallower penetration is avoided; the uniform heat input can be obtained, the current and voltage values are constant in the whole welding process, the influence of a plurality of unknown factors on the heat input is avoided, and the work of a debugger is simplified.
Drawings
FIG. 1 is a flow chart of an embodiment of a method of controlling a consumable electrode gas arc welding system of the present application;
FIG. 2 is a schematic flow chart of another embodiment of a method of controlling a consumable electrode gas arc welding system of the present application;
FIG. 3 is a schematic waveform diagram of voltage, current and wire feed speed in an application scenario of the present application;
FIG. 4 is a schematic diagram showing a process of a droplet transition period in an application scenario of the present application;
FIG. 5 is a schematic diagram of a frame structure of an embodiment of a controller of the present application;
FIG. 6 is a schematic diagram of a frame structure of another embodiment of the controller of the present application;
FIG. 7 is a schematic diagram of a frame structure of a fusion electrode gas arc welding system of the present application;
FIG. 8 is a schematic diagram of an embodiment of a computer-readable storage medium of the present application.
Detailed Description
The following describes the embodiments of the present application in detail with reference to the drawings.
In the following description, for purposes of explanation and not limitation, specific details are set forth such as the particular system architecture, interfaces, techniques, etc., in order to provide a thorough understanding of the present application.
The terms "system" and "network" are often used interchangeably herein. The term "and/or" is herein merely an association relationship describing an associated object, meaning that there may be three relationships, e.g., a and/or B, may represent: a exists alone, A and B exist together, and B exists alone. In addition, the character "/" herein generally indicates that the front and rear associated objects are an "or" relationship. Further, "a plurality" herein means two or more than two.
Referring to fig. 1, fig. 1 is a flow chart illustrating an embodiment of a method for controlling a gas metal arc welding system for a consumable electrode according to the present application. Specifically, please refer to fig. 7, fig. 7 is a schematic diagram of a frame structure of the fusion electrode gas arc welding system of the present application, wherein the fusion electrode gas arc welding system 70 comprises: a welding power source 700, a welding wire 701, an arc 702, a base material 703, an air supply device 704, and a wire feeder 706, wherein the welding power source 700 provides energy to the welding wire 701, the arc 702, and the base material 703, respectively, to melt the welding wire 701, maintain the arc 702, and heat the base material 703. When welding is needed, power is provided for each device through the welding power supply 700, various parameters of each welding part, such as gas, welding wire materials, welding voltage, welding current and the like, are set by a user, then the user presses a switch of the welding gun 705, the welding power supply 700 enters an arc striking stage, the arc 702 melts a molten pool and a welding area formed by the welding wire 701 and the base metal 703 under the protection of inert gas or active gas, the harmful effect of ambient air can be effectively prevented, and then the welding is completed through the molten drop transition process. The droplet transition refers to the whole process that molten metal at the end of the welding wire 701 forms droplets under the thermal action of the arc 702, is separated from the end of the welding wire 701 by various forces and transits to a molten pool, has a direct relationship with the stability of the welding process, the formation of a weld bead, the size of spatter, and the like, and finally affects the welding quality and the production efficiency.
The consumable electrode gas shielded welding system 70 in this embodiment of the present application further includes a controller 707, where the controller 707 is connected to the welding power supply 700 and the wire feeder 706, respectively, and the control method of the consumable electrode gas shielded welding system in this embodiment includes the following steps:
step S11: acquiring electric signal information of an electric arc; the electrical signal information includes a voltage signal and a current signal.
Step S12: and judging the state of the electric arc according to the electric signal information of the electric arc, and generating a first current value according to the state of the electric arc.
Specifically, referring to fig. 4, fig. 4 is a schematic diagram showing a process of a droplet transition period in an application scenario of the present application, wherein the droplet transition is in the form of a short-circuit transition, and the short-circuit transition specifically refers to a transition mode in which when the current is small and the arc voltage is low, the arc length is short, the droplet is not grown into a large droplet and contacts with a molten pool to form a liquid metal short circuit, the arc 702 is extinguished, then the metal droplet is transited into the molten pool under the action of surface tension and electromagnetic shrinkage force, and the arc 702 is ignited again after the droplet falls off, so that the transition is alternately performed. The short-circuit transition is carried out by alternately burning and extinguishing the arc, and the welding average current is smaller during the short-circuit transition. Since there is a short circuit process during welding, the power supply voltage cannot be too high, and the arcing current in steady state is small, so the current change process after the short circuit is finished is an important component of the arcing capability. That is, the dynamic nature of the welding power supply 700 has an important impact on weld formation and penetration. The slower the dynamic characteristic, the longer the current transition time after the short circuit is finished, the larger the provided arcing capability, the better the weld joint forming, and the larger the penetration; however, too slow a movement may result in too slow a current increase rate, resulting in severe spatter and even compromising the stability of the arc 702. Therefore, proper and precise control of the welding power supply 700 is required to ensure the requirements of the welding process and the stability of the welding process.
Therefore, the welding power supply 700 in the consumable electrode gas shielded welding system 70 in the embodiment of the present application needs to have a current waveform control function, and referring to fig. 3, fig. 3 is a schematic waveform diagram of voltage, current and wire feeding speed in an application scenario of the present application, as shown in fig. 3, an abscissa of the current waveform diagram represents time, an ordinate represents output current, and when the welding power supply 700 is controlled by adopting the current waveform control mode, it is necessary to distinguish each stage of droplet transition, adjust the shape of the current waveform at different stages, control droplet size, achieve better droplet transition effect and bath heating effect, reduce welding spatter, and adjust welding penetration. The process needs to detect the voltage signal and the current signal of the arc 702, and then realize the arc state of the arc 702 in the welding process through a specific hardware filtering and judging circuit or software algorithm, so as to realize the judgment of the short circuit and arcing stage according to the arc state; accordingly, based on the current waveform control function of the welding power supply 700, a corresponding first current value may be generated in accordance with the short circuit, arcing phase in which the arc 702 is located.
Step S13: and regulating the current of the electric arc in an arcing state, and generating a second current value to control the average voltage of the electric arc to be in a constant voltage state.
Specifically, the voltage drop across the arc 702 may be controlled to be nearly constant over a macroscopic period by a specific arc length control algorithm, as shown in fig. 3, where the actual voltage magnitude exhibits high frequency varying characteristics at various stages of the droplet transition period of the present application, it is not possible to control the voltage at each point in time to a constant voltage, but macroscopically, it is possible that the average voltage over a long period is constant; by controlling the average voltage to a constant voltage, the arc 702 may be made to remain stable according to self-regulation.
In an embodiment, the step S13 may include: when the arc is in an arcing state, if the arc length of the arc is shortened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be increased, and if the arc length of the arc is lengthened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be decreased. Specifically, as shown in fig. 3, when the arc length becomes short, the initial arcing current and the trailing arcing current become large, the slope corresponding to the current is greater than 0, and conversely, when the arc length becomes long, the initial arcing current and the trailing arcing current become small, and the slope corresponding to the current is less than 0; therefore, by adjusting the current in the arcing stage to the second current value, the stability of the arc 702 is enhanced, and the anti-interference capability of the arc 702 is further improved.
Step S14: and accumulating the first current value and the second current value to obtain a target current value, and outputting a current driving signal related to the target current value to a welding power supply.
It will be appreciated that the current waveform control function based on the welding power supply 700 may be implemented by adding the first current value generated during the arc striking phase according to the short circuit where the arc 702 is located to the second current value generated during the arc striking phase where the arc 702 is in the arc striking state according to the self-adjustment of the arc 702, and the obtained target current value may be used as the driving current of the welding power supply 700, and then a current driving signal related to the target current value may be outputted to the welding power supply 700 to cause the welding power supply 700 to output a suitable current value.
Step S15: and setting a corresponding wire feeding direction and amplitude according to the arc state of the arc, generating a first wire feeding speed, and outputting a corresponding wire feeding driving signal to a wire feeding device.
Specifically, referring to fig. 7, the consumable electrode gas shielded welding system 70 in the embodiment of the present application further includes a wire feeder 706, and the welding wire 701 is fed by the wire feeder 706 into the wire feeding tube of the welding gun 705 at a speed for the arc 702 to melt, so that the feeding speed of the welding wire 701 is consistent with the melting speed of the welding wire 701 to ensure the stability of the welding process, and thus, the feeding speed of the welding wire 701 is an important factor affecting the stability of the welding process. Referring to fig. 3 and fig. 4, the direction and the amplitude of the wire feeding need to be set at different stages of the droplet transition, so after determining that the arc 702 is in the arc state in step S12, the wire feeding device 706 can switch the set direction and amplitude of the wire feeding according to the specific short-circuit stage or the arcing stage. In particular, during a short circuit, the wire feed direction is typically set to a direction away from the puddle to effect droplet detachment from the puddle, and the wire feed speed amplitude may be set to different values at different stages of the short circuit; while during arcing, the wire feed direction is typically set to be near the direction of the puddle, the wire feed speed amplitude may be set to different values at different stages of arcing.
In the above-mentioned scheme, by determining the arc state of the arc 702 based on the electrical signal information of the arc 702, and generating the first current value according to the arc state of the arc 702, that is, the welding power supply 700 has the functions of short circuit, arcing determination and current waveform control, and can set the corresponding wire feeding direction and amplitude according to the arc state of the arc 702, generate the first wire feeding speed, and output the corresponding wire feeding driving signal to the wire feeding device 706, thus the consumable electrode gas shielded welding system
The system 70 can control the current waveform of the welding power supply 700, and simultaneously assist in controlling the back-drawing of the welding wire 701 at the time of short 5-circuit, so as to jointly promote the stability of the molten drop transition in the welding process and to a very large extent
The consistency of the molten drops is maintained in the enclosure; on the other hand, by adjusting the current when the arc 702 is in the arcing state, a second current value is generated to control the average voltage of the arc 702 to be in a constant voltage state, i.e., the welding power supply 700 is macroscopically operated in a constant voltage or quasi-constant voltage control mode, such that the arc 702
The anti-interference capability is further improved, the use range of 0 of gas shielded welding of the melting electrode is indirectly improved, the heat input of welding is further reduced, and therefore thinner metal can be welded; can be used for
So as to realize deeper penetration and avoid the problem that only thin plates can be welded because the penetration is shallower; the uniform heat input can be obtained, the current and voltage values are constant in the whole welding process, the influence of a plurality of unknown factors on the heat input is avoided, and the work of a debugger is simplified.
Referring to fig. 2, fig. 2 is a flow chart illustrating another embodiment of a control method of the gas metal arc welding system for a consumable electrode according to the present invention. Control of a consumable electrode gas shielded welding system in this embodiment
A method comprising the steps of:
step S21: acquiring electric signal information of an electric arc; the electrical signal information includes a voltage signal and a current signal.
Step S22: and judging the state of the electric arc 0 where the electric arc is based on the electric signal information of the electric arc, and generating a first current value according to the state of the electric arc where the electric arc is.
Step S23: and regulating the current of the electric arc in an arcing state, and generating a second current value to control the average voltage of the electric arc to be in a constant voltage state.
Step S24: and accumulating the first current value and the second current value to obtain a target current value, and outputting a current driving signal related to the target current value to a welding power supply.
Steps S21 to S24 in this embodiment are substantially similar to steps S11 to S14 in the above-described embodiment of the method for controlling a consumable electrode gas arc welding system, and are not repeated here.
Further, in the consumable electrode gas shielded welding system 70, the output of the welding power supply 700 is coupled in series with a chopper absorption module 708.
Step S25: and judging the time of the electric arc in the droplet necking stage based on the electric signal information of the electric arc, and starting a chopping absorption module before the electric arc is in the droplet necking stage so as to limit the target current value of the welding power supply corresponding to the time of the electric arc in the droplet necking stage to a preset threshold value.
Step S26: and setting a corresponding wire feeding direction and a corresponding amplitude 5 value according to the arc state of the arc, generating a first wire feeding speed, and outputting a corresponding wire feeding driving signal to a wire feeding device. A corresponding wire feed drive signal may be output based on the first wire feed speed, i.e., the wire feed 706 may feed wire at the first wire feed speed.
Further, in an embodiment, the method for controlling the gas metal arc welding system for a molten electrode according to the present embodiment further includes, after the step S26: 0 step S27: and collecting the wire feeding speed of the wire feeding device in real time, and generating a second wire feeding speed according to the historical wire feeding speed of the wire feeding device so as to adjust the average wire feeding speed of the wire feeding device to be in a constant-speed wire feeding state.
Specifically, the wire feed speed may be controlled macroscopically to a constant value by a specific average wire feed speed control algorithm, i.e., the entire system is macroscopically in a constant speed wire feed state, as shown in fig. 3, with positive actual wire feed speed at various stages of the droplet transition cycle of the present application
Changes in direction and in reverse, but macroscopically, the arc 702 may be made stable by adjusting the wire feed speed amplitude such that the average wire feed speed over a long period is constant, while by controlling the average wire feed speed to a constant speed wire feed state, the arc may be made stable according to self-regulating action. In particular, in
When the arc length changes due to external disturbance, the melting speed of the welding wire 701 is changed by 0 immediately, when the arc length is shortened, the melting speed of the welding wire 701 is larger than the feeding speed of the welding wire 701, and conversely, when the arc length is lengthened, the melting speed of the welding wire 701 is smaller than the feeding speed of the welding wire 701, so that the average wire feeding speed is controlled in a constant-speed wire feeding state, the arc length is promoted to return to a set value, the self-adaptive adjustment of the arc 702 is realized, the stability of the arc 702 is enhanced, and the anti-interference capability of the arc 702 is further improved.
Step 5S 28: and accumulating the first wire feeding speed and the second wire feeding speed to obtain a target wire feeding speed, and outputting a wire feeding driving signal related to the target wire feeding speed to the wire feeding device.
It will be appreciated that the first wire feed speed generated during the short circuit, arcing phase of the arc 702 is summed with the second wire feed speed generated during the self-adjustment of the arc 702, and the resulting target wire feed speed may be used as the motor drive speed for the wire feed 706, and a wire feed drive signal may be output to the wire feed 706 regarding the target wire feed speed to cause the wire feed speed to exhibit a microscopic reciprocating mode and a macroscopic constant speed wire feed mode.
Referring to fig. 5, fig. 5 is a schematic frame structure of an embodiment of the controller of the present application. The controller 50 in this embodiment is applied to a consumable electrode gas shielded welding system that includes a welding power source and a wire feeder. Specifically, the controller 50 includes an electrical signal sampling module 500, an arc state judging module 501, an arc length control module 502, a power driving module 503, a wire feeding reciprocation control module 504, and a wire feeding driving module 505. The electric signal sampling module 500 is connected with the welding power supply and is used for acquiring electric signal information of an electric arc; the electrical signal information includes a voltage signal and a current signal; the arc state judging module 501 is connected to the electric signal sampling module 500, and is configured to judge an arc state in which the arc is located based on electric signal information of the arc, and generate a first current value according to the arc state in which the arc is located; the arc length control module 502 is connected with the electric signal sampling module 500, and is used for adjusting the current when the electric arc is in an arcing state, and generating a second current value to control the average voltage of the electric arc to be in a constant voltage state; the power driving module 503 is connected to the arc state judging module 501 and the arc length control module 502, and is configured to accumulate the first current value and the second current value to obtain a target current value, and output a current driving signal related to the target current value to a welding power supply; the wire feeding reciprocation control module 504 is connected to the arc state judging module 501, and is configured to set a corresponding wire feeding direction and amplitude according to an arc state where the arc is located, so as to generate a first wire feeding speed; the wire feeding driving module 505 is respectively connected with the wire feeding reciprocation control module 504 and the wire feeding device, and is configured to generate and output a corresponding wire feeding driving signal to the wire feeding device based on the first wire feeding speed.
In one embodiment, the arc length control module 502 performs the step of adjusting the current when the arc is in the arcing state, and generating a second current value to control the average voltage of the arc to be in the constant voltage state, and specifically includes: when the arc is in an arcing state, if the arc length of the arc is shortened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be increased, and if the arc length of the arc is lengthened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be decreased.
In one embodiment, the welding power supply includes a chopper absorption module; the controller 50 further comprises a droplet necking judging module 506 and a chopping driving module 507, wherein the droplet necking judging module 506 is respectively connected with the electric signal sampling module 500 and the chopping driving module 507, and the chopping driving module 507 is connected with the chopping absorbing module; the droplet necking judgment module 506 is configured to judge, based on the electrical signal information of the electric arc, a time when the electric arc is in a droplet necking stage, and control the chopper driving module 507 to start the chopper absorption module before the electric arc is in the droplet necking stage, so as to limit a target current value of the welding power supply corresponding to the time when the electric arc is in the droplet necking stage to a preset threshold; the chopper driving module 507 is used for starting or stopping the chopper absorbing module.
In one embodiment, the controller 50 further includes a wire feed speed sampling module 508 and an average wire feed speed control module 509, the wire feed speed sampling module 508 being respectively connected to the average wire feed speed control module 509 and the wire feed apparatus, the average wire feed speed control module 509 being connected to the wire feed apparatus; the wire feed speed sampling module 508 is configured to collect a wire feed speed of the wire feed apparatus in real time; the average wire feed speed control module 509 is configured to generate a second wire feed speed according to the historical wire feed speed of the wire feed apparatus, so as to adjust the average wire feed speed of the wire feed apparatus to be in a constant-speed wire feed state; the wire feed driving module 505 performs the step of generating and outputting a corresponding wire feed driving signal to the wire feed apparatus based on the first wire feed speed, and specifically includes: and accumulating the first wire feeding speed and the second wire feeding speed to obtain a target wire feeding speed, and outputting a wire feeding driving signal related to the target wire feeding speed to the wire feeding device.
In an application scenario, please refer to fig. 7, in the consumable electrode gas shielded welding system 70, the output end of the welding power supply 700 is connected in series with the chopper absorption module 708 to provide energy for the arc 702, the combination of the welding power supply 700 and the chopper absorption module 708 should have the capability of realizing at least 500 ampere current output so as to adapt to most gas shielded welding application occasions, and should also have the capability of reducing the current from the current value to the set value within 100 microseconds so as to avoid electric explosion during the necking transition of molten drops; the combination of welding power supply 700 and chopper absorption module 708 operates macroscopically in a constant voltage mode or quasi-constant voltage mode, i.e., the output average voltage of the combination is nearly constant; the combination can judge whether the arc 702 is in a short circuit or arcing stage according to the arc state of the arc, and adjust the current waveform in each stage to promote the molten drop transition; the combination should be able to anticipate the droplet necking stage of the droplet transition through the sampled electrical signal information of the arc 702 to enable droplet necking control through the chopper absorption module 708. The wire feeder 706 comprises a wire feed loop consisting of a wire storage assembly 7060, a post wire feed assembly 7061, a wire buffer assembly 7062, and a pre wire feed assembly 7063, wherein the wire feeder 706 can achieve stable wire feed in the range of 0.8 meters/min to 18 meters/min to accommodate most gas shielded welding applications; the wire feeder 706 can achieve wire withdrawal at a level of 50 hz-200 hz to facilitate achieving a wide range of droplet short circuit transitions; the wire feeder 706 operates macroscopically in a constant speed wire feed mode, i.e., the average wire feed speed output by the wire feeder 706 is nearly constant. In addition, the shielding gas is supplied through a general-purpose gas supply device 704. The three physical quantities described above are collected at the welding gun 705, and an arc 702 is formed by a contact tip inside the welding gun 705.
Referring to fig. 5 and 7, the controller 50 may include a Digital Signal Processor (DSP) that collects electrical signal information of the arc 702 at a rate above 50kHz through the electrical signal sampling module 500, ensures that the actual condition of the arc 702 is substantially restored, and converts analog signals into digital signals. After the electric signal of the arc 702 is collected into the DSP, the specific digital filtering algorithm in the sampling filtering module 510 filters out the possible interference signals, so as to obtain the arc information which can be real. The filtered electrical signal information from the arc 702 may then be sent to the arc state determination module 501, the arc length control module 502, and the droplet necking down determination module 506, respectively. The arc state judging module 501 may be configured to judge the arc state of the arc 702 and generate a current waveform meeting the droplet transition requirement, and specifically, different current rising and falling slopes and magnitudes are adopted in the short circuit and arcing phases, and even different phases are subdivided in the short circuit and arcing phases, and different current rising and falling slopes and magnitudes are adopted. The slope and amplitude of these current changes function to apply different arc forces and arc energies at various stages of droplet transition, facilitating droplet generation and transition. In addition, the arc state of the arc 702 determined by the arc state determining module 501 may provide a basis for determining the reciprocating motion of the wire feeder 706. The arc length control module 502 may control the pressure drop across the arc 702 to be nearly constant over a macrocycle through a particular arc length control algorithm. The amount of adjustment of the arc length control module 502 is the current at the arcing stage, and when the arc length becomes short, the initial arcing current and the trailing arcing current become large, and conversely, when the arc length becomes long, the initial arcing current and the trailing arcing current become small. The outputs of the arc state judging module 501 and the arc length control module 502 are accumulated to obtain a target current value, the target current value is used as the drive of the welding power supply 700, and the power supply driving module 503 outputs a current driving signal about the target current value to the welding power supply 700 to enable the power supply to output a proper current value. The droplet necking judgment module 506 can pre-judge whether droplet transition necking is formed or not by utilizing the electric signal information of the electric arc 702 obtained after filtering through a specific droplet necking judgment algorithm, and start the chopping absorption module 708 in advance through the chopping driving module 507 so as to limit the current to a proper value, avoid the explosion of necking caused by high current, and then influence the stability of droplet transition and the stability of a molten pool. Accordingly, control of the welding power supply 700 and the chopper absorption module 708 in series with the output of the welding power supply 700 may be achieved by the power supply driving module 503 and the chopper driving module 507 described above. In addition, the output of the arc state judging module 501 may also be connected to a wire feeding reciprocation control module 504, where the wire feeding reciprocation control module 504 is used to set the direction and amplitude of the wire feeding when the arc 702 is in the short circuit and arcing period, and generate the set wire feeding direction and amplitude according to the output of the arc state judging module 501, and then the wire feeding driving module 505 drives the wire feeding device 706 to switch the wire feeding speed. In particular, during a short circuit, the wire feed direction is typically set to a direction away from the puddle to effect droplet detachment from the puddle, and the wire feed speed amplitude may be set to different values at different stages of the short circuit; during arcing, the wire feed direction is typically set to a direction approaching the puddle, and the wire feed speed amplitude may be set to different values at different stages of arcing.
Further, the DSP may also collect the wire feed speed in real time via the wire feed speed sampling module 508, as the frequency of the reciprocating wire feed needs to be about 50Hz to 200Hz, and the sampling rate often needs to be above 50kHz in order not to lose real-time wire feed speed information. After the wire feed speed sampling module 508 collects the wire feed speed, the wire feed speed collection value may be provided as an input to the average wire feed speed control module 509, and the average wire feed speed control module 509 may macroscopically control the wire feed speed to a constant value, i.e., macroscopically, the entire system is in a constant speed wire feed state. The output of the wire feed reciprocation control module 504 and the output of the average wire feed speed control module 509 are added to obtain a target wire feed speed, and the target wire feed speed is given as the motor drive of the wire feed device 706, and a wire feed drive signal about the target wire feed speed is output to the wire feed device 706 by the wire feed drive module 505, so that the wire feed speed is caused to present a microscopic reciprocating motion mode and a macroscopic constant-speed wire feed mode.
Referring to FIG. 3, in the embodiment of the present application, the wire feed speed of the wire feed 706 is adjusted at time to achieve a steady average wire feed speed; the actual current output by the combination of the welding power supply 700 and the chopper absorption module 708 is also continuously adjusted to achieve a stable average voltage. Through the current waveform control and the molten drop necking control of the welding power supply 700, and simultaneously the back drawing control of the auxiliary welding wire 701 during short circuit, the stability of molten drop transition is commonly promoted, the molten drop consistency is maintained in a large range, and the method greatly avoids the problem of simply relying on the reciprocating motion of the welding wire or the current waveform control. On the other hand, because constant voltage or quasi-constant voltage control is arranged and matched with a control element for constant-speed wire feeding, the anti-interference capability of the electric arc 702 is further improved, the application range of the scheme is indirectly improved, the heat input of welding is further reduced, and therefore thinner metal can be welded; in addition, deeper penetration can be realized, and the problem that only a thin plate can be welded due to shallower penetration in the prior scheme is avoided; and the uniform heat input can be obtained, the current and voltage values are constant in the whole welding process, the influence of a plurality of unknown factors on the heat input is avoided, and the work of a debugger is simplified.
Referring to fig. 6, fig. 6 is a schematic frame structure of another embodiment of the controller of the present application. The controller 60 in this embodiment includes a processor 601 and a memory 602 connected to each other; the memory 602 stores program instructions, and the processor 601 retrieves the program instructions from the memory 602 to execute the steps of any of the embodiments of the control method of the consumable electrode gas arc welding system.
In particular, the processor 601 is configured to control itself and the memory 602 to implement the steps of any of the control method embodiments of the consumable electrode gas metal arc welding system described above. The processor 601 may also be referred to as a CPU (Central Processing Unit ). The processor 601 may be an integrated circuit chip with signal processing capabilities. The processor 601 may also be a general purpose processor, a digital signal processor (Digital Signal Processor, DSP), an application specific integrated circuit (Application Specific Integrated Circuit, ASIC), a Field programmable gate array (Field-Programmable Gate Array, FPGA) or other programmable logic device, discrete gate or transistor logic device, discrete hardware components. A general purpose processor may be a microprocessor or the processor may be any conventional processor or the like. In addition, the processor 601 may be commonly implemented by an integrated circuit chip.
For details of the method for implementing the gas metal arc welding system control by the processor 601, please refer to the embodiment of the method for implementing the gas metal arc welding system control, and the details are not repeated here.
Referring to fig. 7, fig. 7 is a schematic diagram of a frame structure of a gas metal arc welding system for a consumable electrode of the present application. The consumable electrode gas shielded welding system 70 in this embodiment includes a welding power supply 700, a wire feeder 706, and a controller 707, where the controller 707 is connected to the welding power supply 700 and the wire feeder 706, respectively, and the controller 707 is the controller 50 or the controller 60 in any of the above embodiments.
Referring to fig. 8, fig. 8 is a schematic structural diagram of an embodiment of a computer readable storage medium of the present application. The present application is directed to a computer readable storage medium 80 having program instructions 800 stored thereon, which program instructions 800 when executed by a processor perform the steps of any of the above-described embodiments of a method of controlling a consumable electrode gas arc welding system.
The computer readable storage medium 80 may be a medium such as a usb disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, which may store the program instructions 800, or may be a server storing the program instructions 800, and the server may send the stored program instructions 800 to another device for execution, or may also self-execute the stored program instructions 800.
In the several embodiments provided in the present application, it should be understood that the disclosed methods, apparatuses, and devices may be implemented in other manners. For example, the above-described apparatus and device embodiments are merely illustrative, e.g., the division of modules or units is merely a logical functional division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another system, or some features may be omitted or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be an indirect coupling or communication connection via some interfaces, devices or units, which may be in electrical, mechanical or other form.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed over a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the embodiment.
In addition, each functional unit in each embodiment of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present application may be embodied essentially or in part or all or part of the technical solution contributing to the prior art or in the form of a software product stored in a storage medium, including several instructions to cause a computer device (which may be a personal computer, a server, or a network device, etc.) or a processor (processor) to perform all or part of the steps of the methods of the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
Claims (11)
1. A method of controlling a consumable electrode gas shielded welding system, the method comprising:
acquiring electric signal information of an electric arc; the electrical signal information includes a voltage signal and a current signal;
based on the electric signal information of the electric arc, judging the state of the electric arc, and generating a first current value according to the state of the electric arc;
Adjusting the current of the electric arc in an arcing state, and generating a second current value to control the average voltage of the electric arc to be in a constant voltage state;
accumulating the first current value and the second current value to obtain a target current value, and outputting a current driving signal related to the target current value to a welding power supply;
and setting a corresponding wire feeding direction and amplitude according to the arc state of the arc, generating a first wire feeding speed, and outputting a corresponding wire feeding driving signal to a wire feeding device.
2. The control method according to claim 1, wherein said adjusting the current when the arc is in an arcing state, generating a second current value to control the average voltage of the arc to be in a constant voltage state, comprises:
when the arc is in an arcing state, if the arc length of the arc is shortened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be increased, and if the arc length of the arc is lengthened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be decreased.
3. The control method according to claim 1, characterized in that the control method further comprises:
And judging the time of the electric arc in the droplet necking stage based on the electric signal information of the electric arc, and starting a chopping absorption module before the electric arc is in the droplet necking stage so as to limit the target current value of the welding power supply corresponding to the time of the electric arc in the droplet necking stage to a preset threshold value.
4. The control method of claim 1, wherein outputting the corresponding wire feed drive signal to the wire feed apparatus comprises:
collecting the wire feeding speed of the wire feeding device in real time, and generating a second wire feeding speed according to the historical wire feeding speed of the wire feeding device so as to adjust the average wire feeding speed of the wire feeding device to be in a constant-speed wire feeding state;
and accumulating the first wire feeding speed and the second wire feeding speed to obtain a target wire feeding speed, and outputting a wire feeding driving signal related to the target wire feeding speed to the wire feeding device.
5. A controller for use in a consumable electrode gas shielded welding system including a welding power source and a wire feeder, the controller comprising:
the electric signal sampling module is connected with the welding power supply and used for acquiring electric signal information of the electric arc; the electrical signal information includes a voltage signal and a current signal;
The electric arc state judging module is connected with the electric signal sampling module and is used for judging the electric arc state of the electric arc based on the electric signal information of the electric arc and generating a first current value according to the electric arc state of the electric arc;
the arc length control module is connected with the electric signal sampling module and is used for adjusting the current when the electric arc is in an arcing state and generating a second current value so as to control the average voltage of the electric arc to be in a constant voltage state;
the power supply driving module is respectively connected with the arc state judging module and the arc length control module, and is used for accumulating the first current value and the second current value to obtain a target current value and outputting a current driving signal related to the target current value to a welding power supply;
the wire feeding reciprocating control module is connected with the electric arc state judging module and is used for setting a corresponding wire feeding direction and amplitude according to the electric arc state of the electric arc to generate a first wire feeding speed;
and the wire feeding driving module is respectively connected with the wire feeding reciprocating control module and the wire feeding device and is used for generating and outputting a corresponding wire feeding driving signal to the wire feeding device based on the first wire feeding speed.
6. The controller of claim 5, wherein the arc length control module performs the step of adjusting the current when the arc is in an arcing state, generating a second current value to control the average voltage of the arc to be in a constant voltage state, comprising: when the arc is in an arcing state, if the arc length of the arc is shortened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be increased, and if the arc length of the arc is lengthened, the second current values corresponding to the initial arcing stage and the trailing arcing stage are controlled to be decreased.
7. The controller of claim 5, wherein the welding power source comprises a chopper absorption module;
the controller also comprises a droplet necking judging module and a chopping driving module, wherein the droplet necking judging module is respectively connected with the electric signal sampling module and the chopping driving module, and the chopping driving module is connected with the chopping absorbing module; the droplet necking judgment module is used for judging the time of the electric arc in a droplet necking stage based on the electric signal information of the electric arc, and controlling the chopping driving module to start the chopping absorption module before the electric arc is in the droplet necking stage so as to limit the target current value of the welding power supply corresponding to the electric arc in the droplet necking stage to a preset threshold value; the chopper driving module is used for starting or closing the chopper absorbing module.
8. The controller of claim 5, further comprising a wire feed speed sampling module and an average wire feed speed control module, the wire feed speed sampling module being coupled to the average wire feed speed control module and the wire feed apparatus, respectively, the average wire feed speed control module being coupled to the wire feed apparatus;
the wire feeding speed sampling module is used for collecting the wire feeding speed of the wire feeding device in real time;
the average wire feeding speed control module is used for generating a second wire feeding speed according to the historical wire feeding speed of the wire feeding device so as to adjust the average wire feeding speed of the wire feeding device to be in a constant-speed wire feeding state;
the wire feeding driving module executes the step of generating and outputting a corresponding wire feeding driving signal to the wire feeding device based on the first wire feeding speed, and specifically includes: and accumulating the first wire feeding speed and the second wire feeding speed to obtain a target wire feeding speed, and outputting a wire feeding driving signal related to the target wire feeding speed to the wire feeding device.
9. A controller comprising a processor and a memory connected to each other; wherein the memory stores program instructions, and the processor retrieves the program instructions from the memory to perform the method of controlling the consumable electrode gas metal arc welding system of any of claims 1-4.
10. A consumable electrode gas shielded welding system comprising a welding power source, a wire feeder, and a controller coupled to the welding power source and the wire feeder, respectively, the controller being the controller of any one of claims 5-8 or 9.
11. A computer-readable storage medium, characterized in that it has stored thereon program instructions, which when executed by a processor, implement a method of controlling a consumable electrode gas-shielded welding system according to any one of claims 1-4.
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