WO2014156290A1 - 抵抗スポット溶接システム - Google Patents
抵抗スポット溶接システム Download PDFInfo
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- WO2014156290A1 WO2014156290A1 PCT/JP2014/052181 JP2014052181W WO2014156290A1 WO 2014156290 A1 WO2014156290 A1 WO 2014156290A1 JP 2014052181 W JP2014052181 W JP 2014052181W WO 2014156290 A1 WO2014156290 A1 WO 2014156290A1
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- welding
- heat generation
- generation amount
- calorific value
- cumulative
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
- B23K11/255—Monitoring devices using digital means the measured parameter being a force
Definitions
- the present invention relates to a resistance spot welding system that performs multi-step energization with two or more energization patterns, and in particular, attempts to make it possible to form an appropriate nugget by utilizing adaptive control welding in each step.
- a resistance spot welding method which is a kind of a lap resistance welding method, is generally used for joining the stacked steel plates.
- This welding method is a method in which two or more superposed steel plates are sandwiched and pressed with a pair of electrodes from above and below, and a high-current welding current is passed between the upper and lower electrodes for a short time to join them.
- a spot-like welded portion can be obtained by utilizing the resistance heat generated by passing the welding current.
- This spot-like weld is called a nugget and is the part where both steel plates melt and solidify at the contact points of the steel plates when an electric current is passed through the stacked steel plates.
- the nugget diameter is determined by welding conditions such as welding current, energization time, electrode shape, and applied pressure. Therefore, in order to form an appropriate nugget diameter, it is necessary to appropriately set the above-described welding conditions in accordance with the welded material conditions such as the material of the welded material, the plate thickness, and the number of stacked sheets.
- the welded material conditions such as the material of the welded material, the plate thickness, and the number of stacked sheets are the same at each welding location, the welding conditions such as the welding current, the energization time, the electrode shape and the applied pressure are also the same.
- the contact surface of the electrode to be welded material gradually wears, and the contact area gradually becomes wider than the initial state.
- a resistance welding apparatus having a function (stepper function) that increases a welding current value when a predetermined number of times of welding is performed and compensates for a decrease in current density due to electrode wear has been conventionally used.
- stepper function a function that increases a welding current value when a predetermined number of times of welding is performed and compensates for a decrease in current density due to electrode wear.
- this stepper function it is necessary to appropriately set the above-described welding current change pattern in advance.
- much time and cost are required to derive a welding current change pattern corresponding to a large number of welding conditions and workpiece conditions by testing or the like.
- a predetermined welding current change pattern is not always appropriate.
- Patent Document 1 describes a resistance welding machine control device in which a set nugget is obtained by comparing the estimated temperature distribution of a welded portion with a target nugget to control the output of the welding machine. Has been.
- Patent Document 2 discloses a resistance welding machine that detects welding current and chip-to-chip voltage, simulates a weld by heat conduction calculation, and estimates the nugget formation state, thereby performing good welding. The welding condition control method is described.
- the cumulative heat generation amount per unit volume capable of satisfactorily welding the workpiece is calculated from the plate thickness of the workpiece and the energization time, and the calculated unit volume / unit is calculated. It is described that by using a welding system that performs a process for adjusting the welding current or voltage to generate a calorific value per hour, good welding can be performed regardless of the type of workpiece and the wear state of the electrodes.
- Patent Documents 1 to 3 are effective against changes in the case where the electrode tip is worn. However, if the effect of the diversion is large, such as when the distance from the welded point is short, no consideration is given. There is a concern that adaptive control will not actually work.
- the present invention has been developed in view of the above-mentioned present situation, and can be applied to resistance spot welding with multi-stage energization, and can effectively cope with the presence of electrode tip wear and disturbance, and can provide a good nugget.
- the purpose is to propose a resistance spot welding system.
- the gist configuration of the present invention is as follows. 1. It is a resistance spot welding system in which a material to be welded on which a plurality of metal plates are stacked is sandwiched between a pair of electrodes and is energized and joined while being pressurized, Means for calculating and storing the temporal change in instantaneous calorific value calculated from the electrical characteristics between the electrodes during welding in the case of forming a proper nugget by energizing with constant current control during test welding prior to the main welding; Based on the stored temporal change in instantaneous calorific value, the energization pattern is divided into a plurality of steps by external input after test welding, and the temporal change in cumulative calorific value and cumulative calorific value at each step are used as target values.
- Means for storing During subsequent main welding, welding is started based on the temporal change curve of instantaneous calorific value memorized as the target value, and if the temporal change amount of instantaneous calorific value deviates from the target temporal change curve in any step The difference is compensated within the remaining energization time of the step, and the welding current or voltage is adjusted during welding so as to generate the instantaneous heat generation amount and the cumulative heat generation amount so as to coincide with the target cumulative heat generation amount of the step.
- a resistance spot welding system comprising adaptive control means.
- the resistance spot welding system further includes a pressure change state detection means for detecting a pressure change state after the start of welding, The pressure change state detection means obtains a timing at which the welding pressure in the test welding becomes a predetermined value, and inputs the obtained timing as a time for dividing the energization pattern into a plurality of steps.
- the resistance spot welding system according to 1.
- a condition for forming a proper nugget by performing welding under constant current control of the material to be welded in an ideal state a state in which there is no sheet gap or electrode misalignment.
- an ideal state a state in which there is no sheet gap or electrode misalignment.
- the material that can be used for normal resistance spot welding is used to calculate and memorize the temporal change in instantaneous calorific value during welding using the welding process as a test welding
- the following adaptive control type Resistance spot welding can be applied to any steel plate.
- the stored temporal change in instantaneous calorific value is divided into two or more steps, and the temporal change in instantaneous calorific value and the cumulative calorific value are newly stored as target values for each step.
- the timing of division into steps can be specified by external input, monitoring parameters such as current during welding, voltage between electrodes, resistance between electrodes, distance between electrodes, and applied pressure can be monitored. From the results, the test welding can be easily divided into a plurality of steps at an appropriate timing desired by the operator. Furthermore, in each step divided as described above, the temporal change of each instantaneous heat generation amount and the cumulative heat generation amount are stored as target values, so that multi-stage adaptation in which the cumulative heat generation amount for each step is guaranteed in the main welding.
- Application of adaptive control welding to multi-stage resistance spot welding which can effectively obtain the good nugget by effectively responding to the wear and disturbance of the electrode tip because it enables controlled welding. Is possible.
- the pressure change during welding in the test welding is designated in advance by the pressure change state detecting means. Measure the timing at which the value is obtained. Then, by providing a mechanism for inputting the obtained timing to the resistance spot control device as a time for dividing the temporal change of the instantaneous calorific value stored in the test welding into a plurality of steps, Appropriate multi-step division timing is automatically applied to multi-stage adaptive control type resistance spot welding that can stably secure the required nugget diameter even for workpieces that are subject to large disturbances, such as when the spot spacing is narrow. To be able to get to.
- FIG. 1 It is a block diagram which shows the suitable form of the resistance spot welding system according to this invention.
- (A) is a cross section of a welded portion when test welding is performed, and (b) is a diagram showing transition of a welding current value, an electric resistance value, a cumulative heating value, and a pressing force at that time.
- (A) is a cross section of a welded part when two-stage adaptive control welding according to the present invention is performed, and (b) is a diagram showing transition of a welding current value, an electric resistance value, and a cumulative calorific value at that time.
- (A) is a cross section of a welded portion when conventional constant current control welding is performed, and (b) is a diagram showing the transition of the welding current value, electrical resistance value, and cumulative heat generation at that time.
- (A) is a cross section of a welded portion when conventional one-stage adaptive control welding is performed, and (b) is a diagram showing transition of a welding current value, an electrical resistance value, and a cumulative heat generation amount at that time.
- test welding is performed to calculate the temporal change of the calorific value and the cumulative calorific value calculated from the electrical characteristics between the electrodes when an appropriate nugget is formed.
- the energization pattern is divided into a plurality of steps based on the stored temporal change in the instantaneous calorific value, and the temporal change in the instantaneous calorific value and the cumulative calorific value for each step are stored as target values. .
- the present invention is characterized in that a good nugget can be obtained by effectively corresponding to the wear of the electrode tip and the presence of disturbance.
- FIG. 1 shows the configuration of a resistance spot welding system according to the present invention.
- reference numeral 1 denotes a resistance spot welding power source
- 2 denotes a control unit that gives a control signal to the resistance spot welding power source
- 3 denotes a welding current detection unit. The detected signal is input to the control unit 2.
- a secondary conductor 4 is connected to the output of the resistance spot welding power source 1 and is connected to the electrode 7 in order to energize the electrode 7.
- a strain sensor 9 is attached to the lower arm 5.
- Reference numeral 10 denotes a pressurizing force input processing unit which is a pressurizing force change state detecting means connected to the strain sensor 9, and the pressurizing force input processing unit 10 converts the strain detected by the strain sensor 9 into data via an A / D converter.
- the pressure can be calculated from the amount of strain of the arm when pressure is applied, and the change in pressure during welding can be measured.
- Reference numeral 11 denotes an interelectrode voltage detection line attached to the electrode 7 and is put in the control unit 2.
- the mode for performing the test welding and the mode for performing the main welding can be switched.
- the instantaneous heat generation amount is calculated from the current input from the welding current detection unit 3 and the voltage input from the interelectrode voltage detection line 11, and the time change is stored.
- the temporal change in the instantaneous calorific value is divided into a plurality of steps at the timing inputted from the 12 external input processing units, and the temporal change in the calorific value and the cumulative calorific value are separately stored as target values for each step. Is done.
- the input to the external input processing unit 12 is automatically input from the collected data at the timing at which the applied pressure during welding becomes a value designated in advance by the applied pressure input processing unit 10 in addition to the numerical input of the division timing by the user.
- the numerical value may be obtained automatically and the numerical value may be automatically input.
- the pressurizing force to be specified is not limited to one point, and a plurality of points can be specified as required, such as two points, three points, or more.
- the monitoring here is not limited to the applied pressure, but is calculated by some formula from the change in the distance between electrodes, the value from the encoder of the servo motor used for pressurization, the resistance value, current, voltage, etc. Any method can be used as long as it can capture changes in phenomena during welding, such as heat. Further, it is more effective to monitor a plurality of parameters by combining them and to provide a large number of division timings because adaptive control is performed with good responsiveness to changes in phenomena during welding.
- the control unit 2 calculates the instantaneous heat generation amount for each sampling time from the current input from the welding current detection unit 3 and the voltage input from the interelectrode voltage detection line 11, and the instantaneous heat generation amount at each time Compare target values. Then, when a difference occurs between the two values, adaptive control welding is performed in which the welding current is controlled according to the difference. That is, the control unit 2 performs adaptive control so that the accumulated heat generation amount of each step in the main welding matches the cumulative heat generation amount of each step stored as the target value within the remaining energization time of the step. The welding current thus applied is applied to the workpiece 8.
- test welding according to the present invention will be described. Welding conditions under which the required nugget diameter can be obtained by conducting constant current control and welding with the same steel type and thickness as the work piece, with no gaps and no shunting to the welded point. Find the appropriate pressure F, energization time T and welding current I. An inverter DC resistance spot welder is suitable as the welder, and a chrome copper electrode with a DR tip is advantageously adapted as the electrode. Further, the nugget diameter can be obtained by a peel test or cross-sectional observation at the center of the nugget (etching with a saturated aqueous solution of picric acid).
- welding is performed as a pressurizing force F, energization time T, and welding current I in the test welding mode, and the temporal change in instantaneous calorific value calculated from the electrical characteristics between the electrodes during welding is stored.
- the electrical characteristic between the electrodes means an interelectrode resistance or an interelectrode voltage.
- the energization pattern is divided into two or more multi-steps.
- adaptive control can be performed with high responsiveness to changes in phenomena during welding, but a desired effect can be obtained in about two stages or three stages. Is possible. Therefore, here, the case of two-stage division and three-stage division will be described in consideration of practicality.
- the molten portion is formed between the steel plates, which is a branching point between the beginning of the formation of the molten portion between the steel plates and the subsequent nugget growth process.
- the timing at which a melted part starts to be formed between steel plates can be determined by performing welding with varying energization time and observing the peel test or observing the cross section of the melted part.
- the material to be welded is a plated steel plate
- the specific resistance of the material to be welded increases as the temperature rises, so the specific resistance value also increases with the energization time. From the decrease in interelectrode resistance due to energization area expansion, A rise will occur, after which a melt zone will be formed. Therefore, the stage where the energization area rapidly expands after the plating is melted, the stage until a stable energization path (melting portion) is formed between the electrodes by energization thereafter, and the subsequent nugget growth process.
- the temporal change in instantaneous calorific value memorized in test welding is divided at the timing inputted from 10 external input processing units, and the temporal change in instantaneous calorific value and cumulative calorific value are stored as target values for each step.
- the timing of the division into multi-steps is as follows: Welding while changing the energization time under the same pressure F and welding current I as in test welding, and finding the timing at which the welding state changes by cross-sectional observation or peel test Good. It is also effective to monitor the resistance between electrodes during welding, the voltage between electrodes, the distance between electrodes, the applied pressure, etc., and determine from the changes.
- a change in pressure during welding is used as an index of the timing of division into multi-steps.
- the change in the applied pressure during welding can be measured from the strain sensor 9 attached to the lower arm 5.
- the vicinity of the welded portion is thermally expanded due to a rise in the temperature of the welded portion, and as a result, the gap between the electrode portions being pinched is expanded and the actual pressurizing force is increased.
- the peak of the waveform is shown, and the pattern that leads to a decrease in the applied pressure due to the formation of the melted part and the softening of the welded material to the plate of the electrode is shown. It can be considered the formation timing.
- the timing at which the maximum value of the welding pressure during welding is obtained by the pressure input processing unit 10 is automatically obtained from the collected data, and the numerical value is stored in the external input processing unit 12.
- main welding is performed. Welding starts welding based on the time variation curve of instantaneous calorific value obtained in the above test welding, and along the time variation curve based on the time variation amount of instantaneous calorific value at any step. If it is, the welding is performed as it is and the welding is finished. However, in any step, if the temporal change in instantaneous calorific value deviates from the standard time change curve, adaptive control welding is performed to control the energization amount according to the difference, and the cumulative amount in the main welding is obtained. Compensation is made within the remaining energization time of the step so that the heat generation amount matches the cumulative heat generation amount obtained in advance by test welding. As a result, it is possible to obtain a proper nugget diameter by securing the necessary accumulated heat generation amount even when the electrode tip is worn or in the presence of disturbance.
- the calorific value calculation method is not particularly limited, but an example thereof is disclosed in Patent Document 3. This method is also adopted in the present invention, and the calorific value per unit volume and the cumulative per unit volume are disclosed.
- the calorific value can be set as a target value.
- the procedure for calculating the cumulative calorific value Q per unit volume by this method is as follows.
- the total thickness of the two workpieces is t
- the electrical resistivity of the workpieces is r
- the voltage between the electrodes is V
- the welding current I
- the area where the electrodes and the workpiece are in contact is S.
- the welding current has a cross-sectional area S and passes through a columnar portion having a thickness t to generate resistance heat.
- the calorific value q per unit volume and unit time in the columnar part is obtained by the following equation (1).
- q (V ⁇ I) / (S ⁇ t) --- (1)
- the electrical resistance R of this columnar part is calculated
- R (r ⁇ t) / S ⁇ (2)
- the calorific value q per unit volume / unit time can be calculated from the voltage V between electrodes, the total thickness t of the workpiece, and the electrical resistivity r of the workpiece, And the area S where the workpiece is in contact is not affected.
- the calorific value is calculated from the interelectrode voltage V in the expression (3)
- the calorific value q can also be calculated from the interelectrode current I.
- the area S where the electrode and the work piece are in contact with each other can also be calculated. Need not be used.
- the cumulative calorific value Q per unit volume applied to welding is obtained.
- the cumulative calorific value Q per unit volume can also be calculated without using the area S where the electrode and the workpiece are in contact. As described above, the case where the cumulative heat generation amount Q is calculated by the method described in Patent Document 3 has been described, but it goes without saying that other calculation formulas may be used.
- the disturbance includes not only the case where there is an already-welded point near the above-mentioned welding point or the case where the contact point of the material to be welded exists, but also the wear of the electrode.
- the test welding in the present invention has been described in the case where the welding is performed without any disturbance such as the existing welding point, but even if the welding is performed with the existing welding point, the difference between the test welding and the main welding is reduced. It only makes adaptive control easier to work effectively, and there is no problem.
- Example 1 Mild steel (thickness: 1.6 mm) was prepared as a material to be welded. Moreover, the welding current was performed by a two-stage energization method. Two pieces of this material to be welded were stacked, and welding was performed under constant current control in a state where there was no gap or diversion to the existing welding point, and the welding conditions under which an appropriate nugget diameter was obtained were obtained. An inverter DC resistance spot welder was used as the welder, and a chrome copper electrode having a DR tip diameter of 6 mm was used as the electrode.
- the welding conditions were a constant pressure of 3.43 kN (350 kgf), energization time of 16 cyc (50 Hz (hereinafter, the unit of time is the number of cycles at 50 Hz)), and the welding current was variously changed.
- FIG. 2A shows a cross section of the welded portion when this test welding is performed
- FIG. 2B shows the transition of the welding current value, electrical resistance value, accumulated heat generation amount, and applied pressure at that time.
- the external input processing unit 12 to the control unit 2 determine that 4 cyc indicating the peak value of the applied pressure during welding is divided into two stages.
- the first step is up to 4 cyc and the second step is from 4 cyc to 16 cyc.
- the temporal change in instantaneous calorific value per unit volume and the cumulative calorific value per unit volume are stored as target values.
- the target cumulative heat generation amount in the first step obtained by this test welding was 138 J
- the target cumulative heat generation amount in the second step was 167 J. Therefore, the final target accumulated heat generation amount is 305J.
- Multi-stage adaptive control resistance spot welding according to the present invention was performed on the basis of the test welding described above under the condition that an existing welding point (welding point center interval: 7.5 mm) was present in the vicinity of the welding point and the influence of the diversion was large. . That is, resistance spot welding was performed based on a time change curve of instantaneous calorific value per unit volume obtained by test welding.
- FIG. 3 (a) shows the cross section of the welded portion at that time
- FIG. 3 (b) shows the transition of the welding current value, the electric resistance value, and the accumulated heat generation amount.
- resistance spot welding with constant current control (Comparative Example 1) and conventional one-stage energization are performed under the same conditions in which an existing welding point (weld point center interval: 7.5 mm) exists in the vicinity of the welding point.
- conventional adaptive control welding by one-stage energization is based on one-stage energization performed without any welding points under the conditions of applied pressure: 3.43 kN (350 kgf), energization time: 16 cyc, and welding current: 6.2 kA.
- FIG. 4 (a) shows a cross section of the weld when constant current control welding is performed, and FIG. 4 (b) shows the transition of the welding current value, electrical resistance value, and cumulative heat generation at that time.
- FIG. 5 (a) shows a cross section of a welded portion when conventional adaptive control welding by one-stage energization is performed, and FIG. 5 (b) shows changes in welding current value, electrical resistance value, and cumulative heat generation at that time. Show.
- the current greatly changes so that the accumulated heat generation amount is equivalent to that in the case of test welding, and as a result, the nugget diameter is 5.0 mm. I was able to get a nugget that was almost the target.
- a shortage of heat generation was observed under the influence of the diversion caused by the already-welded point, particularly in the first stage of the first step.
- the welding current was to be compensated for It can be seen that the target calorific value is secured by increasing.
- the cumulative heat generation amount in the first step in the main welding is 135 J
- the cumulative heat generation amount in the second step is 172 J
- a cumulative heat generation amount 307 J that is substantially similar to that in the test welding is obtained.
- Table 1 shows cumulative heat generation in the first step (up to 4 cyc) when test welding, two-stage adaptive control welding according to the present invention, conventional constant current control welding, and conventional one-stage adaptive control welding are performed. Are shown in comparison
- the cumulative heat generation amount equivalent to the cumulative heat generation amount of the test welding can be given up to the 4th cycle, but in the constant current control welding of the comparative example 1, the heat generation due to the shunt flow. A decrease in quantity was observed.
- the conventional one-stage adaptive control welding gives only a heat generation amount equivalent to that of the constant current control welding even though adaptive control is applied.
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Abstract
Description
この溶接法は、重ね合わせた2枚以上の鋼板を挟んでその上下から一対の電極で加圧しつつ、上下電極間に高電流の溶接電流を短時間通電して接合する方法であり、高電流の溶接電流を流すことで発生する抵抗発熱を利用して、点状の溶接部が得られる。この点状の溶接部はナゲットと呼ばれ、重ね合わせた鋼板に電流を流した際に鋼板の接触箇所で両鋼板が溶融し、凝固した部分であり、これにより鋼板同士が点状に接合される。
また、実際の施工においては、電極摩耗の進行状態にはバラツキがあるため、予め定めた溶接電流変化パターンが常に適正であるとはいえない。
この発熱量不足を補償し、必要な径のナゲットを得るには、予め高い溶接電流を設定することが必要となる。
例えば、特許文献1には、推算した溶接部の温度分布と目標ナゲットを比較して溶接機の出力を制御することによって、設定されたナゲットが得られるようにした抵抗溶接機の制御装置が記載されている。
1.複数枚の金属板を重ね合わせた被溶接材を、一対の電極によって挟み、加圧しながら通電して接合する抵抗スポット溶接システムであって、
本溶接に先立つテスト溶接時に、定電流制御により通電して適正なナゲットを形成する場合の溶接中の電極間の電気特性から算出される瞬時発熱量の時間変化を計算し、記憶させる手段と、
上記記憶させた瞬時発熱量の時間変化に基づき、テスト溶接後の外部からの入力により、通電パターンを複数のステップに区切り、各ステップ毎の瞬時発熱量の時間変化および累積発熱量を目標値として記憶させる手段と、
引き続く本溶接時に、目標値として記憶させた瞬時発熱量の時間変化曲線を基準として溶接を開始し、いずれかのステップにおいて、瞬時発熱量の時間変化量が目標の時間変化曲線から外れた場合に、その差を当該ステップの残りの通電時間内で補償し、当該ステップの目標累積発熱量と一致するように瞬時発熱量および累積発熱量を発生させるように溶接中に溶接電流又は電圧を調整する適応制御手段と
を備える抵抗スポット溶接システム。
この加圧力変化状態検知手段により、前記テスト溶接における溶接中の加圧力が予め指定された値となるタイミングを求め、求められたタイミングを、前記通電パターンを複数のステップに区切る時間として入力する前記1に記載の抵抗スポット溶接システム。
また、記憶された瞬時発熱量の時間変化は、2段以上の複数のステップに分割され、各ステップ毎に瞬時発熱量の時間変化、累積発熱量が目標値として新しく記憶されるが、この複数のステップへの分割するタイミングの指定が外部からの入力により可能であるため、溶接中の電流、電極間電圧、電極間抵抗、電極間距離、加圧力などのパラメータをモニタリングすることにより、モニタリングの結果から作業者が望む適切なタイミングでテスト溶接を複数のステップに容易に分割することができる。
さらに、上記のように分割された各ステップにおいて、それぞれの瞬時発熱量の時間変化および累積発熱量を目標値として記憶させることで、本溶接において、ステップ毎の累積発熱量が保証された多段適応制御溶接を可能としたため、電極先端の摩耗や外乱の存在にも有効に対応して、良好なナゲットを得ることができ、また多段通電が必要となる多段抵抗スポット溶接への適応制御溶接の適用が可能となる。
本発明の抵抗スポット溶接システムでは、本溶接に先立ち、テスト溶接を実施して、適正なナゲットを形成する場合の電極間の電気特性から算出される、瞬時発熱量の時間変化および累積発熱量を記憶させる。そして、記憶させた瞬時発熱量の時間変化に基づき、外部からの入力により、通電パターンを複数のステップに分割し、各ステップ毎の瞬時発熱量の時間変化および累積発熱量を目標値として記憶させる。引き続く本溶接において、いずれかのステップにおいて、瞬時発熱量の時間変化量に目標値からの差が生じたとしても、適応制御溶接を活用して、その差を当該ステップの残りの通電時間内で補償し、本溶接の累積発熱量をテスト溶接で求めた累積発熱量と一致させる。かくして、電極先端の摩耗や外乱の存在にも有効に対応して、良好なナゲットを得るところに特徴がある。
図1は、本発明に従う抵抗スポット溶接システムの構成を示したものである。
図中、符号1は抵抗スポット溶接電源、2は抵抗スポット溶接電源1へ制御信号を与える制御部、3は溶接電流の検出部で、検出した信号を制御部2に入れている。4は抵抗スポット溶接電源1の出力に接続された二次導体で、電極7に通電するために電極7に接続されている。
テスト溶接モードにおいては、溶接電流検出部3から入力された電流と、電極間電圧検出線11から入力された電圧から瞬時発熱量が計算され、その時間変化が記憶される。
記憶された瞬時発熱量の時間変化は、12の外部入力処理部から入力されたタイミングで複数のステップに分割され、各ステップ毎に瞬時発熱量の時間変化および累積発熱量が目標値として別途記憶される。なお、外部入力処理部12への入力は、使用者による分割タイミングの数値入力の他、加圧力入力処理部10にて溶接中の加圧力が予め指定された値となるタイミングを収集データから自動的に求め、その数値を自動的に入力するように構成されていてもよい。
指定する加圧力は、1点に限定されず、必要に応じて2点、3点、それ以上と、複数指定することができる。また、ここでモニタリングするのは加圧力に限定されず、電極間距離の変化、加圧に用いているサーボモータのエンコーダからの値、抵抗値、あるいは電流、電圧等から何らかの式で計算された熱量など、溶接中の現象の変化を捉えることができるものであれば、いずれでも構わない。さらに、それらを組み合わせて複数のパラメータをモニタリングし、多くの分割タイミングを設けることは、溶接中の現象の変化に応答性良く適応制御していくことになるので、より有効である。
まず、本発明に従うテスト溶接について説明する。
被溶接材と同じ鋼種、厚みの試験を、ギャップや既溶接点への分流のない状態で、定電流制御にて種々の条件で溶接を行い、必要とするナゲット径が得られる溶接条件、すなわち適正な加圧力F、通電時間Tおよび溶接電流Iを見つける。
なお、溶接機としてはインバータ直流抵抗スポット溶接機が好適であり、また電極としてはDR形先端のクロム銅電極が有利に適合する。さらに、ナゲット径は、ピール試験やナゲット中央の断面観察(ピクリン酸飽和水溶液にてエッチング)により求めることができる。
以上の実験結果から、テスト溶接モードにて、加圧力F、通電時間T、溶接電流Iとして溶接を行い、溶接中における電極間の電気特性から算出される瞬時発熱量の時間変化を記憶させて、テスト溶接とする。
なお、本発明において電極間の電気特性とは、電極間抵抗あるいは電極間電圧を意味する。
・2段分割の場合
鋼板間に溶融部が形成され始めるまでと、それ以降のナゲット成長過程との分岐点である鋼板間に溶融部が形成される時点とするのが好適である。
というのは、既溶接点への分流は、電極直下に安定した通電経路(溶融部)が形成されるまでがその影響が大きいことから、溶融部が形成されるまで単位体積当たりの累積発熱量を保証するように適応制御溶接を行うことで、近くに既溶接点が存在しても安定して通電経路が形成され、その後の第2ステップで安定したナゲットの成長が可能になるからである。
なお、鋼板間に溶融部が形成され始めるタイミングは、通電時間を変化させた溶接を行い、そのピール試験による観察や、溶融部の断面観察により判断することができる。
また、被溶接材がめっき鋼板の場合、めっきの溶融を考慮した3段分割とすることが、より好適である。というのは、めっきが存在する場合、分流の影響が大きく、その結果、電極直下に安定した通電経路が形成されるまでの現象が大きく変化するためである。めっきの融点は鋼板より低いため、通電を開始するとはじめに鋼板間のめっきが溶融に至り、溶融しためっきは加圧力により鋼板間から一部が吐き出される。このとき吐き出されためっきが通電面積を広げることとなるため、溶接中の電極間抵抗が大きく減少する。一方で、被溶接材の固有抵抗は温度上昇とともに増加するため、通電時間とともに固有抵抗値も上昇し、通電面積拡大による電極間抵抗の減少から、被溶接材の温度の上昇による電極間抵抗の上昇が生じるようになり、その後、溶融部が形成されることになる。よって、めっきが溶融して急激に通電面積が拡大する段階と、その後の通電により電極間に安定した通電経路(溶融部)が形成されるまでの段階、および、その後のナゲット成長過程の3段に溶接プロセスを分割して、それぞれの段階で、単位体積当たりの累積発熱量を保証するように適応制御溶接を行うことで、めっき鋼板の抵抗スポット溶接で近くに既溶接点が存在しても、安定して通電経路が形成され、その後の第3ステップで安定したナゲットの成長が可能になるからである。
本溶接は、上記のテスト溶接で得られた瞬時発熱量の時間変化曲線を基準として溶接を開始し、いずれのステップにおいても、瞬時発熱量の時間変化量が基準である時間変化曲線に沿っている場合には、そのまま溶接行って溶接を終了する。
ただし、いずれかのステップにおいて、瞬時発熱量の時間変化量が基準である時間変化曲線から外れた場合には、その差に応じて通電量を制御する適応制御溶接を行って、本溶接における累積発熱量がテスト溶接で予め求めた累積発熱量と一致するように、当該ステップの残りの通電時間内で補償するのである。
これにより、電極先端が摩耗したり、外乱の存在下においても必要な累積発熱量を確保して、適正なナゲット径を得ることができる。
この方法による単位体積当たりの累積発熱量Qの算出要領は次のとおりである。
2枚の被溶接材の合計厚みをt、被溶接材の電気抵抗率をr、電極間電圧をV、溶接電流をIとし、電極と被溶接材が接触する面積をSとする。この場合、溶接電流は横断面積がSで、厚みtの柱状部分を通過して抵抗発熱を発生させる。この柱状部分における単位体積・単位時間当たりの発熱量qは次式(1)で求められる。
q=(V・I)/(S・t) −−− (1)
また、この柱状部分の電気抵抗Rは、次式(2)で求められる。
R=(r・t)/S −−− (2)
(2)式をSについて解いてこれを(1)式に代入すると、発熱量qは次式(3)
q=(V・I・R)/(r・t2)
=(V2)/(r・t2) −−− (3)
となる。
なお、(3)式は電極間電圧Vから発熱量を計算しているが、電極間電流Iから発熱量qを計算することもでき、このときにも電極と被溶接物が接触する面積Sを用いる必要がない。
以上、特許文献3に記載の方法によって、累積発熱量Qを算出する場合について説明したが、その他の算出式を用いても良いのは言うまでもない。
また、本発明におけるテスト溶接に関しては、既溶接点等の外乱のない状態で行う場合について説明したが、既溶接点のある状態で行っても、テスト溶接と本溶接の状態の差が小さくなり適応制御が効果的に働きやすくなるだけであり、何ら問題はない。
被溶接材として、軟鋼(厚み:1.6mm)を準備した。また、溶接電流は2段通電方式で行うものとした。
この被溶接材を2枚重ねにし、ギャップや既溶接点への分流のない状態にて定電流制御にて溶接を行い、適切なナゲット径が得られる溶接条件を求めた。溶接機にはインバータ直流抵抗スポット溶接機を用い、電極にはDR形先端径6mmのクロム銅電極を用いた。なお、溶接条件は、加圧力は3.43kN(350kgf)、通電時間は16cyc(50Hz(以降、時間の単位はすべて50Hzにおけるcycle数とする))の一定とし、溶接電流を種々に変更して、ナゲット径:4√t(t:板厚)が得られる電流値を求めた。この例で、適正なナゲット径は4√t=5.1mmとなる。
このテスト溶接を行ったときの溶接部断面を図2(a)に、その時の溶接電流値、電気抵抗値、累積発熱量および加圧力の推移を図2(b)に示す。
ここに、このテスト溶接で得られた第1ステップでの目標累積発熱量は138J、第2ステップでの目標累積発熱量は167Jであった。従って、最終的な目標累積発熱量は305Jとなる。
溶接点の近傍に予め既溶接点(溶接点中央間隔:7.5mm)が存在し、分流の影響が大きい条件で、上記したテスト溶接を基準として本発明に従う多段適応制御抵抗スポット溶接を行った。すなわち、テスト溶接で得られた単位体積当たりの瞬時発熱量の時間変化曲線を基準として抵抗スポット溶接を行った。
図3(a)にその時の溶接部断面を、また図3(b)に溶接電流値、電気抵抗値および累積発熱量の推移を示す。
図4(a)に定電流制御溶接を行った時の溶接部断面を、また図4(b)にその時の溶接電流値、電気抵抗値および累積発熱量の推移を示す。
また、図5(a)に従来の1段通電による適応制御溶接を行った時の溶接部断面を、また図5(b)にその時の溶接電流値、電気抵抗値および累積発熱量の推移を示す。
本発明例では、特に第1ステップの前段において、既溶接点に起因した分流の影響を受けて発熱量の不足が見受けられたが、第1ステップの後段では、この不足分を補うべく溶接電流を増加させて目標とする発熱量を確保していることが分かる。
ここに、本溶接における第1ステップでの累積発熱量は135J、第2ステップでの累積発熱量は172Jであり、テスト溶接とほぼ同様な累積発熱量307Jが得られている。
また、従来の1段通電による適応制御溶接では、電流の制御が溶接現象の変化に対応できず、累積発熱量がテスト溶接よりも多くなり、5.6mmとナゲット径が過大になっており、散りが発生しやすい状態になっていた。
2 抵抗スポット溶接電源へ制御信号を与える制御部
3 溶接電流の検出部
4 抵抗スポット溶接電源の出力に接続された二次導体
5 下部アーム
6 加圧シリンダ
7 電極
8 被溶接材
9 ひずみセンサ
10 加圧力入力処理部
11 電極間電圧検出線
12 外部入力処理部
Claims (2)
- 複数枚の金属板を重ね合わせた被溶接材を、一対の電極によって挟み、加圧しながら通電して接合する抵抗スポット溶接システムであって、
本溶接に先立つテスト溶接時に、定電流制御により通電して適正なナゲットを形成する場合の溶接中の電極間の電気特性から算出される瞬時発熱量の時間変化を計算し、記憶させる手段と、
上記記憶させた瞬時発熱量の時間変化に基づき、テスト溶接後の外部からの入力により、通電パターンを複数のステップに区切り、各ステップ毎の瞬時発熱量の時間変化および累積発熱量を目標値として記憶させる手段と、
引き続く本溶接時に、目標値として記憶させた瞬時発熱量の時間変化曲線を基準として溶接を開始し、いずれかのステップにおいて、瞬時発熱量の時間変化量が目標の時間変化曲線から外れた場合に、その差を当該ステップの残りの通電時間内で補償し、当該ステップの目標累積発熱量と一致するように瞬時発熱量および累積発熱量を発生させるように溶接中に溶接電流又は電圧を調整する適応制御手段と
を備える抵抗スポット溶接システム。 - 前記抵抗スポット溶接システムが、さらに溶接開始後の加圧力変化状態を検知する加圧力変化状態検知手段を備え、
この加圧力変化状態検知手段により、前記テスト溶接における溶接中の加圧力が予め指定された値となるタイミングを求め、求められたタイミングを、前記通電パターンを複数のステップに区切る時間として入力する請求項1に記載の抵抗スポット溶接システム。
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Also Published As
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EP2979806B1 (en) | 2017-07-26 |
US9895764B2 (en) | 2018-02-20 |
KR101584495B1 (ko) | 2016-01-13 |
MX2015013788A (es) | 2016-02-16 |
KR20150121262A (ko) | 2015-10-28 |
EP2979806A4 (en) | 2016-06-15 |
EP2979806A1 (en) | 2016-02-03 |
US20160008914A1 (en) | 2016-01-14 |
CN105073326A (zh) | 2015-11-18 |
MX344288B (es) | 2016-12-13 |
CN105073326B (zh) | 2018-01-30 |
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