CN112894080A - Method and device for controlling length of welding arc - Google Patents
Method and device for controlling length of welding arc Download PDFInfo
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- CN112894080A CN112894080A CN201911137468.4A CN201911137468A CN112894080A CN 112894080 A CN112894080 A CN 112894080A CN 201911137468 A CN201911137468 A CN 201911137468A CN 112894080 A CN112894080 A CN 112894080A
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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
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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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
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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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
- B23K9/32—Accessories
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- Arc Welding Control (AREA)
Abstract
The invention discloses a method and a device for controlling the length of a welding arc, and belongs to the technical field of welding. The method comprises the following steps: the current sensor acquires welding current during welding; the data acquisition card transmits the welding current to an operation controller; the operation controller acquires a first arc length according to the welding current, and compares the first arc length with a theoretical arc length to obtain a comparison result; the operation controller obtains arc length adjustment information according to the comparison result and sends the adjustment information to a stepping motor driver; and the step motor driver adjusts the distance between the welding gun and the base metal according to the adjustment information, so as to control the arc length. The invention solves the problems of inaccurate and unstable automatic control of the arc length of gas shielded welding and the like, and leads the control of welding process parameters to be faster and more accurate.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a method and a device for controlling the length of a welding arc.
Background
In the gas shielded welding construction process, the length of the electric arc needs to be adjusted according to the requirements of the welding process so as to achieve different welding effects and ensure the welding quality.
In the related art, a mechanical probe in a welding gun is contacted with a base metal, and the arc length is indirectly judged according to the position change condition of the mechanical probe, so that the arc length is adjusted.
The inventors found that the related art has at least the following problems:
the mechanical probe is easy to wear, the control precision of the arc length is difficult to ensure, and the welding effect is poor.
Disclosure of Invention
The embodiment of the invention provides a method and a device for controlling the length of a welding arc, which can solve the problems that a mechanical probe is easy to wear, the control precision of the length of the arc is difficult to guarantee, and the welding effect is poor in the related technology.
The technical scheme is as follows:
in one aspect, a method of controlling a length of a welding arc is provided, the method comprising:
acquiring welding current during welding;
transmitting the welding current to an arithmetic controller;
the operation controller acquires a first arc length according to the welding current, and compares the first arc length with a theoretical arc length to obtain a comparison result;
the operation controller obtains arc length adjustment information according to the comparison result and sends the adjustment information to a stepping motor driver;
and the step motor driver adjusts the distance between the welding gun and the base metal according to the adjustment information so as to control the arc length.
Optionally, the method further comprises:
acquiring a wire feeding speed and a preset welding current during welding;
and obtaining the theoretical arc length according to the wire feeding speed and the preset welding current.
Optionally, the operation controller obtains a first arc length according to the welding current, and compares the first arc length with a theoretical arc length to obtain a comparison result, including:
obtaining a first comparison result when the first arc length is greater than the theoretical arc length;
and obtaining adjustment information for reducing the arc length according to the first comparison result, and sending the adjustment information for reducing the arc length to the stepping motor driver.
Optionally, the operation controller obtains a first arc length according to the welding current, and compares the first arc length with a theoretical arc length to obtain a comparison result, including:
when the first arc length is smaller than the theoretical arc length, obtaining a second comparison result;
and obtaining adjustment information for increasing the arc length according to the second comparison result, and sending the adjustment information for increasing the arc length to the stepping motor driver.
Optionally, the step motor driver adjusts a distance between the welding gun and the base material according to the adjustment information, and further controls the arc length, including:
and the stepping motor driver drives a mechanical arm connected with a welding gun to move according to the adjustment information, and adjusts the distance between the welding gun and the base metal.
In another aspect, there is provided a control apparatus for a welding arc length, the apparatus comprising:
the device comprises a current sensor arranged on a welding gun, a data acquisition card electrically connected with the current sensor, an operation controller electrically connected with the data acquisition card, and a stepping motor driver connected with an operation control unit;
the current sensor is used for acquiring welding current during welding;
the data acquisition card is used for transmitting the welding current to the operation controller;
the operation controller is used for acquiring a first arc length according to the welding current and comparing the first arc length with a theoretical arc length to obtain a comparison result;
the operation controller is also used for obtaining arc length adjustment information according to the comparison result and sending the adjustment information to a stepping motor driver;
and the step motor driver is used for adjusting the distance between the welding gun and the base metal according to the adjustment information by the step motor driver so as to control the length of the electric arc.
Optionally, the apparatus further comprises:
the acquisition unit is used for acquiring the length and the diameter of a target welding wire and preset welding current;
and obtaining the theoretical arc length of the target welding wire according to the length and the diameter of the target welding wire and the preset welding current.
Optionally, the stepping motor driver is configured to drive a manipulator connected to a welding gun to move according to the adjustment information, so as to adjust a distance between the welding gun and the base material.
Optionally, the step of obtaining a first comparison result when the first arc length is greater than the theoretical arc length;
and obtaining adjustment information for reducing the arc length according to the first comparison result, and sending the adjustment information for reducing the arc length to the stepping motor driver.
Optionally, the step of obtaining a second comparison result when the first arc length is smaller than the theoretical arc length;
and obtaining adjustment information for increasing the arc length according to the second comparison result, and sending the adjustment information for increasing the arc length to the stepping motor driver.
The technical scheme provided by the embodiment of the invention has the beneficial effects that at least:
according to the method provided by the embodiment of the invention, the real-time welding current of the welding gun during welding is obtained through the current sensor, and in gas shielded welding, the welding current is determined by the wire feeding speed of the welding wire and the length of the welding arc. The welding current, the wire feed speed and the arc length are related. The wire feeding speed of the welding wire is a preset value and is a known quantity; the welding current can be measured by a sensor; therefore, the arc length can be calculated according to the wire feeding speed and the welding current of the welding wire, and the purpose of adjusting the arc length is achieved. The method provided by the embodiment of the invention solves the problems of inaccurate and unstable automatic control of the arc length of gas shielded welding and the like, and enables the control of welding process parameters to be faster and more accurate; the automatic control level of the welding process is improved, manual intervention in the welding process is avoided, partial energy of operators is liberated, the intellectualization of an automatic welding control system is realized, and compared with other control modes, the automatic control system is small in size and low in cost.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a flow chart of control of the welding arc length provided by an embodiment of the present invention;
fig. 2 is a schematic structural diagram of a welding arc length control device according to an embodiment of the present invention.
Detailed Description
Unless defined otherwise, all technical terms used in the examples of the present invention have the same meaning as commonly understood by one of ordinary skill in the art.
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
In the gas shielded welding construction process, the length of the electric arc needs to be adjusted according to the requirements of the welding process so as to achieve different welding effects and ensure the welding quality. In traditional manual welding, the arc is observed manually, and the length of the arc is adjusted manually. The manual adjustment precision is difficult to guarantee, and the labor intensity is high. In order to achieve automatic control, a contact follow-up tracking technology has emerged. The mechanical probe contacts the base metal, and the arc length is indirectly judged according to the position change condition of the probe, so that automatic adjustment is realized. However, in this technique, the mechanical contact is easily worn and the accuracy is difficult to ensure. With the development of automatic control technology, arc length control technology based on laser vision has emerged. The control technology based on laser vision is often influenced by arc light, and the arc splashing often pollutes the laser lens device, influences the automatic tracking effect, and has higher cost. In view of this, the embodiment of the present invention provides a method and an apparatus for controlling a welding arc length.
In one aspect, an embodiment of the present invention provides a method for controlling a length of a welding arc, as shown in fig. 1, the method including:
And 102, transmitting the welding current to the operation controller by the data acquisition card.
And 103, acquiring a first arc length according to the welding current by the operation controller, and comparing the first arc length with a theoretical arc length to obtain a comparison result.
And step 104, the operation controller obtains arc length adjustment information according to the comparison result and sends the adjustment information to the stepping motor driver.
And 105, adjusting the distance between the welding gun and the base metal by the stepping motor driver according to the adjustment information, and further controlling the arc length.
The method provided by the embodiment of the invention at least has the following technical effects:
according to the method provided by the embodiment of the invention, the real-time welding current of the welding gun during welding is obtained through the current sensor, and in gas shielded welding, the welding current is determined by the wire feeding speed of the welding wire and the length of the welding arc. The welding current, the wire feed speed and the arc length are related. The wire feeding speed of the welding wire is a preset value and is a known quantity; the welding current can be measured by a sensor; therefore, the arc length can be calculated according to the wire feeding speed and the welding current of the welding wire, and the purpose of adjusting the arc length is achieved. The method provided by the embodiment of the invention solves the problems of inaccurate and unstable automatic control of the arc length of gas shielded welding and the like, and enables the control of welding process parameters to be faster and more accurate; the automatic control level of the welding process is improved, manual intervention in the welding process is avoided, partial energy of operators is liberated, the intellectualization of an automatic welding control system is realized, and compared with other control modes, the automatic control system is small in size and low in cost.
The methods provided by embodiments of the present invention will be further described below by way of alternative embodiments.
Optionally, the current sensor may be mounted on the welding gun to obtain the current during welding. The current sensor can sense the information of the current to be measured and convert the sensed information into an electric signal meeting certain standard requirements or information in other required forms to be output according to a certain rule. The embodiment of the invention monitors the welding current during welding through the current sensor, and ensures that the welding current can be detected by the current sensor when the welding current changes.
And 102, transmitting the welding current to the operation controller by the data acquisition card.
Optionally, in the embodiment of the present application, the welding current may be transmitted to the operation controller through the data acquisition card, and the current signal monitored by the current sensor may be acquired through the data acquisition card and transmitted to the operation controller for analysis and processing. For example, the data acquisition card may be electrically connected to the current sensor to acquire and transmit current data.
And 103, acquiring a first arc length according to the welding current by the operation controller, and comparing the first arc length with a theoretical arc length to obtain a comparison result.
It should be noted that the operation controller provided in the embodiment of the present invention may be an upper computer, and may also be a programmable logic controller, a microcontroller, or a digital signal processor.
Optionally, the method further comprises obtaining a theoretical arc length: namely, the wire feeding speed and the preset welding current during welding are obtained; and obtaining the theoretical arc length according to the wire feeding speed and the preset welding current.
In gas metal arc welding, the welding current is determined by the wire feed speed and the length of the welding arc. The welding current, wire feed speed, and arc length are related. The wire feed speed is also the welding current, in other words the current is larger the faster the wire feed speed. The wire feed speed refers to the wire feed speed during the welding process, i.e., the length of wire fed out of the contact tip per unit time. The wire feeding speed is matched with the process parameters of electric arc, voltage and the like. Taking carbon dioxide arc welding as an example: that is, the wire feed speed is determined based on the thickness of the base material, the welding position, and the diameter of the welding wire. For example, when the thickness of the base material is large and the diameter of the welding wire is large, the wire feeding speed is slow.
Therefore, the theoretical arc length of the target welding wire can be obtained according to the length and the diameter of the target welding wire and the preset current of welding by obtaining the length and the diameter of the target welding wire and the preset current of welding. For example, the preset current may be 600A-1000A according to the base material to be welded.
As an example, the calculation controller provided in the embodiment of the present invention calculates according to the welding current to obtain the first arc length, and may obtain the first arc length according to the following formula: h ═ aI + bS + c. Wherein I is the welding current, S is the wire feed speed, h is the arc length, and a, b, and c are constants.
Optionally, step 103 comprises: and when the first arc length is larger than the theoretical arc length, obtaining a first comparison result, and taking the first comparison result as the comparison result.
Optionally, step 103 comprises: and when the first arc length is smaller than the theoretical arc length, obtaining a second comparison result, and taking the second comparison result as the comparison result.
It will be appreciated that the calculation controller performs a calculation based on the welding current to obtain the first arc length. The constants a, b, and c need to be determined in advance in the formula h ═ aI + bS + c. The constants a, b, c can be calculated by the above formula through a pre-designed experiment.
As an example, the test method provided by the embodiment of the present invention is: under the conditions of the determined wire feeding speed and arc length, 3 groups of welding currents are measured, and the wire feeding speed S, the arc length h and the measured welding current I are substituted into the formula to calculate the values of a, b and c. In the actual welding process, the wire feeding speed S is a known quantity, the welding current I can be obtained through a sensor, S and I are substituted into the formula to obtain the theoretical arc length, the first arc length and the theoretical arc length are compared to obtain a difference value, and then the height of the welding gun is adjusted by driving a manipulator through a stepping motor, so that the arc length is adjusted.
The first arc length may be longer than the theoretical arc length or shorter than the theoretical arc length. Therefore, the result obtained when the first arc length is greater than the theoretical arc length is used as the first comparison result, and the adjustment information of the arc length is obtained from the first comparison result. And when the first arc length is smaller than the theoretical arc length, obtaining a second comparison result, and obtaining the adjustment information of the arc length through the second comparison result.
And step 104, the operation controller obtains arc length adjustment information according to the comparison result and sends the adjustment information to the stepping motor driver.
Optionally, step 104 comprises: and obtaining adjustment information for reducing the arc length according to the first comparison result, and sending the adjustment information for reducing the arc length to the stepping motor driver.
Optionally, step 104 comprises: and obtaining the adjustment information for increasing the arc length according to the second comparison result, and sending the adjustment information for increasing the arc length to the stepping motor driver.
When the first arc length is compared with the theoretical arc length and the length of the first arc length is larger than the theoretical arc length, the length of the first arc length is too long, and the length of the first arc length needs to be reduced.
When the length of the first arc length is smaller than the theoretical arc length after the first arc length is compared with the theoretical arc length, the length of the first arc length is too small, and the length of the first arc length needs to be increased. It should be noted that the operation controller provided in the embodiment of the present invention may be a programmable logic controller or a combination of an operator and a programmable logic controller.
And 105, adjusting the distance between the welding gun and the base metal by the stepping motor driver according to the adjustment information, and further controlling the arc length.
Optionally, step 105 comprises: and the stepping motor driver drives the mechanical arm connected with the welding gun to move according to the adjustment information, so that the distance between the welding gun and the base metal is adjusted.
In the method according to the embodiment of the present invention, when welding is performed, the welding gun is connected to the robot, the robot is connected to the stepping motor driver, the robot is driven by the stepping motor driver, and the distance between the welding gun and the base material is adjusted by the robot. Therefore, the problem that in the related art, the welding gun and the base metal are adjusted manually to cause inaccurate adjustment results and further influence on welding effect is avoided.
It should be noted that the stepping motor driver provided in the embodiment of the present invention may also be a servo motor driver.
In another aspect, an embodiment of the present invention provides a device for controlling a length of a welding arc, as shown in fig. 2, the device including:
a current sensor 201 arranged on the welding gun, a data acquisition card 202 electrically connected with the current sensor 201, an operation controller 203 electrically connected with the data acquisition card 202, and a stepping motor driver 204 connected with the operation control unit 203;
the current sensor 201 is used for acquiring welding current during welding;
the data acquisition card 202 is used for transmitting the welding current to the operation controller;
the operation controller 203 is used for acquiring a first arc length according to the welding current, and comparing the first arc length with a theoretical arc length to obtain a comparison result;
the operation controller 203 is also used for obtaining arc length adjustment information according to the comparison result and sending the adjustment information to the stepping motor driver;
the stepping motor driver 204 is used for adjusting the distance between the welding gun and the base metal according to the adjustment information by the stepping motor driver, and further controlling the arc length.
Optionally, the device further comprises an obtaining unit, configured to obtain a wire feeding speed and a preset welding current during welding;
and obtaining the theoretical arc length according to the wire feeding speed and the preset welding current.
Optionally, the operation controller 203 is configured to obtain a first comparison result when the first arc length is greater than the theoretical arc length;
and obtaining adjustment information for reducing the arc length according to the first comparison result, and sending the adjustment information for reducing the arc length to the stepping motor driver.
Optionally, the operation controller 203 is configured to obtain a second comparison result when the first arc length is smaller than the theoretical arc length;
and obtaining the adjustment information for increasing the arc length according to the second comparison result, and sending the adjustment information for increasing the arc length to the stepping motor driver.
Optionally, the stepping motor driver 204 is configured to drive a manipulator connected to the welding gun to move according to the adjustment information, so as to adjust a distance between the welding gun and the base material.
According to the device provided by the embodiment of the invention, the real-time welding current of the welding gun during welding is obtained through the current sensor, and in gas shielded welding, the welding current is determined by the wire feeding speed of a welding wire and the length of a welding arc. The welding current, the wire feed speed and the arc length are related. The wire feeding speed of the welding wire is a preset value and is a known quantity; the welding current can be measured by a sensor; the arc length can thus be calculated from the wire feed speed of the welding wire and the welding current. Therefore, when the welding current changes, the welding current can be timely and accurately acquired through the current sensor; the welding current output by the current sensor is converted into a digital signal through a data acquisition card and transmitted to an operation controller; the operation controller calculates the welding arc length according to the welding current and compares the welding arc length with a standard arc length value to obtain a comparison result, and simultaneously obtains arc length adjustment information according to the comparison result, the operation controller sends the adjustment information to a stepping motor driver electrically connected with the welding gun, and the stepping motor driver adjusts the distance between the welding gun and the base metal according to the adjustment information, so that the purpose of adjusting the arc length is achieved.
All the above optional technical solutions may be combined arbitrarily to form the optional embodiments of the present disclosure, and are not described herein again.
The above description is only an illustrative embodiment of the present invention, and should not be taken as limiting the scope of the invention, and any modifications, equivalents, improvements and the like that are within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A method of controlling the length of a welding arc, the method comprising:
the current sensor acquires welding current during welding;
the data acquisition card transmits the welding current to an operation controller;
the operation controller acquires a first arc length according to the welding current, and compares the first arc length with a theoretical arc length to obtain a comparison result;
the operation controller obtains arc length adjustment information according to the comparison result and sends the adjustment information to a stepping motor driver;
and the step motor driver adjusts the distance between the welding gun and the base metal according to the adjustment information so as to control the arc length.
2. The method of claim 1, further comprising:
acquiring a wire feeding speed and a preset welding current during welding;
and obtaining the theoretical arc length according to the wire feeding speed and the preset welding current.
3. The method of claim 1, wherein the operator obtains a first arc length from the welding current and compares the first arc length to a theoretical arc length to obtain a comparison result, comprising:
obtaining a first comparison result when the first arc length is greater than the theoretical arc length;
and obtaining adjustment information for reducing the arc length according to the first comparison result, and sending the adjustment information for reducing the arc length to the stepping motor driver.
4. The method of claim 1, wherein the operator obtains a first arc length from the welding current and compares the first arc length to a theoretical arc length to obtain a comparison result, comprising:
when the first arc length is smaller than the theoretical arc length, obtaining a second comparison result;
and obtaining adjustment information for increasing the arc length according to the second comparison result, and sending the adjustment information for increasing the arc length to the stepping motor driver.
5. The method of claim 1, wherein the step motor driver adjusts a distance between the welding torch and the base material according to the adjustment information, thereby controlling the arc length, comprising:
and the stepping motor driver drives a mechanical arm connected with a welding gun to move according to the adjustment information, and adjusts the distance between the welding gun and the base metal.
6. A device for controlling the length of a welding arc, said device comprising:
the device comprises a current sensor arranged on a welding gun, a data acquisition card electrically connected with the current sensor, an operation controller electrically connected with the data acquisition card, and a stepping motor driver connected with an operation control unit;
the current sensor is used for acquiring welding current during welding;
the data acquisition card is used for transmitting the welding current to the operation controller;
the operation controller is used for acquiring a first arc length according to the welding current and comparing the first arc length with a theoretical arc length to obtain a comparison result;
the operation controller is also used for obtaining arc length adjustment information according to the comparison result and sending the adjustment information to a stepping motor driver;
and the step motor driver is used for adjusting the distance between the welding gun and the base metal according to the adjustment information by the step motor driver so as to control the length of the electric arc.
7. The apparatus of claim 6, further comprising:
the acquisition unit is used for acquiring the length and the diameter of a target welding wire and preset welding current;
and obtaining the theoretical arc length of the target welding wire according to the length and the diameter of the target welding wire and the preset welding current.
8. The apparatus according to claim 6, wherein the stepping motor driver is configured to drive a robot connected to a welding gun to move according to the adjustment information, thereby adjusting a distance between the welding gun and the base material.
9. The apparatus of claim 6, wherein the calculation controller is configured to obtain a first comparison result when the first arc length is greater than the theoretical arc length;
and obtaining adjustment information for reducing the arc length according to the first comparison result, and sending the adjustment information for reducing the arc length to the stepping motor driver.
10. The apparatus of claim 6, wherein the calculation controller is configured to obtain a second comparison result when the first arc length is less than the theoretical arc length;
and obtaining adjustment information for increasing the arc length according to the second comparison result, and sending the adjustment information for increasing the arc length to the stepping motor driver.
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| CN113857620A (en) * | 2021-10-25 | 2021-12-31 | 天津新松机器人自动化有限公司 | Robot double-wire welding method |
| CN114289843A (en) * | 2021-12-27 | 2022-04-08 | 唐山松下产业机器有限公司 | Welding gun control method and device, arc sensing control equipment and storage medium |
| CN114603239A (en) * | 2022-03-02 | 2022-06-10 | 华南理工大学 | Arc length control method based on K-TIG welding system |
| CN115502515A (en) * | 2022-09-21 | 2022-12-23 | 中车青岛四方机车车辆股份有限公司 | Adaptive welding method and system |
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| CN113857620A (en) * | 2021-10-25 | 2021-12-31 | 天津新松机器人自动化有限公司 | Robot double-wire welding method |
| CN114289843A (en) * | 2021-12-27 | 2022-04-08 | 唐山松下产业机器有限公司 | Welding gun control method and device, arc sensing control equipment and storage medium |
| CN114603239A (en) * | 2022-03-02 | 2022-06-10 | 华南理工大学 | Arc length control method based on K-TIG welding system |
| CN114603239B (en) * | 2022-03-02 | 2022-12-16 | 华南理工大学 | Arc length control method based on K-TIG welding system |
| CN115502515A (en) * | 2022-09-21 | 2022-12-23 | 中车青岛四方机车车辆股份有限公司 | Adaptive welding method and system |
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Application publication date: 20210604 |