CN1836818A - Arc length control method for impulse arc welding - Google Patents
Arc length control method for impulse arc welding Download PDFInfo
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- CN1836818A CN1836818A CN 200610071707 CN200610071707A CN1836818A CN 1836818 A CN1836818 A CN 1836818A CN 200610071707 CN200610071707 CN 200610071707 CN 200610071707 A CN200610071707 A CN 200610071707A CN 1836818 A CN1836818 A CN 1836818A
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- 238000003466 welding Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000002789 length control Methods 0.000 title claims description 19
- 239000002184 metal Substances 0.000 claims description 8
- 238000001514 detection method Methods 0.000 description 12
- 238000010891 electric arc Methods 0.000 description 6
- 230000007423 decrease Effects 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
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Abstract
In a method for controlling the arc length in pulse arc welding, the mean value of welding voltage Vw composed of peak voltage and base voltage is calculated, and the arc length is kept to be optimum by controlling the pulse period such that the mean value of the welding voltage is approximately equal to the preset value of the voltage. When a short circuit state Ts occurs during a base period and the voltage has changed from the base voltage to the short circuit voltage Vs, the mean value of the welding voltage is calculated by limiting the short circuit voltage Vs to the lower limit Vbt of the base voltage, wherein the lower limit value Vbt of the base voltage is varied so as to be furthermore low with the lapse of time in the short circuit state Ts. In consumable electrode type pulse arc welding the high speed welding, etc. are carried out with a mean arc length set to be short in order to improve the controllability of an arc length.
Description
Technical field
The present invention relates to improve the length control method for impulse of the controlled pulsed arc welding of arc length by the short-circuit voltage value in during the restriction short circuit.
Background technology
In the arc welding of consumable electrode formula,, be necessary the arc length in the welding is maintained appropriate value in order to obtain good welding quality.During the consumable electrode formula pulsed arc that the energising of the base current in during the energising of the peak point current between the peak period and the basis was switched on repeatedly as 1 pulse period welds, a kind of length control method for impulse is arranged so far, it is by the control impuls cycle, make weldingvoltage mean value and predefined voltage setting value about equally, thereby make arc length maintain appropriate value.The following describes the length control method for impulse of the pulsed arc welding of conventional art.
Fig. 4 is the electric current and the voltage oscillogram of pulsed arc welding.Fig. 4 (A) expression to the welding current Iw that switches on as the welding rod of consumable electrode over time, Fig. 4 (B) is illustrated in the weldingvoltage Vw that adds between power supply sheet and the mother metal over time.Describe below with reference to Fig. 4.
Shown in Fig. 4 (A), between the peak period of moment t1～t2 among the Tp, be used to make the peak point current Ip energising of the big current value that molten drop changes, shown in Fig. 4 (B), and the roughly proportional crest voltage Vp of arc length is added between power supply sheet and the mother metal.Then, shown in Fig. 4 (A), during the basis of moment t2～t3 among the Tb, on one side pilot arc, be used to make the base current Ib energising of the little electric current that molten drop do not grow up on one side, shown in Fig. 4 (B), add and the roughly proportional basic voltage Vb of arc length.In the following description, crest voltage Vp and basic voltage Vb represent the magnitude of voltage of electric arc in taking place, during the short circuit in, be called short-circuit voltage to show difference.
The very big influence of the average arc length among the pulse period Tf that welding quality is subjected to being made of Tb during Tp between the peak period and the basis significantly.Therefore, in order to obtain good welding quality, be necessary that an average arc length is controlled at appropriate value.Generally, the arc length of moment is with the approximate direct ratio of the weldingvoltage Vw that is made of crest voltage Vp and basic voltage Vb.Therefore, average arc length, just roughly proportional with weldingvoltage mean value Va.Utilize this relation, detect weldingvoltage mean value Va, and by control weldingvoltage Vw, thus the voltage setting value Vr that this detected value is substantially equal to be predetermined.As the control method of weldingvoltage Vw, as shown in Figure 4, from just habitual by FEEDBACK CONTROL makes pulse period Tf, at least more than one value between the peak period Tp, peak point current Ip or the base current Ib changes method in the past.
As mentioned above, in the prior art, detect weldingvoltage Vw, calculate weldingvoltage mean value Va, the control arc length from this weldingvoltage detected value., as described in 5, in the pulsed arc welding, be accompanied by molten drop and change, the short circuit of short time usually takes place.Usually, molten drop changes during the basis after usually Tp finishes between the peak period and carries out among the Tb, so short circuit almost occurs in during the basis among the Tb.Because comprise the short-circuit voltage Vs among the Ts during the short circuit, calculate weldingvoltage mean value Va, so between weldingvoltage mean value Va and average arc length, produce error.Therefore, the problem that has the controlled variation of arc length.In order to address this problem, the conventional art of following explanation is proposed.
The oscillogram of the length control method for impulse of the conventional art when Fig. 5 is expression short circuit generation.The time of Fig. 5 (A) expression weldingvoltage Vw changes, and the time of Fig. 5 (B) expression weldingvoltage limits value Vf changes, and the time of Fig. 5 (C) expression arc length La changes, the appearance of each electric arc generating unit constantly of Fig. 5 (D)～(F) expression.Describe below with reference to Fig. 5.
Shown in Fig. 5 (A), when the moment t4 place molten drop in during the basis changes, constantly t4～t5 during in (Ts during the short circuit), the short circuit of short time takes place.Weldingvoltage Vw during the short circuit among the Ts is changed to short-circuit voltage Vs from basic voltage Vb.Basic voltage Vb is about 15～25V, and short-circuit voltage Vs is for counting about V.
Shown in Fig. 5 (C), arc length La is elongated gradually between the peak period of moment t1～t2.This is because shown in Fig. 5 (D), because the energising of crest voltage, the fusing of welding rod 1 top forms molten drop 1a.Arc length La during between the peak value decrement phase of moment t2～t3 of following during the basis shortens gradually.This is that molten drop 1a moves downwards, so arc length La shortens because on the top of molten drop 1a necking down 1b takes place.During moment t3～t4 then, molten drop 1a is because gravity falls rapidly, and necking part 1b slenderly extends, and arc length La shortens rapidly.Then, at moment t4, shown in Fig. 5 (E), under the state that necking part 1b slenderly extends, molten drop 1a contacts with mother metal 2, becomes short-circuit condition.At moment t5, when molten drop 1a owing to the surface tension of melting tank changes, then shown in Fig. 5 (F), electric arc 3 takes place again, shown in Fig. 5 (C), arc length La is elongated.During moment t5～t6 then, base current is the low value that does not melt welding rod 1, thus do not form molten drop 1a at electrode tip, with the given speed feeding, so shown in Fig. 5 (C), arc length La shortens gradually.By above-mentioned action, the average arc length in the pulse period of t1～t6 constantly is controlled to be appropriate value.
Shown in Fig. 5 (E), when the moment, t4 was short-circuited, necking part 1b was in the state of elongated extension.If is the distance definition between the melting end of electrode tip and the mother metal arc length Lb of essence, then shown in Fig. 5 (D)～(F), gently shorten.The arc length Lb of essence at moment t2～t5, gently descends shown in Fig. 5 (C).Particularly necking part 1b extension, short circuit and cause the rapid variation of the arc length La of t3～t4 constantly are so preferably use the arc length Lb of essence to the average arc length of decision welding quality.Therefore, in the prior art, the arc length Lb for the essence among the Ts during the short circuit that detects moment t4～t5 shown in Fig. 5 (B), is limited in basic voltage lower limit Vbt to short-circuit voltage Vs, calculates weldingvoltage limits value Vf.That is, weldingvoltage limits value Vf, the weldingvoltage Vw for shown in Fig. 5 (A) is limited in basic voltage lower limit Vbt to the short-circuit voltage Vs of Ts during the short circuit, and the voltage during remains untouched in addition.Use weldingvoltage limits value Vf, calculate weldingvoltage mean value Va, the control arc length, thus can maintain appropriate value to the arc length Lb of the essence shown in Fig. 5 (C).
Described basic voltage lower limit Vbt as input, is set basic voltage a reference value Vbc and the correction value Δ V that is predetermined by Vbt=Vbc-Δ V.Correction value Δ V is about 1～3V, according to welding conditions such as the material of welding rod, welding rod feed speeds, is set at appropriate value.Described basic voltage a reference value Vbc can be according to the predefined value of welding condition, also can be the basic voltage value before being about to be short-circuited.In addition, basic voltage a reference value Vbc can be the moving average (about above-mentioned conventional art, with reference to patent documentation 1,2) of the basic voltage of given period.
[patent documentation 1] spy opens the 2003-311409 communique
[patent documentation 2] spy opens the 2005-34853 communique
Fig. 6 is in the high-speed welding, and the average arc length setting is got in short-term the oscillogram corresponding with Fig. 5.Each signal shown in Fig. 6 (A)～(F) is identical with Fig. 5.Because of average arc length shorter than Fig. 5, so the instant value step-down of the weldingvoltage limits value Vf of the weldingvoltage Vw shown in Fig. 6 (A) and Fig. 6 (B).In addition, the instant value of the arc length La shown in Fig. 6 (C) also shortens.
If average arc length shortens, then shown in Fig. 6 (A), there is the elongated tendency of Ts during the short circuit.Among the Ts, shown in Fig. 6 (B), short-circuit voltage Vs is limited in basic voltage lower limit Vbt during the short circuit.This is because shown in Fig. 6 (C), detects the arc length Lb of essence, and it is controlled to improve arc length.
If the setting of average arc length is shortened, then the arc length of moment shortens, and takes place to change irrelevant short circuit with molten drop, and sputter usually takes place, or welded condition becomes unstable easily.Therefore, be necessary with high precision control arc length more.As a method, the method for the magnifying power that improves feedback control system is arranged., in the method, it is unstable that feedback control system becomes easily, has boundary.
Summary of the invention
Therefore, in the present invention, be provided at the average arc length setting is got the length control method for impulse that can improve the controlled pulsed arc welding of arc length in short-term.
In order to solve above-mentioned problem, invention 1 is a kind of length control method for impulse of pulsed arc welding, the energising of the base current in during the energising of the peak point current between the peak period and the basis repeats energising as 1 pulse period, and calculate the mean value of the weldingvoltage that constitutes by the basic voltage in during crest voltage between the described peak period and the described basis, by controlling the described pulse period, between the described peak period, at least more than one of described peak point current or described base current, the voltage setting value that makes this weldingvoltage mean value equal to be predetermined, thereby arc length is maintained appropriate value, it is characterized in that:
Welding rod and mother metal become short-circuit condition in during described basis, when described basic voltage becomes short-circuit voltage, this short-circuit voltage are restricted to value---basic voltage lower limit than the low set-point of described basic voltage value, calculate described weldingvoltage mean value;
Be accompanied by the effluxion during the described short circuit, make described basic voltage lower limit become lower value.
In addition, invention 2 is that it is characterized in that: the variation of described basic voltage lower limit is step-like according to the length control method for impulse of invention 1 described pulsed arc welding.
In addition, invention 3 is that it is characterized in that: the variation of described basic voltage lower limit is a ramped shaped according to the length control method for impulse of invention 1 described pulsed arc welding.
In addition, invention 4 is according to the length control method for impulse of any described pulsed arc welding in the invention 1～3, it is characterized in that: the variation of described basic voltage lower limit is provided with the restriction of greatest lower bound value.
According to the present invention, be accompanied by the effluxion of Ts during the short circuit, make basic voltage lower limit Vbt become lower value with step-like or ramped shaped, thus the detection of the arc length of length during in detection, adding based on short circuit based on the arc length of weldingvoltage Vw.Therefore, must be short the average arc length setting, produce in the high-speed welding of long short circuit, can detect arc length with high accuracy, it is controlled to improve arc length.
Description of drawings
Briefly explain accompanying drawing below.
Fig. 1 is the oscillogram of length control method for impulse of the pulsed arc welding of the expression embodiment of the invention 1.
Fig. 2 is the block diagram of the source of welding current of the embodiment of the invention 1.
Fig. 3 be the basic voltage lower limit Vbt of the expression embodiment of the invention 2 for short circuit during the figure of changing pattern of effluxion of Ts.
Fig. 4 is the electric current and the voltage oscillogram of the consumable electrode formula arc welding of conventional art.
Fig. 5 is the oscillogram of the length control method for impulse of indicating impulse arc welding.
Fig. 6 is the Fig. 5 in the problem that is used for illustrating conventional art, and the average arc length setting is got in short-term oscillogram.
Among the figure: the 1-welding rod; The 1a-molten drop; The 2-mother metal; 3-electric arc; The 4-welding torch; The 5-feed rolls; EI-current error amplifying circuit; Ei-current error amplifying signal; EV-voltage error amplifying circuit; Ev-voltage error amplifying signal; The Ib-base current; IBR-base current initialization circuit; Ibr-base current setting signal; ICR-Current Control initialization circuit; Icr-Current Control setting signal; The ID-current detection circuit; The Id-current detection signal; The Ip-peak point current; IPR-peak point current initialization circuit; Ipr-peak point current setting signal; The Iw-welding current; The L1-characteristic; The L2-characteristic; The La-arc length; The arc length of Lb-essence; The PM-electric power main circuit; S-tilts; During the Tb-basis; The Tf-pulse period (signal); TP-timer circuit between the peak period; Tp-is (signal) between the peak period; Testing circuit during the TS-short circuit; During the Ts-short circuit; V/F-voltage and frequency-conversion circuit; VA-voltage average computation circuit; Va-weldingvoltage mean value/average voltage signal; The Vb-basic voltage; VBC-basic voltage a reference value counting circuit; Vbc-basic voltage a reference value; Vbm-greatest lower bound value; VBT-basic voltage lower limit counting circuit; Vbt-basic voltage lower limit (signal); The VD-voltage detecting circuit; The Vd-voltage detection signal; VF-voltage limit counting circuit; Vf-weldingvoltage limits value/voltage limit signal; The Vp-crest voltage; The VR-voltage setting circuit; The Vr-voltage setting signal; The Vs-short-circuit voltage; The Vw-weldingvoltage; Δ V-correction value.
The specific embodiment
The embodiment of the invention is described with reference to the accompanying drawings.
[embodiment 1]
Fig. 1 is the oscillogram of length control method for impulse of the pulsed arc welding of the expression embodiment of the invention 1.The time of Fig. 1 (A) expression weldingvoltage Vw changes, and the time of Fig. 1 (B) expression weldingvoltage limits value Vf changes, and the time of Fig. 1 (C) expression arc length La changes, the appearance of each electric arc generating unit constantly of Fig. 1 (D)～(F) expression.Fig. 1 is corresponding with above-mentioned Fig. 6, is the average arc length setting is got in short-term.In Fig. 1, constantly during the short circuit of t4～t5 beyond the Ts during action identical with above-mentioned Fig. 5 and Fig. 6, so the omission explanation.The following describes the action of Ts during the short circuit.
In embodiment 1, shown in Fig. 1 (B), be accompanied by the effluxion among the Ts during the short circuit, basic voltage lower limit Vbt descends gradually.The gradient S[V/ms that descends] be about 0.3～3 scope, according to welding conditions such as the material of welding rod, welding rod feed speeds, be set at appropriate value.Make the reasons are as follows of basic voltage lower limit Vbt decline described.If average arc length reduces, be accompanied by then that there is elongated in proportion tendency in the time span of Ts during the short circuit that molten drop changes.Therefore, according to weldingvoltage average detection average arc length the time,, just can comprise the information of the proportionate relationship of length and average arc length during the short circuit if basic voltage lower limit Vbt is descended according to the length of Ts during the short circuit.In view of the above, can according to length during crest voltage, basic voltage and the short circuit, detect average arc length with high accuracy.Its result, even the average arc length setting is got in short-term, it is controlled also to improve arc length.
Fig. 2 is the block diagram of the source of welding current of length control method for impulse that is used to implement the pulsed arc welding of embodiment 1.Electric power main circuit PM as input, according to the current error amplifying signal Ei that describes later, carries out the output control of phase inverter control, limiter control etc. to source power supplies such as 3 phase 200V, output welding current Iw and weldingvoltage Vw.Welding rod 1 in welding torch 4, and produces electric arc 3 by the rotation of the feed rolls 5 of welding rod feed arrangement between the mother metal 2.
Voltage detecting circuit VD detects weldingvoltage Vw, voltage sense signal Vd.Basic voltage a reference value counting circuit VBC as input, calculates the moving average through the basic voltage of given period to this voltage detection signal Vd, and exports as basic voltage a reference value Vbc.Basic voltage a reference value Vbc as mentioned above, both can be predefined value, also can be the basic voltage value before being about to be short-circuited.Testing circuit TS during the short circuit detects the generation of short circuit according to the value of described voltage detection signal Vd, and output is signal Ts during the short circuit of high level in during short circuit.Basic voltage lower limit counting circuit VBT, as input, output is accompanied by the effluxion during the short circuit and becomes the basic voltage lower limit signal Vbt of lower value from the value of basic voltage a reference value Vbc signal Ts during described basic voltage a reference value Vbc and the short circuit.Voltage limit counting circuit VF as input, is limited in the basic voltage lower limit to described voltage detection signal Vd and described basic voltage lower limit signal Vbt to the voltage during the short circuit, output voltage limits value signal Vf.Voltage average computation circuit VA, the mean value of calculating voltage limits value signal Vf, output voltage average value signal Va.
Voltage setting circuit VR exports predefined voltage setting signal Vr.Voltage error amplifying circuit EV amplifies the error of voltage setting signal Vr and described average voltage signal Va output voltage error amplifying signal Ev.Voltage and frequency-conversion circuit V/F, the pulse-period signal Tf of output and the proportional frequency of voltage error amplifying signal Ev.That is, the described pulse-period signal Tf of Fig. 4 changes, thereby voltage setting signal Vr and average voltage signal Va become about equally.Timer circuit TP between the peak period, output is from the zero hour of the phase weekly of described pulse-period signal Tf, signal Tp between the peak period that between the predefined peak period is high level.That is, when signal Tp is high level between the peak period, be exactly between the peak period, during for low level, be exactly the basis during.
Peak point current initialization circuit IPR exports predefined peak point current setting signal Ipr.Base current initialization circuit IBR exports predefined base current setting signal Ibr.Current Control initialization circuit ICR, when signal Tp is high level between the described peak period, described peak point current setting signal Ipr is exported as Current Control setting signal Icr, and when low level, described base current setting signal Ibr is exported as Current Control setting signal Icr.Current detection circuit ID detects welding current Iw, output current detection signal Id.Current error amplifying circuit EI amplifies the error of described Current Control setting signal Icr and described current detection signal Id output current error amplification signal Ei.Fig. 2 is the situation that pulse period Tf is changed by FEEDBACK CONTROL, but also can make between the peak period by described voltage error amplifying signal Ev, peak point current, base current or their combination change.
[embodiment 2]
Fig. 3 is the figure of the changing pattern of the expression basic voltage lower limit Vbt that is accompanied by the effluxion during the short circuit.The transverse axis of Fig. 3 is represented the elapsed time of the zero hour during the short circuit, and the longitudinal axis is represented the value of basic voltage lower limit Vbt.As shown in Figure 3, characteristic L1 presses step-like decline from basic voltage a reference value Vbc.At this moment, every number ms, V is counted in decline.In addition, characteristic L2 descends by ramped shaped, and greatest lower bound value Vbm is set, and can not drop to this below value.Greatest lower bound value Vbm is about 4～15V, selects appropriate value according to welding condition.
Claims (4)
1. the length control method for impulse of pulsed arc welding, welding rod is carried out repeatedly the energising of the energising of the base current in during the energising of the peak point current between the peak period and the basis as 1 pulse period, and calculate the mean value of the weldingvoltage that constitutes by the basic voltage in during crest voltage between the described peak period and the described basis, by controlling the described pulse period, between the described peak period, at least more than one of described peak point current or described base current, make this weldingvoltage mean value be substantially equal to the voltage setting value that is predetermined, arc length is maintained appropriate value, it is characterized in that:
Welding rod and mother metal become short-circuit condition and when described basic voltage becomes short-circuit voltage in during described basis, this short-circuit voltage is restricted to value---the basic voltage lower limit of hanging down set-point than described basic voltage value, calculate described weldingvoltage mean value
Be accompanied by the effluxion during the described short circuit, make described basic voltage lower limit become lower value.
2. the length control method for impulse of pulsed arc welding according to claim 1 is characterized in that:
The variation of described basic voltage lower limit is step-like.
3. the length control method for impulse of pulsed arc welding according to claim 1 is characterized in that:
The variation of described basic voltage lower limit is a ramped shaped.
4. according to the length control method for impulse of any described pulsed arc welding in the claim 1～3, it is characterized in that:
The variation of described basic voltage lower limit is provided with the restriction of greatest lower bound value.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2005082915A JP2006263757A (en) | 2005-03-23 | 2005-03-23 | Method for controlling arc length in pulse arc welding |
| JP2005082915 | 2005-03-23 |
Publications (2)
| Publication Number | Publication Date |
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| CN1836818A true CN1836818A (en) | 2006-09-27 |
| CN100571954C CN100571954C (en) | 2009-12-23 |
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| Application Number | Title | Priority Date | Filing Date |
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| CNB2006100717077A Expired - Fee Related CN100571954C (en) | 2005-03-23 | 2006-03-16 | The length control method for impulse of pulsed arc welding |
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| JP (1) | JP2006263757A (en) |
| CN (1) | CN100571954C (en) |
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2005
- 2005-03-23 JP JP2005082915A patent/JP2006263757A/en active Pending
-
2006
- 2006-03-16 CN CNB2006100717077A patent/CN100571954C/en not_active Expired - Fee Related
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| CN100571954C (en) | 2009-12-23 |
| JP2006263757A (en) | 2006-10-05 |
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