A kind of low-yield input arc welding system and method
Technical field
The present invention relates to be used for low-yield input arc welding system and method, belong to welding equipment and automatic field.
Background technology
The lonely welding of low-yield input electricity is a kind of welding method that is directed to thin plate, still is in the starting stage, and everybody is different to the understanding of this method, and the view of a lot of problems is not also reached common understanding.Mainly contain two kinds of welding methods at present, a kind ofly be called cold metal transition welding, another kind is called the cold plasma welding, and these two kinds of welding methods all adopt the droplet transfer mode of short circuiting transfer, but its process characteristic differs widely.For first kind of form, adopt the wire feeding mode of push-and-pull silk, use custom-designed wire feed system, wire-feed motor can be finished the rotating action under very high frequency, monitor short-circuit signal in welding process, feeds back to wire-feed motor, wire-feed motor gives a response the pumpback welding wire, thereby welding wire is separated with molten drop, reduced the energy input, whole welding process does not almost have and splashes.And second kind of form adopts continuous wire feeding mode forward, uses common wire feed system to cooperate the Waveform Control technology of short circuiting transfer, uses the welding wire that contains special component, reaches the effect that reduces the welding energy input.No matter yet which kind of process form, bigger deficiency is all arranged: first kind of substantive requirements of form the welding interval of tens microseconds Rigen control the motion of motor in real time according to the state of welding, make its requirement according to welding procedure finish rotating, the complicated relatively difficulty that realizes of its control: second kind of form adopts special welding wire to be not easy to promote.
Summary of the invention
Deficiency based on existing low-yield input arc-welding method the present invention proposes a kind of low-yield input arc welding system and method, and native system adopts the wire feeding mode of push-and-pull silk, has the advantage of simple controllable, assurance arc stability.
Low-yield arc welding system proposed by the invention is divided into two parts: welding system (as shown in Figure 1) and wire feed system (as shown in Figure 2), wire feed system adopts a kind of AC servo motor, require to finish in advance motor rotating program according to actual welding, just configure the movement locus of welding wire, judge welding process according to voltage feedback signal by control circuit then, cooperate the welding wire motion to provide corresponding welding current, guarantee that the welding arc length is constant relatively, make welding process reliable and stable.
The present invention has adopted following technical scheme, native system includes the control circuit part 2 that directly provides main circuit part 1, the wire feed system 3 of power output for welding and be used to regulate main circuit part 1 power output, and control circuit part 2 includes input and display part D, the wire feed system control interface part E of core control section A, control operating part B, peripheral unit control and operating part C, front panel.Wherein, D/A conversion A2, current sample and filtering A3, voltage sample and filtering A4 that core control section A includes dsp system A1 and is connected with dsp system A1 respectively, the input of current sample and filtering A3 and voltage sample and filtering A4 are electric current, the voltage signal of bonding power output 1.7 outputs of main circuit part 1; Input and display part D, the wire feed system control interface part E of control operating part B, peripheral unit control and operating part C, front panel are connected with dsp system A1 respectively.Control operating part B includes pulse-width modulation circuit B1, IGBT drive circuit B3, holding circuit B2; the end of pulse-width modulation circuit B1 links to each other with dsp system A1 by D/A conversion A2; the other end links to each other with IGBT drive circuit B3; the IGBT drive circuit links to each other with the inverter circuit 1.3 of main circuit part 1 as the output of control operating part B, and pulse-width modulation circuit also is connected with holding circuit B2.Peripheral unit control and operating part C include arc welding gun switch C1, air valve C2, arc welding gun switch C1 and air valve C2 all link to each other with dsp system A1, arc welding gun switch C1 provides the welding switching signal for dsp system A1, and the instruction that air valve C2 receives dsp system A1 provides protection gas for welding process; The input of front panel and display part D include the welding parameter that links to each other with dsp system A1 and show that D1 and welding parameter preset D2.Wire feed system control interface part E links to each other with wire feed system 3 by wire feed system control interface circuit E1.Described wire feed system 3 includes host computer F, electric machine controller G, wire feeding motor, host computer F links to each other with wire feeding motor H by electric machine controller G, and electric machine controller G accepts the signal that dsp system A1 sends by the wire feed system control interface circuit E1 in the control circuit part 2.
Described welding parameter demonstration D1 demonstration is earlier preset the welding parameter that D2 presets by welding parameter, shows actual welding current/voltage value more in real time.
The control method of above-described a kind of low-yield input arc welding system is characterized in that, this method realizes according to the following steps:
1) according to actual requirement, determine welding parameter: comprise wire feed rate V, background current Ib, time to peak Tp, short circuit current, average voltage reference value Uac, input by front panel and display part D are with above welding parameter input dsp system A1;
2) according to actual requirement, determine welding wire curve movement L, before the welding welding wire curve movement L is downloaded to electric machine controller G from host computer, wire feeding motor H will do corresponding motion according to welding wire curve movement L during welding;
3) whether dsp system A1 detection arc welding gun switch C1 opens, be then to open pulse-width modulation circuit B1, promptly export energy, start wire feeding motor H, dsp system judges by the weldingvoltage feedback signal that receives from voltage sample and filtering A4 whether welding process is short-circuited, if be short-circuited, just provide corresponding short circuit current,, just provide the peak point current Ip of this moment by calculation procedure if be not short-circuited, when peak point current Ip effect after the time to peak Tp, provide background current Ib.
Described calculation procedure is, dsp system (A1) calculates the average voltage from 3~10 cycles of voltage sample and filtering (A4), and this average voltage level and predefined average voltage reference value Uac compared, determine peak point current Ip according to the difference of the two then; Perhaps
Described calculation procedure is that dsp system A1 calculates the average voltage from 3~10 cycles of voltage sample and filtering A4, and this average voltage level and predefined average voltage reference value Uac are compared the difference DELTA U (n) that obtains the two; Again the Δ U (n) of this calculating and previous value Δ U (n-1) are subtracted each other that to obtain difference be average voltage rate of change e (Ub), determine peak point current Ip according to Δ U (n) and e (Ub) then.
Described short circuit current includes short circuit initial stage electric current I dc, short circuit later stage electric current I dh, and short circuit provides short circuit initial stage electric current I dc when just having begun, and Tdc is after the time in short circuit initial stage electric current I dc effect, provides short circuit later stage electric current I dh.
The general value of described short circuit initial stage electric current is 3~50A, and the short circuit initial stage, function of current time T dc was 0.5~3ms, and short circuit later stage electric current value is 20~100A.
The span of described wire feed rate V is 3~7m/min, the span of background current Ib is 10~50A, span 0.5~3ms of time to peak Tp, the span of short circuit current are that the span of 3~100A, average voltage reference value Uac is 10~15V, and peak point current Ip span is 120~300A.
Adopt said method to make electric current, voltage parameter cooperate the welding wire motion, guarantee that arc length is stable, finishes welding process.
Design philosophy of the present invention is: welding system and wire feed system are cooperated, require to finish in advance motor rotating program according to actual welding, just configure the movement locus of welding wire, make electric current, the voltage parameter of welding process cooperate predefined welding wire motion, in conjunction with special control method, reach low-yield input, realize stable welding process.Wherein the control method that two systems are cooperated is core of the present invention, i.e. energy control method, and its principle is: judge short circuit and arcing state according to feedback voltage signal.Short-circuit stage, at the short circuit initial stage, current constant guarantees not produce instantaneous splashing at a smaller value; In the short circuit later stage, electric current remains on a big slightly value, and electric arc ignites smoothly again and helps forming constriction when guaranteeing that molten drop is broken.Arc stage, when short circuit just finishes, the average voltage level that calculates according to the voltage feedback signal of some cycles (as 5 cycles) also compares the difference DELTA U (n) that obtains the two with the average voltage reference value, again the Δ U (n) of this calculating and previous value Δ U (n-1) are subtracted each other that to obtain difference be average voltage rate of change e (Ub), draw peak current value according to Δ U (n) or Δ U (n) and e (Ub), keep peak current value constant in time to peak, when time to peak arrives, provide constant background current value.If the energy variation that the variation of the main dependence of arc length recovery peak point current caused when arc length was interfered is regulated.Pattern has determined whole welding process to be made up of the constant electric current of different multistages thus, can regulate arc length automatically according to the variation of energy, and the welding wire motion is cooperated with welding parameter, realizes stable welding process.
Compared with prior art, the control method and the arc welding system of the present invention's employing have the following advantages:
1, the input of welding process energy is low, process stabilization is reliable, does not almost have and splashes, and arc stability is strong.Because the inventive method cooperates welding system and wire feed system, the pumpback of advancing of welding parameter and welding wire matches, adopt the energy control model, can better control the interference of external factor, splash so can improve arc stability and welding process is not almost had to arc length.
2, whole control is simple, need not the motion of the motor of control control in real time, greatly reduces the complexity and the difficulty of equipment and control method.According to the curve movement of reality requirement and the pre-set welding wire of welding parameter, wire feeding motor just by this curvilinear motion, does not need to control in real time in welding process.
3, applied range; Can be applied to the following aluminium alloy plate of 3mm, galvanized steel plain sheet welding, also can be used for the welding of steel aluminum dissimilar metal, be with a wide range of applications.
Description of drawings
Fig. 1 welding system structure composition diagram
Fig. 2 wire feed system structure composition diagram
Fig. 3 welding wire movement profiles
Fig. 4 main program software scenario figure
Fig. 5 welding procedure block diagram
Fig. 6 calculating program frame chart
Fig. 7 Δ U and peak point current mapping table
Fig. 8 Δ U and voltage change ratio and peak point current mapping table
The specific embodiment
To describe present embodiment in conjunction with the accompanying drawings now.(embodiment carries out the welding of butt weld at the thick 3A21 aluminium alloy plate of 1mm)
The low-yield input arc welding system of example of the present invention structure composition diagram as shown in Figure 1, 2, main generally two parts that comprise: welding system and wire feed system 3.
Welding system comprises main circuit part 1 and is control core circuit part 2 with TMS320F2812DSP.The main circuit input voltage is three-phase 380V; Input rectifying 1.1 adopts Fuji's rectifier bridge rectification, and model is FUJ 6RI100G-160; Inverter circuit 1.3 adopts the semi-bridge inversion structure, and the IGBT that is BSM150GB120DN2 by two models forms; Intermediate-frequency transformer 1.4 adopts the ultracrystallite magnetic core, and transformation ratio is 15: 2; Magnetic core pulsactor, the about 30 μ H of inductance value are adopted in filtering 1.6.The control system that control circuit part 2 adopts based on TMS320F2812DSP is mainly finished calculation of parameter, proportional integral adjusting (PI) adjusting, SECO, and can realize communicating by letter with wire feed system 3.Below in conjunction with accompanying drawing it is elaborated.
Its job order is: after three-phase input 380V alternating current at first partly carries out rectification and 1.2 filtering through 1.1 input rectifyings, become the direct current of 540V.After this become the alternating current of 20KHZ after this direct current is isolated through the step-down of (this is by 2 controls of control circuit part) inversion of 1.3 inverter circuits and 1.4 intermediate-frequency transformers.Become the used big current low voltage direct current of welding then after the filtering through 1.5 output rectifiers and 1.6 and supply with the output of 1.7 bonding powers.Because the operating frequency of above circuit is 20KHZ, outputting inductance also very little (about 30 μ H) is adjusted the control that inverse switch frequency or pulsewidth can reach the microsecond level simultaneously, so the type power supply reaction speed is fast, dynamic property is good.
The composition and the function of welding system control circuit part 2 are respectively:
Core control section A mainly is made up of TMS320F2812DSP, comprises three importations.First importation is to be input to the signal of current sample and filtering A3 and voltage sample and filtering A4 to obtain the real-time weldingvoltage current value of welding from electric current, magnitude of voltage that bonding power output 1.7 is exported, wherein current sample and filtering A3 adopt the actual current value in the reflow termination process because PI controls (proportional plus integral control), adjust current deviation in real time, realize reaching closed-loop control; The actual voltage value that voltage sample and filtering A4 adopt in the reflow termination process is used to calculate peak point current, can also reach the purpose of monitoring welded condition.Second importation is the arc welding gun switch signal C1 that obtains from portion C.The 3rd importation derives from the input of front panel and the welding parameter of display part D presets D2, obtains the welding initial parameter.Part A is as the core control section, mainly finish the response of welding parameters input and external signal, and, make whole welding system co-ordination finish predetermined welding purpose through after software processing calculating and the conversion B, C, D, E four parts being controlled.
Control operating part B, the D/A conversion A2 that it is input as core control section A is input to IGBT drive circuit B3 after the PWM pulsewidth modulation of via pulse width modulation B1, be input to inverter circuit 1.3 after treatment, finishes this control function.
Portion C is peripheral unit control and operating part.Carrying out deriving from the input of arc welding gun switch C1, and part A is to the output control of air valve C2 to part A.
Part D is the input and the display part of front panel.Welding parameter presets D2 to core control section A input, realizes the setting of welding parameter, and shows that by welding parameter D1 shows.When welding, core control section A output welding current and voltage show D3 to welding parameter, make its energy real-time monitored welding parameter.
Part E is a wire feed system control interface part.Wire feed system control interface circuit E1 links to each other with dsp system A1, receives the signal of dsp system A1 and passes to wire feed system 2, the start and stop of control wire-feed motor.
Wire feed system 3 is by host computer F, electric machine controller G, and wire feeding motor H forms.The welding wire curve movement that host computer F will weave in advance downloads to electric machine controller G, by the rotation of electric machine controller G control wire feeding motor H.The electric machine controller G of wire feed system 3 also accepts the signal that core control all divides the dsp system A1 of A by the wire feed system control interface circuit E2 of welding system control circuit 2 wire feed system control interface part E.
Programme-control of the present invention divides two parts: welding wire curve movement L (being the wire feeding motor rotary motion trace) programme-control and the programme-control of welding process dsp system are elaborated respectively below.
Welding wire curve movement L (being the wire feeding motor rotary motion trace) programme-control:
Require to determine welding parameter according to welding is actual, according to the wire feed rate V in the welding parameter determine wire feed frequency F (advancing and the pumpback number of times of welding wire per second, last time can be regarded as once) and wire feed step-length d (each welding wire advance with pumpback apart from poor).Determine the distance that each welding wire advances according to welding requirement of actual working condition and welding parameter average voltage reference value Uac.Utilize the GlobalDrive Control software programming welding wire curve movement L of German Lenze company with host computer F, the fixing welding wire running orbit that the pumpback that obtains advancing hockets.The curve movement L that is done as shown in Figure 3.This curve is downloaded to electric machine controller G from host computer F, as long as wire feeding motor H operation enables, wire feeding motor H will move according to welding wire curve movement L according to the control of electric machine controller G.Whole motion process is stable, need not real-time control, and is simple and reliable.
The programme-control of welding process dsp system is elaborated to this example with reference to program flow diagram:
Fig. 4 is that DSP controls low-yield inversion electric arc welding power supply main program software scenario figure.Software main program comprises: initialization subroutine, preset parameter and display subroutine, time delay subroutine, counting subroutine and welding subprogram.The concrete execution sequence of its main program is: behind the electrification reset, program brings into operation from initial address, and system carries out initialization subroutine earlier, finishes the initial value of each welding parameter and sets.Execution parameter presets subprogram then, preset wire feed rate V and be 3.5m/min, background current Ib and be 20A, time to peak Tp and be 1.5ms, short circuit initial stage electric current I dc and be 20A, short circuit initial stage time T dc and be 2ms, short circuit later stage electric current 1dh and be 70A, average voltage reference value Uac and be welding parameter such as 12.5V and be used for Control Welding Process, through display subroutine relevant parameter is set then and shown.Judge that then whether the welding switch is opened is then to open pulsewidth modulation (promptly can export energy), starter motor, judge whether success of striking, if striking success then enter welding procedure, up to detecting the welding end signal, close the pulsewidth modulation disable motor, withdraw from welded condition.Carry out the front program as not welding the commencing signal circulation once more of then delaying time behind the certain hour (as 20ms).Control method of the present invention is mainly reflected in welding procedure and the calculation procedure process.
Figure 5 shows that the welding procedure block diagram, mainly carry out state judgement, SECO and according to the different current parameters of different sequential outputs.Its process is: at first calculate peak point current Ip, judge whether then to be short-circuited.If be short-circuited, electric current is changed to lower short circuit initial stage electric current I dc (preventing to produce instantaneous splashing), then timing to short circuit initial stage time T dc then, electric current is changed to big slightly short circuit later stage electric current I dh (guarantee electric arc ignite again smoothly and help forming constriction).If be not short-circuited, at first export peak point current Ip, this electric current draws by calculation procedure, then timing to time to peak Tp then, electric current is changed to background current Ib.Whole process is to judge the motion conditions of welding wire and providing corresponding current value according to welded condition, welding parameter and welding wire motion conditions are well combined, realizing low-yield welding.
Another core of control method is embodied in the calculation procedure process, is illustrated in figure 6 as calculating program frame chart.Major function is to carry out the calculating of peak point current Ip.Its implementation is: dsp system A1 calculates interior average voltage level Ua of several cycles (as 5) according to the voltage sampling signal of voltage sample and filtering A4 gained, and this magnitude of voltage and average voltage reference value Uac compared, obtain the difference DELTA U (n) of the two, determine peak point current Ip according to Δ U (n), when Fig. 7 is 12.5V for average reference magnitude of voltage Uac, the mapping table of Δ U and peak point current Ip.Calculation procedure can also be determined Ip according to the rate of change e (Ub) of Δ U (n) and average voltage, the Δ U (n) that is about to this calculating and previous value Δ U (n-1) subtract each other that to obtain difference be average voltage rate of change e (Ub), determine the peak point current Ip of next cycle according to Δ U (n) and e (Ub), when Fig. 8 is 12.5V for average reference magnitude of voltage Uac, the mapping table of Δ U and e (Ub) and peak point current Ip.Regulating arc length according to changing peak point current, adapt to the variation of arc length, guarantee the stable of welding process, avoided the arc length wild effect that causes owing to the movement locus that welding wire is set in advance, is the core of control method of the present invention.
This low-yield arc welding system is directed to the following plate sheet welding of 3mm, comprises the dissimilar metal welding between the welding of aluminium and aluminium alloy plate, galvanized steel plain sheet welding and aluminium and aluminium alloy plate and the galvanized steel plain sheet.When adopting Φ 1.2mm welding wire, can realize 1.5m/min (thickness of slab δ=0.5mm), average current 45A, average voltage 11V and 0.7m/min (the stable welding of thickness of slab δ=1mm), average current 55A, average voltage 12.5V.Whole welding process stablizes, is easy to that realization and control, energy input are low, arc stability, appearance of weld is good, distortion is minimum, almost do not have and splash.The requirement that reaches design and use.
The above is an example of native system and control method thereof, and we also can carry out some conversion to it.Can adopt full bridge inverter to replace the half-bridge form such as the main circuit part, control section replaces TMS320F2812 to realize its function etc. with other DSP or single-chip microcomputer.As long as it is consistent that its system and control thought and the present invention are narrated, all should be considered as the included scope of the present invention.