CN100999037A - Control method of digital pulse consumable electrode gas protection welding - Google Patents
Control method of digital pulse consumable electrode gas protection welding Download PDFInfo
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- CN100999037A CN100999037A CN 200710036335 CN200710036335A CN100999037A CN 100999037 A CN100999037 A CN 100999037A CN 200710036335 CN200710036335 CN 200710036335 CN 200710036335 A CN200710036335 A CN 200710036335A CN 100999037 A CN100999037 A CN 100999037A
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Abstract
The present invention relates to a digital pulsed consumable electrode gas shielded welding control method, belonging to the field of welding technology. It is characterized by that it adopts a cascade-connected three-closed-loop control structure, its internal loop is current loop, second loop is voltage loop and external loop is metal transition loop, every loop is equipped with a regulator, these regulators can be used for respectively controlling impulse current, arc length and metal transition process. Said invention adopts an all-digitalization pulsed consumable electrode gas shielded welding control system made up by using high-speed digital signal processor as kernel control device. Besides, said invention also provides the working principle of said system and its concrete operation method.
Description
Technical field
What the present invention relates to is a kind of control method of welding technology field, specifically is a kind of control method of digital pulse consumable electrode gas protection welding.
Background technology
Gas metal-arc welding (GMAW) is a kind of high-quality, high efficiency welding procedure, and wherein pulsed gas metal arc welding (GMAW-P) has the electric current adjustable range of broad, has further enlarged the welding conditions interval, and has the excellent protection effect.In order to obtain good welding quality, for pulsed gas metal arc welding, at first desirable mode of metal transfer is " one in an arteries and veins ", i.e. an interior molten drop of transition of pulse period; Simultaneously, be necessary arc length is maintained appropriate value; Require during pulse and base value, to keep constant pulse current and background current in addition.Only control at the control method of pulsed gas metal arc welding at present, can't realize closed-loop control the droplet transfer process at single voltage of employing or electric current loop in above-mentioned three aspects.
Find through literature search prior art; Wang Weiming is at " welding journal " the 25th volume; the 2nd phase; deliver in February, 2004 " impulse welding Digital Control System "; this article has designed the digitial controller of pulse current and arc length at pulsed gas metal arc welding; realized the control of electric current and arc length, but do not accomplished to control at the droplet transfer process of pulsed gas metal arc welding.In further retrieving, find the bibliographical information identical as yet with theme of the present invention.
Summary of the invention
The objective of the invention is at deficiency of the prior art; a kind of control method of digital pulse consumable electrode gas protection welding is proposed; carry out digital control for the welding current in the pulsed gas metal arc welding welding process, arc length and droplet transfer process; make it utilize the advantage of the powerful data-handling capacity of digital signal processor and the high speed of service; mode by software realizes control strategy; hardware components is finished signals collecting and processing capacity, thereby has improved control accuracy, real-time and the reliability of control system.
The present invention is achieved by the following technical solutions, three closed loop controlling structures that the present invention adopts tandem to connect, and innermost ring is an electric current loop, second ring is Voltage loop, outer shroud is the droplet transfer ring, and each link is provided with an adjuster, respectively control impuls electric current, arc length and droplet transfer process; Adopting high speed digital signal processor is that kernel control chip makes up totally digitilized pulsed gas metal arc welding control system; all control strategies of system the i.e. data processing of three adjusters are all realized by the mode of software; hardware components is finished signals sampling and processing capacity; wherein; the output of droplet transfer controller is as the desired value of arc voltage; the output of arc length adjuster is as the desired value of electric current, and the output of current regulator removes to control the output voltage of power circuit as the control signal of power model.
In described electric current loop, utilize Hall current sensor that detected welding current signal is converted into proportional voltage signal by current sample conditioning shaping circuit, this voltage signal is sent into the A/D ALT-CH alternate channel of digital signal processor inside after signal filtering, be converted to digital quantity, this digital quantity is the value of feedback U of electric current
IfThe desired value U of electric current
IrReceive from exporting through the D/A conversion chip by the control of current target value given algorithm again behind the signal of arc length adjuster.The desired value U of electric current
IrValue of feedback U with electric current
IfDifference through the adjusting of current PI adjuster, directly export control signal U
Ct, U
CtGo to control the open-minded of power circuit power component, and then realized accurate control electric current.All the time carry out for being controlled in the welding process of pulse current and background current.
Arc length usually roughly and the voltage between electrode (welding wire) and the mother metal proportional, therefore, described Voltage loop is just to the control loop of electric arc arc length.
In described Voltage loop, utilize the Hall voltage sensor that detected weldingvoltage signal is converted into proportional voltage signal by voltage sample conditioning shaping circuit, this voltage signal is sent into the A/D ALT-CH alternate channel of digital signal processor inside after signal filtering, be converted to digital quantity, this digital quantity is the instantaneous value of feedback of voltage.The sample frequency of voltage is decided by digital signal processor.At pulse and base value sampled voltage respectively in the time, and calculate average voltage in the pulse period by digital signal processor, and with this as voltage value of feedback U
UfThe desired value of arc voltage is made up of two parts, wherein a part of U
Ur1Given by potentiometer, the A/D ALT-CH alternate channel of supplied with digital signal processor inside is converted to digital quantity.Desired value another part U of arc voltage
Ur2Provide by the droplet transfer ring.The arc length adjuster adopts adaptive algorithm, has only the desired value U of voltage
Ur1With voltage value of feedback U
UfEqual the time and the desired value U of voltage
Ur2Be low level, the output control signal corresponding, this control signal begins a new pulse period as the current target given algorithm pulse switching signal of current loop control.Desired value U when voltage
Ur2During for high level, the arc length adjuster can be exported the extra current echo signal, and the control electric current loop produces an extra-pulse electric current.The control cycle of Voltage loop is identical with the pulse period, i.e. electric arc arc length of each pulse period inner control.
In described droplet transfer ring, by droplet transfer testing circuit output droplet transfer signal, this signal is a switching value.In a pulse period, a molten drop is finished transition, and then output low level is exported arc voltage desired value U through the droplet transfer controller
Ur2Be 0.If after time to peak finishes, still do not detect the droplet transfer to finish, droplet transfer circuit output high level then, this moment is through droplet transfer controller output U
Ur2Be high level.U
Ur2Another part as the given signal of Voltage loop target voltage.
Usually, pulsed gas metal arc welding is followed the definite droplet transfer characteristic signal of having of droplet transfer, it can be exported a switching value through the droplet transfer testing circuit.Through guaranteeing molten drop of output in a pulse period after the droplet transfer control, also provided the desired value U of the arc voltage of pulsed gas metal arc welding simultaneously
Ur2The desired value U of arc voltage
Ur1(according to concrete welding procedure, given by potentiometer with the form of analog quantity) is constant, after promptly regulating in welding process the desired value of arc voltage be constant, arc voltage desired value U
Ur1Value of feedback U with arc voltage
UrRegulate the output current desired value through arc length control figure adjuster.Through the control of electric current loop, output control signal U
Ct, control the open-minded of power circuit power component, realized the accurate control of pulsed gas metal arc welding electric current, arc length and droplet transfer process.
The present invention adopts three grades of cascaded structure closed loop (electric current loops; arc voltage; the droplet transfer ring) the powerful data-handling capacity of controller combined digital signal processor and the advantage of the high speed of service; realized pulsed gas metal arc welding full-digital control truly; control system is easy to realize that complicated control algolithm and all control strategies mode by software is realized; compare with control strategy with traditional control device, the control strategy adjustment is flexible; the control accuracy height; characteristics such as dynamic response characteristic that the control parametric stability is good and good and speed-regulating range width.Control method of the present invention can either make system keep higher degree of regulation and regulate sensitivity, can guarantee that again system works is stable, guarantee molten drop of transition in each pulse period in the welding process, realized accurate control to the droplet transfer process, arc length stability improves greatly simultaneously, realized accurate control, and guaranteed stable welding current arc length.
Description of drawings
Fig. 1 principle of the invention block diagram.
The specific embodiment
Below in conjunction with accompanying drawing embodiments of the invention are elaborated: present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
Carry out the dull and stereotyped built-up welding test of mild steel, weldingvoltage desired value U with 1.2mm H08Mn2Si welding wire
Ur1Be 24V, welding current desired value U
Ir100A.As shown in Figure 1, the desired value U of arc voltage
UrBe made up of two parts, wherein a part is U
Ur1, another part is U
Ur2The desired value U of electric current
IrThe control signal U of power circuit
CtIn welding process, calculate executed arc voltage feedback U by software
Uf, the value of feedback U of electric current
LfSend into DSP inside through hardware circuit, calculate or be converted to the digital quantity of correspondence by DSP by DSP.
Implementation process is as follows:
1, in welding process, can detect the state of droplet transfer in a pulse period by the droplet transfer testing circuit, it is output as a switching value, and the droplet transfer controller is output as arc voltage desired value U
Ur2After time to peak finished, a molten drop was finished transition, and droplet transfer testing circuit output low level is through droplet transfer controller output arc voltage desired value U
Ur2Be 0.After time to peak finishes, still do not detect the droplet transfer to finish, droplet transfer circuit output high level then, this moment is through droplet transfer controller output U
Ur2Be high level.
2, in welding process, the desired value of arc voltage is made up of two parts.Wherein a part of U
Ur2By the output of molten drop control loop, another part U
Ur1To preset be given with the form of analog quantity by potentiometer, this analog quantity converts corresponding digital quantity to through the A/D of digital signal processor ALT-CH alternate channel.During normal the welding, the real-time value of feedback of arc voltage is to nurse one's health the A/D ALT-CH alternate channel that shaping circuit is sent into digital signal processor inside by the arc voltage that takes out in the source of welding current main circuit through voltage sample, is converted to digital quantity.At pulse and base value sampled voltage respectively in the time, and calculate average voltage in the pulse period by digital signal processor, and with this as voltage value of feedback U
UfThe desired value U of arc voltage
UrWith voltage value of feedback U
UfImport the arc length adjuster together, arc length is regulated it and is adopted adaptive algorithm, has only the desired value U of voltage
Ur1With voltage value of feedback U
UfEqual the time and the desired value U of voltage
Ur2Be low level, the output control signal corresponding, the current target given algorithm pulse switching signal as current loop control begins a new pulse period.Desired value U when voltage
Ur2During for high level, the arc length adjuster can be exported extra-pulse current target signal, and the control electric current loop produces an extra-pulse electric current, impels and finish the droplet transfer process in the pulse period.Can realize the arc length of paired pulses gas metal-arc welding and the accurate control of droplet transfer by electric current loop, Voltage loop.
3, in welding process, the desired value U of electric current
LrReceive from exporting through the D/A conversion chip by the control of current target value given algorithm again behind the signal of arc length adjuster.The value of feedback U of electric current
IfUtilize Hall current sensor that detected welding current signal is converted into proportional voltage signal by current sample conditioning shaping circuit, this voltage signal is sent into the A/D ALT-CH alternate channel of digital signal processor inside after signal filtering, be converted to digital quantity.The desired value U of electric current
LrValue of feedback U with electric current
IfDifference through the adjusting of current PI adjuster, directly export control signal U
Ct, U
CtGo to control the open-minded of power circuit power component in the source of welding current, and then realized accurate control electric current.
Present embodiment detects the droplet transfer process and finishes in welding process in a pulse period, arc voltage desired value U
Ur2Be 0.After time to peak finishes, still do not detect the droplet transfer to finish, droplet transfer circuit output high level then, this moment is through droplet transfer controller output U
Ur2Be high level.The desired value U of arc voltage
UrWith voltage value of feedback U
UfBy the arc length adjuster, the control arc length is 24V thereby keep actual welding voltage, and is consistent with the weldingvoltage desired value.Simultaneously, by the effect of electric current loop, making the welding actual output current is 100A.Thereby control accuracy, real-time and the reliability of control system have been improved.
Claims (4)
1, a kind of full digital pulse gas metal-arc welding control method, it is characterized in that, three closed loop controlling structures that adopt tandem to connect, innermost ring is an electric current loop, second ring is Voltage loop, outer shroud is the droplet transfer ring, and each link is provided with an adjuster, respectively control impuls electric current, arc length and droplet transfer process; Adopting high speed digital signal processor is that kernel control chip makes up totally digitilized pulsed gas metal arc welding control system; all control strategies of system the i.e. data processing of three adjusters are all realized by the mode of software; hardware components is finished signals sampling and processing capacity; wherein; the output of droplet transfer controller is as the desired value of arc voltage; the output of arc length adjuster is as the desired value of electric current, and the output of current regulator removes to control the output voltage of power circuit as the control signal of power model.
2, full digital pulse gas metal-arc welding control method according to claim 1; it is characterized in that; utilize Hall current sensor that detected welding current signal is converted into proportional voltage signal by the conditioning of the current sample in described electric current loop shaping circuit; this voltage signal is sent into the A/D ALT-CH alternate channel of digital signal processor inside after signal filtering; be converted to digital quantity, this digital quantity is the value of feedback U of electric current
IfThe desired value U of electric current
LrReceive from exporting through the D/A conversion chip by the control of current target value given algorithm again behind the signal of arc length adjuster; The desired value U of electric current
IrValue of feedback U with electric current
IrDifference through the adjusting of current PI adjuster, directly export control signal U
Ct, U
CtGo to control the open-minded of electronic circuit power component in the source of welding current, and then realized control electric current.
3, full digital pulse gas metal-arc welding control method according to claim 1, it is characterized in that, utilize the Hall voltage sensor that detected weldingvoltage signal is converted into proportional voltage signal by the conditioning of the voltage sample in described Voltage loop shaping circuit, this voltage signal is sent into the A/D ALT-CH alternate channel of digital signal processor inside after signal filtering, be converted to digital quantity, this digital quantity is the instantaneous value of feedback of voltage; At pulse and base value sampled voltage respectively in the time, and calculate average voltage in the pulse period by digital signal processor, and with this as voltage value of feedback U
UfThe desired value of arc voltage is made up of two parts, wherein a part of U
Ur1Given by potentiometer, the A/D ALT-CH alternate channel of supplied with digital signal processor inside is converted to digital quantity; Desired value another part U of arc voltage
Ur2Provide by the droplet transfer ring; The arc length adjuster adopts adaptive algorithm, has only the desired value U of voltage
Ur1With voltage value of feedback U
UfEqual the time and the desired value U of voltage
Ur2Be low level, the output control signal corresponding, this control signal begins a new pulse period as the current target given algorithm pulse switching signal of current loop control; Desired value U when voltage
Ur2During for high level, the arc length adjuster can be exported the extra current echo signal, and the control electric current loop produces an extra-pulse electric current.
4, full digital pulse gas metal-arc welding control method according to claim 1; it is characterized in that; detect the state of droplet transfer in a pulse period by the droplet transfer testing circuit in the described droplet transfer ring; it is output as a switching value, and the droplet transfer controller is output as arc voltage desired value U
Ur2After time to peak finished, a molten drop was finished transition, and droplet transfer testing circuit output low level is through droplet transfer controller output arc voltage desired value U
Ur2Be 0; After time to peak finishes, still do not detect the droplet transfer to finish, droplet transfer circuit output high level then, this moment is through droplet transfer controller output U
Ur2Be high level.
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| CNB2007100363359A CN100475404C (en) | 2007-01-11 | 2007-01-11 | Control method of digital pulse consumable electrode gas protection welding |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB2007100363359A CN100475404C (en) | 2007-01-11 | 2007-01-11 | Control method of digital pulse consumable electrode gas protection welding |
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101362246B (en) * | 2008-09-23 | 2011-01-12 | 四川电子焊接设备公司 | Pulse energy control method for carbon dioxide shield-arc welding and drug-core no gas welding |
| CN101406980B (en) * | 2008-11-21 | 2011-04-27 | 北京工业大学 | Method for controlling length of electric arc |
| CN102873435A (en) * | 2012-09-25 | 2013-01-16 | 北京工业大学 | Gas metal arc welding method and system |
| CN103008835A (en) * | 2012-11-29 | 2013-04-03 | 北京工业大学 | Short circuit transition welding system of coupling arcs and control method thereof |
| CN103028815A (en) * | 2012-11-29 | 2013-04-10 | 北京工业大学 | Arc length regulating system of coupling electric arcs and control method of arc length regulating system |
| CN103769721A (en) * | 2014-01-27 | 2014-05-07 | 深圳市佳士科技股份有限公司 | Electric arc welding actuate molten dropping short-circuit transitioning control circuit based on AVR (automatic voltage regulation) singlechip |
| CN105598558A (en) * | 2016-03-10 | 2016-05-25 | 大连理工大学 | Arc welding power source current double-closed-loop control method |
| CN112658441A (en) * | 2020-04-30 | 2021-04-16 | 天津大学 | Voltage sensing method and system for monitoring metal transition state in GTA forming process |
| CN113814524A (en) * | 2021-09-30 | 2021-12-21 | 沪东中华造船(集团)有限公司 | Low-carbon medium-alloy quenched and tempered high-strength steel non-swing vertical fillet welding method |
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2007
- 2007-01-11 CN CNB2007100363359A patent/CN100475404C/en not_active Expired - Fee Related
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101362246B (en) * | 2008-09-23 | 2011-01-12 | 四川电子焊接设备公司 | Pulse energy control method for carbon dioxide shield-arc welding and drug-core no gas welding |
| CN101406980B (en) * | 2008-11-21 | 2011-04-27 | 北京工业大学 | Method for controlling length of electric arc |
| CN102873435B (en) * | 2012-09-25 | 2014-07-09 | 北京工业大学 | Gas metal arc welding method and system |
| CN102873435A (en) * | 2012-09-25 | 2013-01-16 | 北京工业大学 | Gas metal arc welding method and system |
| CN103008835A (en) * | 2012-11-29 | 2013-04-03 | 北京工业大学 | Short circuit transition welding system of coupling arcs and control method thereof |
| CN103028815A (en) * | 2012-11-29 | 2013-04-10 | 北京工业大学 | Arc length regulating system of coupling electric arcs and control method of arc length regulating system |
| CN103028815B (en) * | 2012-11-29 | 2015-09-02 | 北京工业大学 | A kind of arc length adjustment system of coupled arc and control method thereof |
| CN103008835B (en) * | 2012-11-29 | 2016-02-17 | 北京工业大学 | A kind of short-circuiting transfer soldering system of coupled arc and control method thereof |
| CN103769721A (en) * | 2014-01-27 | 2014-05-07 | 深圳市佳士科技股份有限公司 | Electric arc welding actuate molten dropping short-circuit transitioning control circuit based on AVR (automatic voltage regulation) singlechip |
| CN103769721B (en) * | 2014-01-27 | 2015-08-05 | 深圳市佳士科技股份有限公司 | The accurate short circuiting transfer control circuit of arc welding based on AVR single chip |
| CN105598558A (en) * | 2016-03-10 | 2016-05-25 | 大连理工大学 | Arc welding power source current double-closed-loop control method |
| CN112658441A (en) * | 2020-04-30 | 2021-04-16 | 天津大学 | Voltage sensing method and system for monitoring metal transition state in GTA forming process |
| CN113814524A (en) * | 2021-09-30 | 2021-12-21 | 沪东中华造船(集团)有限公司 | Low-carbon medium-alloy quenched and tempered high-strength steel non-swing vertical fillet welding method |
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| CN100475404C (en) | 2009-04-08 |
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