CN101513689B - Short circuit determination method for electrode fused arc welding - Google Patents
Short circuit determination method for electrode fused arc welding Download PDFInfo
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Abstract
The invention provides a short circuit judgment method for electrode fused arc welding, by which even the electric cable for welding is long in the electrode fused arc welding, whether the welding filament and the base metal in short circuit status or arc generation status can be accurately determined, and welding of high quality can be executed. A welding voltage (Vw) is compared with a short circuit standard value (Vt), a short circuit status is judged when the welding voltage (Vw) is lower than the short circuit standard value (Vt), while an arc generation status is judged when the welding voltage (Vw) is higher than the short circuit standard value (Vt). The short circuit standard value (Vt) varies according to the welding current value, and an upper limit is set in the arc generation status, which is a function of the welding current. Therefore, error judgment of short circuit status caused by welding voltage sudden decrease after arc generation can be prevented.
Description
Technical field
The present invention relates to the short circuit determination method for the consumable electrode arc welding of the short-circuit condition between welding wire and mother metal that judges rightly.
Background technology
In consumable electrode arc welding, welding wire and mother metal between repeatedly carry out short-circuit condition and electric arc generation state on one side, welded on one side.In carbonic acid gas arc welding, the active gas shielded arc welding of the metal utmost point, connect, during MIG (metal intert gas) welding connects etc., during becoming the short circuit of repeatedly carrying out regularly 3～5ms left and right in little/middle galvanic areas below the 200A degree and the short circuiting arc welding of the arc period of 10～30ms left and right.On the other hand, in large galvanic areas, from the droplet transfer mode of welding wire, be particle transfer or spray transfer, during the following short circuit of 1ms occurs brokenly.The situation of pulse electric charge welding is also roughly the same with the situation of large galvanic areas.In this consumable electrode arc welding, in order to obtain stable welded condition, with the welding current in during suitable waveform energising short circuit (below be called short circuit current) and to make be important to the arc period transition smoothly.Thereby, during the short circuit that judges rightly, need to be with the waveform energising short circuit current of regulation, the performance of short circuit determination method becomes one of important key element that determines welding quality.Below, the short circuit determination method of prior art is described.
Fig. 3 is the figure of the general structure of expression arc welding with consumable connection device.Welding starts circuit ST output welding commencing signal St.This welding starts circuit ST and is built in the programmable logic controller (Programmable Logic Controller, PLC) for managing welding sequence, in robot welding, is built in robot controller etc.When source of welding current PS inputs this welding commencing signal St, output is suitable for weldingvoltage Vw and the welding current Iw of arc welding, and output is given control signal Fc for the rotation of controlling wire feed motor WM.
At this, when welding wire 1 and mother metal 2 short circuit, following formula is set up.
Vw=(Rc+Rsx+Rp) Iw ... formula (1)
Wherein, the resistance value that Rc is the used for welding cable, silk protuberance resistance value when Rsx is short circuit, Rp is the resistance value that comprises the mother metal of fusion pool.In addition, when electric arc 3 produces, following formula is set up.
Vw=(Rc+Rax+Rp) Iw+Va ... formula (2)
Wherein, silk protuberance resistance value when Rax is the electric arc generation, Va is arc voltage value.
At this, can roughly think Rsx=Rax=Rx, if, therefore as shown in the formula setting like that short circuit a reference value Vt, can judge short-circuit condition and electric arc generation state.
Vt=K1Iw+K2 ... formula (3)
Wherein, K1 is constant, K1=(Rc+Rx+Rp).In addition, K2 is also constant, K2=Va/2.When constant K 1 can be ignored, also can be set as Vt=K2.Below the short circuit determination method that uses this short circuit a reference value Vt is described.
Fig. 4 is the figure of the current/voltage waveform of expression consumable electrode arc welding.Figure (A) means welding current Iw, and figure (B) means weldingvoltage Vw.The oscillogram that this figure is the stable welded condition in short circuiting arc welding.Below, with reference to this figure, describe.
Constantly during the short circuit of t1～t2 in Ts, as shown in figure (A), welding current Iw has suitable slope and increases, as shown in this figure (B), weldingvoltage Vw becomes the short-circuit voltage value of little value, as shown in above-mentioned formula (1), along with the increase of welding current Iw, increases gradually.Current waveform during short circuit in Ts is suitable this point has larger impact to the stability of welded condition.Constantly in the arc period Ta in t2～t3, as shown in figure (A), welding current Iw reduces gradually according to arc load, as shown in this figure (B), the magnitude of voltage when electric arc of weldingvoltage Vw large value while becoming than short circuit occurs, as shown in above-mentioned formula (2), along with the minimizing of welding current Iw, reduce gradually.In Ts, in order correctly to control welding current Iw, and source of welding current Ps is carried out to constant current control during short circuit, in order to control electric arc length, the welding power ps being carried out to constant voltage control in arc period Ta is general situation.
As shown in the dotted line of this figure (B), while by above-mentioned formula (3), setting short circuit a reference value Vt, short circuit a reference value Vt increases in Ts during short circuit according to welding current value Iw, in arc period Ta, reduces.At this, weldingvoltage Vw is this short circuit a reference value Vt when following, is judged as YES Ts during short circuit, when weldingvoltage Vw surpasses short circuit a reference value Vt, is judged as YES arc period Ta.Thus, Ts and arc period Ta during the short circuit that can judge rightly, control by the output during being suitable for respectively, can access good welding quality (reference example is as patent documentation 1,2).
Patent documentation 1: Japanese kokai publication sho 61-176474 communique
Patent documentation 2: Japanese kokai publication sho 61-238469 communique
The oscillogram that Fig. 5 is above-mentioned resistance value (Rc+Rx+Rp) weldingvoltage Vw when large.Resistance value as described above, that Rc is the used for welding cable, Rx is silk protuberance resistance value, the resistance value that Rp is mother metal.Becoming large situation as resistance value, is general situation from the lead-out terminal detection weldingvoltage Vw of the source of welding current, be therefore because the used for welding cable is long, and Rc becomes large situation.In addition, as other situation, can consider in the situation that the diameter of welding wire is thin, when the outstanding length of silk is elongated, the situation that welding wire is the material that resistance value is large as stainless steel etc. are such, and silk protuberance resistance value Rx becomes large situation.In addition, as other situation, consider the situation that mother metal is the material that resistance value is large as stainless steel.Below, with reference to this figure, problem of the present invention is described.
Weldingvoltage Vw in Ts during the short circuit of t1～t2, when as above-mentioned formula (1), resistance value (Rc+Rx+Rp) is large, increase to the precipitous gradient along with the increase of welding current constantly.Equally, the short circuit a reference value Vt shown in dotted line, as shown in above-mentioned formula (3), increase along with the increase of welding current.Therefore, during the short circuit of moment t1～t2, in Ts, welding voltage value Vw is less than short circuit a reference value Vt, therefore as being judged rightly during short circuit.But because resistance value (Rc+Rx+Rp) is large, so weldingvoltage Vw increases with the precipitous gradient, so the difference of welding voltage value Vw and short circuit a reference value Vt is little.
While producing electric arc in moment t2, weldingvoltage Vw moment rises sharp.This is, will be transitioned into electric arc generation state and the result of the voltage recruitment of the energy that needs and the arc voltage value caused voltage recruitment addition corresponding with arc length from short-circuit condition for supplying with in order to make.In moment t2, because welding voltage value Vw is larger than short circuit a reference value Vt, the electric arc that therefore can judge rightly occurs.
Once electric arc produces in moment t2, need to be along with the voltage recruitment of above-mentioned transfer, so welding voltage value Vw is die-offed.Its result, with irrelevant for arc period, in moment t3, welding voltage value Vw is less than short circuit a reference value Vt, till this state continuance arrives moment t4.Therefore, erroneous judgement disconnected this constantly t3～t4 during for during short circuit.Produce erroneous judgement when disconnected, irrelevant with arc period, the output of carrying out during short circuit is controlled, and it is unstable that welded condition becomes.The reason that initial this erroneous judgement stopping pregnancy is given birth to is, because resistance value (Rc+Rx+Rp) is large, so the cause that diminishes of the difference of weldingvoltage Vw and short circuit a reference value Vt.In other words, for because judgement nargin diminishes, therefore in easy generation, judge the cause of disconnected state by accident.
Summary of the invention
At this, even the object of the present invention is to provide a kind of in the situation that resistance value (Rc+Rx+Rp) is large, during the short circuit that also can judge rightly and the short circuit determination method of the consumable electrode arc welding of arc period.
In order to solve above-mentioned problem, the short circuit determination method of one of the present invention's consumable electrode arc welding, this consumable electrode arc welding is alternately repeatedly during short circuit and arc period, and during becoming the short circuit a reference value and judge above-mentioned short circuit to get off by welding voltage value, above-mentioned short circuit a reference value is set as to the value corresponding with welding current, it is characterized in that, higher limit is set as to above-mentioned short circuit a reference value in above-mentioned arc period, stipulate the function that this higher limit is welding current.
The present invention's two, the short circuit determination method of described consumable electrode arc welding, is characterized in that one of according to the present invention, only the zero hour to specified time limit from each arc period, sets above-mentioned higher limit.
According to the present invention, by higher limit being set as to the short circuit a reference value in arc period, can prevent that the erroneous judgement of short-circuit condition and electric arc generation state is disconnected.Therefore, during can being suitable for short circuit respectively and the output of arc period control, therefore can access stable welded condition, can carry out high-quality welding.
The accompanying drawing explanation
Fig. 1 is the oscillogram of the weldingvoltage Vw of the short circuit determination method of the relevant consumable electrode arc welding of expression embodiments of the present invention.
The block diagram of the source of welding current that Fig. 2 is the short circuit determination method for implementing the consumable electrode arc welding relevant to embodiments of the present invention.
The structure chart that Fig. 3 is consumable electrode arc welding device of the prior art.
Fig. 4 is the current/voltage oscillogram of the short circuit determination method of expression consumable electrode arc welding of the prior art.
Fig. 5 is the oscillogram of the weldingvoltage Vw for problem is described.
In figure:
1 welding wire
2 mother metals
The 2a fusion pool
3 electric arcs
4 welding torch
5 give roller
6a, 6b used for welding cable
The DV drive circuit
Dv drives signal
The Ea error amplification signal
EI current error amplifying circuit
Ei current error amplifying signal
EV voltage error amplifying circuit
Ev voltage error amplifying signal
FC gives control circuit
Fc gives control signal
The ID current detector
The Id current detection signal
ISR short circuit current initialization circuit
Isr short circuit current setting signal
The Iw welding current
K1, K2 constant
The PM electric power main circuit
The PS source of welding current
Silk protuberance resistance value when Rax electric arc occurs
The resistance value of Rc used for welding cable
Rp comprises the resistance value of the mother metal of fusion pool
Silk protuberance resistance value during the Rsx short circuit
Rx silk protuberance resistance value
SD short circuit decision circuitry
Sd short circuit judgement signal
SP external behavior commutation circuit
The ST welding starts circuit
St welds commencing signal
The Ta arc period
During the Ts short circuit
The Va arc voltage value
The VD voltage detector
The Vd voltage detection signal
The VR voltage setting circuit
The Vr voltage setting signal
VT short circuit a reference value initialization circuit
Vt short circuit a reference value (signal)
VTA higher limit limiting circuit
The Vta higher limit
Vtm higher limit restriction short circuit a reference value signal
The Vw weldingvoltage
The WM silk is given motor
α, β constant
The specific embodiment
Below, with reference to accompanying drawing, embodiments of the present invention are described.
Fig. 1 is the oscillogram of the weldingvoltage Vw of the short circuit determination method of the relevant consumable electrode arc welding of expression embodiments of the present invention.In this figure, solid line means weldingvoltage Vw, and dotted line means short circuit a reference value Vt.This figure is corresponding with above-mentioned Fig. 5, is the large situation of resistance value (Rc+Rx+Rp).In this figure, the short circuit determination method of Ts by the prior art short-circuit condition that can judge rightly during the short circuit of t1～t2 constantly, therefore the action in during this period is identical with Fig. 5.Below, from Fig. 5 different action later to moment t2 with reference to this figure describes.
Short circuit a reference value Vt, same as the prior art, by above-mentioned formula (3), set.Be that short circuit a reference value Vt changes according to the welding current value.Thus, by setting short circuit a reference value Vt, as mentioned above, Ts during the short circuit of the moment t1～t2 that can judge rightly.
In moment t2, larger than short circuit a reference value Vt by welding voltage value Vw, thus when judgement electric arc has produced, short circuit a reference value Vt is arranged to higher limit Vta as follows like that.
Vt=K1Iw+K2 ... above-mentioned formula (3)
Vta=α Iw+ β ... formula (4)
Wherein, Iw is the welding current value, and α and β are constant.This higher limit Vta only sets at arc period, during short circuit, does not set.If the act numerical example, α is probably that 0.005～0.05, β is probably 2～20.This α and β give the welding condition of speed etc. and are set as appropriate value according to kind, the silk of the kind of welding wire, protective gas.
As shown in the drawing, in moment t2, while producing electric arc, welding voltage value Vw sharply rises.Therefore, welding voltage value Vw becomes larger than short circuit a reference value, and arc period therefore can judge rightly.If be judged as arc period, the higher limit of short circuit a reference value Vt is restricted to the Vta shown in above-mentioned formula (4).Therefore, constantly t2～t3 during in the higher limit of short circuit judgment value be restricted to Vta.Its result, after moment t2, even welding voltage value Vw is die-offed for the above reasons, do not have the little situation than the confined short circuit a reference value of higher limit Vt, therefore can not produce during as Fig. 5 with short circuit during erroneous judgement break.Constantly t3 later during in, the short circuit a reference value Vt set by above-mentioned formula (3) is less than the higher limit Vta of above-mentioned formula (4), therefore is not restricted to higher limit Vta.In this period, because welding voltage value Vw is larger than short circuit a reference value Vt, arc period therefore can judge rightly.
To how setting short circuit a reference value Vt, arranged.In the figure, the short circuit a reference value Vt in during the short circuit of t1～t2 is constantly set by above-mentioned formula (3).Capping value not in during this short circuit.Next, constantly the short circuit a reference value Vt in the later arc period of t2 is set by above-mentioned formula (3), by above-mentioned formula (4), is restricted to higher limit Vta.Short circuit a reference value Vt in during moment t2～t3, because the value of above-mentioned formula (3) is larger than the higher limit of above-mentioned formula (4), therefore become the value that is restricted to higher limit Vta.On the other hand, constantly t3 later during in short circuit a reference value Vt, because the value of above-mentioned formula (3) is less than the higher limit of above-mentioned formula (4), therefore become the value of formula (3).At this, consider above-mentioned formula (4) is defined as the situation of Vta=β.Being the situation that higher limit Vta is made as to setting β, is the situation with welding current value it doesn't matter ground sets this value.Now, setting β hour, can not prevent that electric arc from erroneous judgement afterwards occurring disconnected.In addition, when setting β is large, can prevent that the erroneous judgement of electric arc after occurring is disconnected, but after arc period in produce the disconnected possibility increase of erroneous judgement.By higher limit Vta being set as above-mentioned formula (4) to the value corresponding with welding current value Iw, thereby prevent that both erroneous judgements are disconnected, during the short circuit that can judge rightly and arc period.
Fig. 2 is the block diagram of the source of welding current of the short circuit determination method for implementing the consumable electrode arc welding that above-mentioned embodiments of the present invention are relevant.Below, with reference to this figure, each block diagram is described.
It is input that electric power main circuit PM be take the industrial power of 3 phase 200V etc., carries out the output of inverter control according to driving signal Dv described later and controls, and output is suitable for weldingvoltage Vw and the welding current Iw of arc welding.This electric power main circuit PM consists of following part: the 1 rank rectifier that 3 cross streams is carried out to rectification; The direct current be rectified is carried out to level and smooth smmothing capacitor; The inverter circuit that is high-frequency ac by smoothed DC converting; It by the high-frequency ac step-down, is the high frequency transformer that is suitable for the magnitude of voltage of arc welding; High-frequency ac by step-down is carried out 2 rank rectifiers of rectification and the direct current be rectified is carried out to level and smooth reactor.Welding wire 1 is fed in welding torch 4 by with silk, giving the rotation of giving roller 5 that motor WM is coupled, and mother metal 2 between produce electric arc 3.
Voltage detector VD detects weldingvoltage Vw, voltage sense signal Vd.Current detector ID detects welding current Iw, output electric current measure signal Id.Short circuit a reference value initialization circuit VT is usingd above-mentioned current detection signal Id as input, the formula based on above-mentioned (3) output short-circuit a reference value signal Vt.Higher limit limiting circuit VTA, using above-mentioned current detection signal Id as input, all the time calculate higher limit Vta based on above-mentioned formula (4), when short circuit judgement signal Sd is low level (arc period), when the value of above-mentioned short circuit reference signal Vt surpasses calculated higher limit Vta, be restricted to higher limit Vta, output higher limit restriction short circuit reference signal Vtm.Short circuit decision circuitry SD compares the value of above-mentioned voltage detection signal Vd and the value of this higher limit restriction short circuit a reference value signal Vtm, become high level (during short circuit) when Vd≤Vtm, when Vd>Vtm, output becomes the short circuit judgement signal Sd of low level (arc period).
Give control circuit FC output for control above-mentioned silk give motor WM rotation give control signal Fc.The short circuit current setting signal Isr of the short circuit current initialization circuit ISR output current waveform in being used to form during predetermined short circuit.Current error amplifying circuit EI is amplified the error between this short circuit current setting signal Isr and above-mentioned current detection signal Id, output current error amplification signal Ei.Voltage setting circuit VR exports predetermined voltage setting signal Vr.Voltage error amplifying circuit EV is amplified the error between this voltage setting signal Vr and above-mentioned voltage detection signal Vd, output voltage error amplifying signal Ev.
External behavior commutation circuit SP, when above-mentioned short circuit judgement signal Sd is high level (during short circuit), export above-mentioned current error amplifying signal Ei as error amplification signal Ea, when being low level (arc period), export above-mentioned voltage error amplifying signal Ev as error amplification signal Ea.Therefore, become constant-current characteristics during short circuit, arc period becomes constant-voltage characteristic.Drive circuit DV is usingd above-mentioned error amplification signal Ea as input, carries out pulse width modulation control, based on the driving signal Dv of this pulse width modulation control signal output for the inverter circuit comprised at above-mentioned electric power main circuit PM is driven.
In the above-described embodiment, in arc period, at the short circuit a reference value Vt calculated by formula (3), when the higher limit Vta calculated by formula (4) is above, be restricted to higher limit.But in the prior art, producing erroneous judgement disconnected is after electric arc produces, and therefore can not stride across arc period set overall higher limit, also can only start to capping value specified time limit from each arc period.
By above-mentioned embodiment, by the capping value, be the short circuit a reference value in arc period, therefore can prevent that the erroneous judgement of short-circuit condition and electric arc generation state is disconnected.Therefore, during can being suitable for short circuit respectively and the output of arc period control, therefore can access stable welded condition, can carry out high-quality welding.
Claims (2)
1. the short circuit determination method of a consumable electrode arc welding, this consumable electrode arc welding is alternately repeatedly during short circuit and arc period, and during the short circuit determination method of this consumable electrode arc welding becomes the short circuit a reference value and judges above-mentioned short circuit to get off by welding voltage value, above-mentioned short circuit a reference value is set as to the value corresponding with welding current, it is characterized in that
Be set as the higher limit of above-mentioned short circuit a reference value in above-mentioned arc period, stipulate the function that this higher limit is welding current,
If above-mentioned short circuit a reference value is Vt, above-mentioned higher limit is Vta, and above-mentioned welding current is Iw, and K1, K2, α, β are constant, and functional relation is as follows:
Vt＝K1·Iw+K2
Vta＝α·Iw+β，
Wherein, K1=(Rc+Rx+Rp); the resistance value that Rc is the used for welding cable; Rx is silk protuberance resistance value, and Rp is the resistance value that comprises the mother metal of fusion pool, K2=Va/2; Va is arc voltage value; α is that 0.005～0.05, β is 2～20, and this α and β give speed and are set as appropriate value according to kind, the kind of protective gas, the silk of welding wire.
2. the short circuit determination method of consumable electrode arc welding according to claim 1, is characterized in that,
Only the zero hour to specified time limit from each arc period, set above-mentioned higher limit.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2008040232A JP2009195952A (en) | 2008-02-21 | 2008-02-21 | Method for discriminating short circuit in consumable electrode arc welding |
| JP2008040232 | 2008-02-21 | ||
| JP2008-040232 | 2008-02-21 |
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| CN101513689A CN101513689A (en) | 2009-08-26 |
| CN101513689B true CN101513689B (en) | 2014-01-08 |
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| CN102441722B (en) * | 2010-09-30 | 2015-05-27 | 株式会社大亨 | Arc welding method |
| JP2013043209A (en) * | 2011-08-25 | 2013-03-04 | Daihen Corp | Welding power source |
| JP6054184B2 (en) * | 2013-01-21 | 2016-12-27 | 株式会社ダイヘン | Power supply device for arc welding and output voltage monitoring method for power supply device for arc welding |
| CN103286420B (en) * | 2013-05-30 | 2015-06-03 | 唐山松下产业机器有限公司 | Electric arc welder and electric arc welding short-circuit determining method |
| CN109799429B (en) * | 2018-12-14 | 2020-12-15 | 唐山松下产业机器有限公司 | Arcing state determination method and device |
| CN109317786B (en) * | 2018-12-14 | 2020-08-21 | 唐山松下产业机器有限公司 | Short circuit transition welding control method |
| CN111215727B (en) * | 2019-12-02 | 2022-05-13 | 唐山松下产业机器有限公司 | Method and device for detecting welding short circuit arcing |
| CN111299757B (en) * | 2019-12-06 | 2021-11-09 | 唐山松下产业机器有限公司 | Control method, device and system for pulse welding process |
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| JPS61176474A (en) * | 1985-01-31 | 1986-08-08 | Daihen Corp | Short-circuit detection circuit |
| JPH0632859B2 (en) * | 1985-04-15 | 1994-05-02 | 株式会社神戸製鋼所 | Short circuit / arc discrimination method in consumable electrode arc welding |
| US4717807A (en) * | 1986-12-11 | 1988-01-05 | The Lincoln Electric Company | Method and device for controlling a short circuiting type welding system |
| JP4547850B2 (en) * | 2002-07-12 | 2010-09-22 | 株式会社ダイヘン | How to detect short circuit in arc welding |
| JP2005349406A (en) * | 2004-06-08 | 2005-12-22 | Daihen Corp | Method for discriminating short circuit of ac pulsed arc welding |
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