CN102029460B - Pulsed arc welding method of carbon oxide - Google Patents
Pulsed arc welding method of carbon oxide Download PDFInfo
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Abstract
The present invention provides a pulsed arc welding method of carbon oxide. A peak period (Tp) of a peak current flow (Ip) and a reference period (Tb) of a reference current flow (Tp) are used as one pulse period (Tpb) for welding repeatedly. The peak current (Ip) is vibrated through an amplitude (Ws) and a vibration period (Ts) in a peak period (Tp) for forming a molten drop at a front end of a welding wire. In the reference period (Tb), the formed molten drop smoothly transits to a molten pool through short circuiting transfer. Therefore, short circuiting transfer is performed to the molten drop formed in the peak period (Tp) is performed in the reference period (Tb). Therefore one molten drop transition state in one pulse period can be realized. Therefore the welding with little splash can be performed. Therefore in the electrode fused pulsed arc welding of carbon oxide, the formation and release state of the molten drop are stabilized, and high-quality welding with little splash can be performed.
Description
Technical field
The present invention relates to in the consumable electrode formula pulse electric arc welding using with carbon dioxide the protective gas being principal component, carry out the pulsed arc welding method of carbon oxide of stable droplet transfer.
Background technology
The consumable electrode formula pulse electric arc welding of the protective gas using argon gas as principal component is adopted to be widely used.As the protective gas being principal component with this argon gas; 20 volume % carbon dioxide+80 volume % argon gas (active gases protection pulse welding is used when mother metal is ferrous materials; マ グ パ Le ス welds), mother metal uses 100 volume % argon gas (inert gas shielding pulse welding, ミ グ パ Le ス welds) when being aluminum.In the pulse electric arc welding adopting the protective gas using this argon gas as principal component; the spray transfer state of stably carrying out periodically because the droplet transfer is in the such particulate of the diameter that becomes welding wire, thus can carry out sputtering and produce few good welding.Below to adopting with argon gas the pulse electric arc welding of the protective gas being principal component to be described.
Fig. 4 is the general current-voltage waveform figure of the pulse electric arc welding adopting with argon gas the protective gas being principal component.This figure (A) represents the time variations to the welding current Iw that electric arc is energized, and this figure (B) represents the time variations of the weldingvoltage Vw between welding wire and mother metal.Below, be described with reference to this figure.
Between the peak period of moment t1 ~ t2 in Tp, as shown in this figure (A), formed to make molten drop and be transitioned into welding wire front end, peak point current Ip more than energising critical electric current value, as shown in this figure (B), between welding wire and mother metal, apply the crest voltage Vp growing up to ratio with electric arc.
In the base value period Tb of moment t2 ~ t3, as shown in this figure (A), the background current Ib of the small area analysis value that is energized to not form molten drop, as shown in this figure (B), applies base value voltage Vb.Repeatedly weld as pulse period Tpb during till moment t1 ~ t3.
In order to carry out good pulse electric arc welding, it is important that electric arc length is maintained appropriate value.Carry out following output like that in order to electric arc length is maintained appropriate value and control (electric welding arc control).Electric arc length and this figure (B) are by the roughly proportional relation of weldingvoltage mean value Vav shown in dotted line.Therefore, detect weldingvoltage mean value Vav, the mode equal according to the weldingvoltage setting value that this detected value is long with being equivalent to suitable electric arc carries out the output changed by the welding current mean value Iav shown in the dotted line of this figure (A) is controlled.Weldingvoltage mean value Vav time larger than weldingvoltage setting value be electric arc length longer than appropriate value time, therefore reduce welding current mean value Iav reduce silk melting speed, electric arc is long to shorten.Conversely, when weldingvoltage mean value Vav is less than weldingvoltage setting value be electric arc length than appropriate value in short-term, therefore increase of weld current mean value Iav increase silk melting speed, electric arc is long elongated.As above-mentioned weldingvoltage mean value Vav, usually use smoothing to weldingvoltage Vw after the situation of value more.
In above-mentioned, the output as the source of welding current for making welding current mean value Iav change controls, and main frequency of utilization modulation control and pulse width modulation control.During frequency modulation(PFM) controls, by peak point current Ip, background current Ib and between the peak period Tp be fixed as setting, control the length of base value period Tb to make weldingvoltage mean value Vav equal with weldingvoltage setting value.When base value period, Tb changed, Tpb changes the pulse period, and therefore this mode is called frequency modulation(PFM) and controls.In addition, peak point current Ip, background current Ib and pulse period Tpb are fixed as setting in controlling by pulse width modulation, control the length of Tp between the peak period to make weldingvoltage mean value Vav equal with weldingvoltage setting value.
Next, with reference to this figure, the droplet transfer is described.By the energising of peak point current Ip, welding wire front end is melted, and forms molten drop.Now, using with argon gas is the protective gas of principal component, and the anode spot being therefore formed as electric arc does not concentrate on molten drop bottom, and expansion is distributed in molten drop entirety.Thus, pushing force is not acted on to molten drop.When peak point current Ip is energized to formed molten drop, the convergent force of electromagnetism is acted on to molten drop top and produces necking down.Afterwards, before and after between the peak period, Tp terminates (before closing to an end, at the end of or after terminating soon), molten drop departs from and also carries out transition to fusion pool.If above-mentioned peak point current Ip and between the peak period combination of Tp be called unit pulse (unit pulse) condition, be then set as that the such molten drop of the diameter of welding wire is formed and carries out the value that departs from.Therefore, molten drop carries out spray transfer as the particulate that the diameter of welding wire is such by Tp between each peak period.This state is called 1 pulse 1 droplet transfer state.As above, what sputtering generation was considerably less is welded into possibility.
As mentioned above, in the pulse electric arc welding adopting with argon gas the protective gas being principal component, the stable spray transfer state of 1 pulse 1 droplet transfer is in.At this, argon gas cost compared with carbon dioxide uprises, and therefore attempts the ratio by reducing argon gas and the ratio increasing carbon dioxide cuts down the cost of protective gas in the past.But in the mist of carbon dioxide and argon gas, if the ratio of carbon dioxide is more than 30 volume %, then due to following illustrated reason, stable spray transfer becomes difficulty gradually.Especially, when using the protective gas that the ratio of carbon dioxide is principal component more than the carbon dioxide of 50 volume %, stable spray transfer state can not be in, produce the sputtering thing of large grain.In explanation after this, record with carbon dioxide be the protective gas of principal component time, mean the mist of the ratio of carbon dioxide more than 50 volume %.When use take carbon dioxide as the protective gas of principal component, the anode spot being formed as electric arc when peak point current Ip is energized concentrates on the foot of molten drop.This is because the electric potential gradient of carbon dioxide is large compared with argon gas, the long effect becoming the shortest of electric arc is therefore made to occur.Its result, the state that the temperature being in anode spot significantly uprises, is in metallic vapour and blows afloat the state come, to molten drop effect pushing force.Namely form molten drop by the energising of peak point current Ip, and this pushing force acts on, molten drop is in the state do not departed from simply.In this condition, in order to make molten drop depart from forcibly, needing to make Tp between the peak period increase about 3 ~ 5 times than general value, molten drop being grown up significantly, is departed from by gravity.But if done like this, then the block that molten drop becomes the size of the several times degree of the diameter of welding wire departs from, and produces the sputtering thing of large grain.And then the asynchronous and transition randomly of the energising of this large molten drop and peak point current Ip, welded condition plays pendulum, and welding quality is also deteriorated.In order to solve the problem as described above of the pulse electric arc welding (hereinafter referred to as carbon dioxide pulse electric arc welding) adopting with carbon dioxide the protective gas being principal component, following such prior art is proposed.
In the invention of patent document 1, if the first-half period of peak point current Ip is than value large between latter half, become the stepped of right shoulder decline.By carrying out as above, between the latter half of peak point current Ip, forming molten drop, next by base value period Tb, shaping being carried out to molten drop, then making the droplet transfer by the first-half period of peak point current Ip.In addition, in the invention of patent document 2 ~ 4, peak point current Ip is energized as multiple peak point current group, makes the formation stabilisation also easily transition of molten drop.
The clear 60-56486 publication of [patent document 1] TOHKEMY
The clear 61-17369 publication of [patent document 2] TOHKEMY
[patent document 3] JP Laid-Open 1-254385 publication
[patent document 4] TOHKEMY 2007-237270 publication
[patent document 5] TOHKEMY 2006-116546 publication
As mentioned above, in carbon dioxide pulse electric arc welding, in order to improve formation and the disengaging of molten drop, propose the various schemes shown in patent document 1 ~ 4.But at current time, not talkative carbon dioxide pulse electric arc welding is practical, and the welder of carbon dioxide pulse electric arc welding is not sold yet.Even if foregoing represents the improvement implemented patent document 1 ~ 4 and propose, problem still exists.
According to the invention of patent document 1, by the peak point current of first-half period, the transition probability of molten drop uprises, but the transition of molten drop is not synchronous with peak point current and situation that is that produce randomly is still more.This forms necking down on molten drop top due to the value of the peak point current by increasing first-half period, thus promote to depart from, but then, because pushing force also increases, and the therefore cause that do not depart from veritably of molten drop.In addition, according to the invention of patent document 2 ~ 4, by being energized as multiple peak point current group by peak point current, thus molten drop can be formed smoothly.This be a side owing to carrying out being energized as multiple peak point current group compared with energising continuous print peak point current, the pushing force that molten drop is acted on can be disperseed, thus the formation of molten drop becomes level and smooth.But in order to make the molten drop of this formation be departed from by peak point current, it is necessary for forming necking down on the top of molten drop, now also acts on pushing force simultaneously.Its result, it is difficult for by the energising of multiple peak point current group, molten drop being departed from veritably.Therefore, in the invention of patent document 2 ~ 4, the formation of molten drop is enhanced, but the problem that residual molten drop reliably departs from.
At this, when tapping into row consideration to the direct current CO2 welding of ferrous materials, be less than in the galvanic areas of about 200A in average welding current value, molten drop is in short circuiting transfer.Namely during arc period and short circuit by periodically repeatedly, the molten drop formed in arc period during short circuit in carry out transition.By critically controlling the welding current in during this short circuit, thus the state of the generation reducing sputtering can be in.But, adopt with argon gas the pulse electric arc welding of the protective gas being principal component (active gases protection pulse welding or inert gas shielding pulse welding) to reach the generation reducing sputtering further.But can say in this galvanic areas, the generating capacity of the sputtering that CO2 welding connects is level no problem in practical.If be in the galvanic areas that average welding current value is about more than 200A, be then in the droplet transfer when electric arc length is elongated, molten drop does not carry out transition with short circuit by freely falling due to gravity.Therefore, the generation of sputtering is few.In this galvanic areas, owing to carrying out the high-speed welding that speed of welding is more than 80cm/min, therefore in order to prevent the weld defect of undercut (undercut) etc., need electric arc to be grown set to weld shortlyer.If it is long to shorten electric arc, then molten drop is in short circuit to carry out the state of transition.And the timing produced due to short circuit is random, and therefore the size of molten drop also has various sizes, owing to being in irregular droplet transfer state, therefore the sputtering produce of large grain are raw more.Therefore, in the galvanic areas of more than 200A, when carrying out high-speed welding, by carrying out adopting with argon gas the pulse electric arc welding of the protective gas being principal component, the generation of sputtering can be reduced.
As mentioned above, adopting with carbon dioxide is that the protective gas of principal component welds, and wants the welding condition of the generation reducing sputtering to be the situation of carrying out high-speed welding especially in the galvanic areas of more than 200A.At this, the object of the invention is to, in the high-speed welding in the galvanic areas of more than 200A, by improving the droplet transfer state of carbon dioxide pulse electric arc welding, thus when connecing than CO2 welding, reducing sputtering generating capacity.
Summary of the invention
In order to solve above-mentioned problem, the invention of technical scheme 1, use the protective gas using carbon dioxide as principal component, feeding welding wire, and weld between the peak period of circulation peak point current and during the base value of circulation background current repeatedly as 1 pulse period, the feature of this pulsed arc welding method of carbon oxide is, in between the above-mentioned peak period, current constant control is carried out to above-mentioned peak point current, and undertaken by making above-mentioned peak point current vibrating and form molten drop in the front end of welding wire, make the molten drop of this formation to fusion pool transition by short circuiting transfer in during above-mentioned base value, electric welding arc control is carried out by carrying out Isobarically Control to the weldingvoltage in during above-mentioned base value.
The invention of technical scheme 2, pulsed arc welding method of carbon oxide according to technical scheme 1, it is characterized in that, above-mentioned carry out the peak point current vibrated amplitude and the vibration period be set to suppress the overheated of molten drop and the molten drop of sputtering thing not from the formed value of dispersing.
The invention of technical scheme 3, the pulsed arc welding method of carbon oxide according to technical scheme 1 or 2, is characterized in that, the above-mentioned waveform carrying out the peak point current vibrated is that rectangle is wavy.
The invention of technical scheme 4, according to the pulsed arc welding method of carbon oxide according to any one of technical scheme 1 ~ 3, is characterized in that, between the above-mentioned peak period for the feed speed according to welding wire and during setting.
The invention of technical scheme 5, according to the pulsed arc welding method of carbon oxide according to any one of technical scheme 1 ~ 4, is characterized in that, for during continuing before carrying out short circuiting transfer during above-mentioned base value.
The invention of technical scheme 6, according to the pulsed arc welding method of carbon oxide according to any one of technical scheme 1 ~ 4, it is characterized in that, formed during the molten drop of the short circuit standby period before being occurred by short circuit during above-mentioned base value and then this short circuit standby period carries out the short circuit of short circuiting transfer, above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, in during above-mentioned short circuit circulation from the value of above-mentioned 1st background current along with the time through and the 2nd background current that increases gradually.
The invention of technical scheme 7, according to the pulsed arc welding method of carbon oxide according to any one of technical scheme 1 ~ 4, it is characterized in that, short circuit standby period before being occurred by short circuit during above-mentioned base value, then during the molten drop of this short circuit standby period carries out the short circuit of short circuiting transfer and then during this short circuit prevent electric arc again occur after the predetermined short circuit again that is again short-circuited prevent period from being formed, above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, the 2nd background current that in during above-mentioned short circuit, circulation increases gradually along with time process from the value of above-mentioned 1st background current, above-mentioned short circuit again prevents the 3rd background current that in period, circulation is larger than the value of above-mentioned 1st background current.
The invention of technical scheme 8, according to the pulsed arc welding method of carbon oxide according to any one of technical scheme 1 ~ 4, it is characterized in that, short circuit standby period before being occurred by short circuit during above-mentioned base value, then the predetermined timing period during the molten drop of this short circuit standby period carries out the short circuit of short circuiting transfer and then during this short circuit is formed, above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, the 2nd background current that in during above-mentioned short circuit, circulation increases gradually along with time process from the value of above-mentioned 1st background current, the 4th background current that in above-mentioned timing period, circulation is less than the value of above-mentioned 2nd background current of the end time point during above-mentioned short circuit.
The invention of technical scheme 9, according to the pulsed arc welding method of carbon oxide according to any one of technical scheme 1 ~ 4, it is characterized in that, short circuit standby period before being occurred by short circuit during above-mentioned base value, then during the molten drop of this short circuit standby period carries out the short circuit of short circuiting transfer, then during this short circuit prevent electric arc again occur after the predetermined short circuit again that is again short-circuited prevent period and then this again short circuit prevent the predetermined timing period of period from being formed, above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, the 2nd background current that in during above-mentioned short circuit, circulation increases gradually along with time process from the value of above-mentioned 1st background current, above-mentioned short circuit again prevents the 3rd background current that in period, circulation is larger than the value of above-mentioned 1st background current, the 4th background current that in above-mentioned timing period, circulation is less than the value of above-mentioned 2nd background current of the end time point during above-mentioned short circuit.
Pass through the present invention; in the pulsed arc welding method of carbon oxide adopting the protective gas using carbon dioxide as principal component; to arrange between the peak period and during base value; vibrate by making the peak point current between the peak period and molten drop is formed as roughly desired size, in can making the molten drop of this formation during base value, carry out short circuiting transfer.Therefore, it is possible to realize 1 pulse period 1 droplet transfer state, thus can carry out sputtering the few high-quality welding of generation.During high-speed welding especially in the galvanic areas of more than 200A, the generation sputtered can be suppressed compared with connecing method with the CO2 welding of direct current, also can improve welding bead outward appearance.
Accompanying drawing explanation
Fig. 1 is the current-voltage waveform figure representing the pulsed arc welding method of carbon oxide that embodiments of the present invention are correlated with.
Fig. 2 is the figure of the appropriate value illustrating Tp between embodiments of the present invention peak period corresponding with feed speed of being correlated with.
Fig. 3 is the block diagram of the source of welding current for implementing the pulsed arc welding method of carbon oxide that embodiments of the present invention are correlated with.
Fig. 4 is the current-voltage waveform figure of existing pulse arc welding method.
The explanation of symbol:
1-welding wire; 2-mother metal; 3-electric arc; 4-welding torch; 5-feed rolls; Bi-current differential signal; E-output voltage; Ecr-Control of Voltage setting signal; ED-output voltage detecting circuit; Ed-voltage sense signal; EI-current error amplifying circuit; Ei-current error amplifying signal; ERC-electronic inductor control circuit; ER-output voltage initialization circuit; Er-output voltage setting signal; EV-voltage error amplifying circuit; Ev-voltage error amplifying signal; Hip-high peak current; HIPR-high peak current initialization circuit; HIpr-high peak current setting signal; During HTp-peak value; Iav-welding current mean value; Ib-background current; Ib1-the 1st background current; Ib2-the 2nd background current; Ib3-the 3rd background current; Ib4-the 4th background current; ID-current detection circuit; Id-welding current detection signal; Ip-peak point current; IPR-peak point current initialization circuit; Ipr-peak point current setting signal; Iw-welding current; Lip-low peak current; During LTp-low peak; PM-electric power main circuit; Sd-short circuit discrimination circuit; Sd-short circuit discrimination signal; Spb-pulse-period signal; Control switching circuit during ST-; Switch-over control signal during St-; SUB-subtraction circuit; SW-commutation circuit; During Tb-base value; Td-timing period; TDR-timing period initialization circuit; Tdr-timing period setting signal; Th-again short circuit prevents period; THR-again short circuit prevents period initialization circuit; Thr-again short circuit prevents period setting signal; Between the Tp-peak period; The Tpb-pulse period; The Ts-vibration period; TSR-vibration period initialization circuit; Tsr-vibration period setting signal; Vb-base value voltage; VD-voltage detecting circuit; Vd-weldingvoltage detection signal; Vp-crest voltage; Vw-weldingvoltage; Ws-amplitude; WSR-amplitude setting circuit; Wsr-amplitude setting signal
Detailed description of the invention
Below, with reference to accompanying drawing, embodiments of the present invention are described.
Fig. 1 is the current-voltage waveform figure representing the pulsed arc welding method of carbon oxide that embodiments of the present invention are correlated with.This figure (A) represents the time variations of welding current Iw, and this figure (B) represents the time variations of weldingvoltage Vw.This figure is the situation of the pulsed arc welding method of carbon oxide adopting with carbon dioxide the protective gas being principal component.Below, be described with reference to this figure.
In the pulsed arc welding method of carbon oxide that embodiments of the present invention are relevant, the pulse period Tpb of moment t1 ~ t3 was formed by two periods.First period is the base value period Tb of moment t1 ~ t2, Tp between the peak period that second period is moment t2 ~ t3.Therefore, using base value period Tb and between the peak period Tp as 1 pulse period Tpb, repeatedly weld.In base value period Tb, molten drop carries out short circuiting transfer, between the peak period, form molten drop in Tp.Between the peak period, Tp is redefined for appropriate value to make the molten drop of formation roughly fixed dimension.Between this peak period in Tp, the output of the source of welding current by current constant control, therefore, it is possible to directly control the value of peak point current Ip.Molten drop for being formed in Tp between the peak period in base value period Tb becomes different values during continuing before carrying out short circuiting transfer by each cycle.The output of the source of welding current in this base value period Tb is by Isobarically Control.This is because same with during general consumable electrode arc welding, by carrying out to output the cause that Isobarically Control carries out electric welding arc control.Therefore, the value of background current Ib becomes and can not directly control and the value determined by arc load.Below, each period is explained.
(1) base value period Tb (during short circuiting transfer)
The state forming molten drop is in Tp between the peak period of last period.Afterwards, as shown in this figure (A), the 1st background current Ib1 determined by arc load goes into circulation from moment t1.Because the welding current mean value be under stable state is determined accordingly with the feed speed of welding wire, if therefore feed speed is fixed value, then welding current mean value also can see fixed value as.Because peak point current Ip is set to large value, therefore in order to make welding current mean value become fixed value, relatively background current Ib becomes little value.Therefore, the value of the 1st above-mentioned background current Ib1 also becomes the value less than the mean value of peak point current Ip.As shown in this figure (B), weldingvoltage Vw becomes base value magnitude of voltage Vb.In this condition, welding wire is fed to fusion pool with the fixed speed of regulation, and the 1st above-mentioned background current Ib1 is small area analysis value, and therefore feed speed is faster than melting speed, and silk front end is close to fusion pool gradually.Afterwards, at moment t11, when the molten drop of silk front end contacts with fusion pool and is in short-circuit condition, as shown in this figure (B), weldingvoltage Vw drops sharply to the short circuit voltage value of several V degree.When differentiating this short-circuit condition by the change of weldingvoltage Vw, as shown in this figure (A), circulate from the value of the 1st above-mentioned background current Ib1 along with 2nd background current (short circuit current) Ib2 of time through little by little increasing, and short-circuit condition is removed.During the short circuit of moment t11 ~ t12, molten drop carries out short circuiting transfer, and in moment t12, electric arc occurs again.If electric arc occurs again, then as shown in this figure (B), weldingvoltage Vw sharply rises to the arc voltage value of tens of V degree.If differentiated the generation again of electric arc by the change of weldingvoltage Vw, then as shown in this figure (A), the predetermined short circuit again of moment t12 ~ t13 prevents the value i.e. 3rd background current Ib3 larger than the value of the 1st above-mentioned background current Ib1 that circulate in period Th.By the circulation of the 3rd background current Ib3, prevent from being again short-circuited soon after electric arc occurs again.Namely again there is time point at electric arc, because silk front end and fusion pool are in the distance be close, according to welding condition (kind of welding wire, feed speed, groove distribute (opening on first Meter), speed of welding etc.) due to the vibration of a little of fusion pool, be in the incidental state of short circuit again.If short circuit occurs again, then sputter generation, and welded condition also becomes unstable.In order to prevent the generation of this short circuit again, the 3rd background current Ib3 of circulation large value when again being occurred by electric arc, thus strengthen the arc force to fusion pool, extrusion molten pond, the distance between growth silk front end and fusion pool, thus prevent short circuit again.By carrying out controlling to make the 3rd background current Ib3 gently reduce from the electric current the time point again occurred at moment t12 electric arc, thus maintain large value.Above-mentioned short circuit again prevents period Th to be set at the scope of 0.5 ~ 3ms degree.Preferably this again short circuit prevent period Th from carrying out standardization according to welding condition.
Afterwards, as shown in this figure (A), the moment t2 after the moment t13 preventing period Th from terminating from above-mentioned short circuit again have passed through predetermined timing period Td, to Tp transfer between the peak period.In the timing period Td of this moment t13 ~ t2, as shown in this figure (A), circulate the value i.e. 4th background current Ib4 less than the value of above-mentioned 2nd background current of the end time point during above-mentioned short circuit, and as shown in this figure (B), weldingvoltage Vw becomes base value voltage Vb.This timing period Td is set to the scope of 0.5 ~ 3ms degree.The reason arranging this timing period Td is the 4th background current Ib4 by the small area analysis value that circulates after electric arc occurs again, thus weakens the arc force to fusion pool, makes fusion pool surface become smooth cause.Thereby, it is possible to reduce the sputtering from fusion pool when going into circulation from the peak point current Ip of big current value.
Droplet transfer in this base value period Tb is described, as described below.Between the last peak period in Tp, molten drop is formed as roughly fixed dimension as described later like that.Afterwards, the 1st background current Ib1 of the small area analysis value that circulates in the short circuit standby period of moment t1 ~ t11, therefore less act on lift force to molten drop, gravity and surface tension act on, and its shape is shaped as ball shape.In addition, under the state that the 1st background current Ib1 of small area analysis value circulates, occur in moment 11 short circuit, reducing of sputtering when therefore short circuit occurs.Contact with fusion pool under the state be simultaneously shaped at molten drop, therefore become to be integrated smoothly with fusion pool.Therefore, molten drop is in short circuiting transfer state, thus large without the need to the value than the 2nd background current Ib2 in during short circuit, and carries out transition smoothly, again produces electric arc.When this electric arc produces again, a small amount of sputtering occurs, but owing to being level and smooth short circuiting transfer, therefore this amount can not become many, can not reach level practicality becoming problem.
Above-mentioned short circuit standby period be before molten drop carries out short circuit in fusion pool during, be therefore not fixed value and be the value all the time changed according to welded condition.Equally, during above-mentioned short circuit for carrying out short circuit from molten drop and fusion pool to complete transition and electric arc again occur during, be therefore not fixed value but carry out the value that changes according to droplet transfer state.But when being in stable welded condition, the deviation during this short circuit is little.Above-mentioned short circuit again prevents period Th and above-mentioned timing period Td from being predetermined fixed value.Therefore, as during the total during these namely base value period Tb be not fixed value but carry out the value that changes according to welded condition.But under stable welded condition, base value period Tb can regard roughly fixed value as.Background current Ib in base value period Tb is formed by the 1st above-mentioned background current Ib1 ~ the 4th background current Ib4.Whether above-mentioned short circuit again prevents from period Th and timing period Td from can set according to welding condition arranging.This is because there is the situation that the side during setting each according to welding condition realizes the effect of the minimizing of sputtering etc.Conversely, even if also there is the welding condition of the effect of the minimizing that can not realize sputtering etc. during setting these.Therefore, as long as according to welding condition, from following four model selections pattern like that, form base value period Tb.
(a) short circuit standby period+short circuit during
(b) short circuit standby period+short circuit during+again short circuit prevent period Th
(c) short circuit standby period+short circuit during+timing period Td
(d) short circuit standby period+short circuit during+again short circuit prevent period Th+ timing period Td
(2) Tp (between molten drop Formation period) between the peak period of moment t2 ~ t3
Between the peak period of moment t2 ~ t3 in Tp, as shown in this figure (A), the peak point current Ip vibrated is carried out in circulation, and as shown in this figure (B), weldingvoltage Vw becomes the crest voltage Vp that carrying out corresponding thereto vibrates.The vibrational waveform of peak point current Ip, as shown in this figure (A), becomes high peak current HIp in the peak value period HTp shown in moment t2 ~ t21, becomes low peak current LIp in the low peak period LTp of ensuing moment t21 ~ t22.Vibration period Ts is become during the total of peak value period HTp and low peak period LTp.In addition, the difference (HIp-LIp) of high peak current HIp and low peak current LIp becomes amplitude Ws.And then, dutycycle Ds=HTp/Ts.Therefore, peak point current Ip is vibrated by amplitude Ws and vibration period Ts.The example of the scope of each value when welding wire becomes the stone dead wire of diameter 1.2mm is as follows.High peak current HIp:350 ~ 500A, amplitude Ws:200 ~ 400A, vibration period Ts:1.5 ~ 3.0ms, dutycycle Ds:0.5 ~ 0.75.In the figure, exemplified with peak point current Ip with the wavy situation of carrying out vibrating of rectangle, but also can trapezoidal wavy, triangle is wavy, sinusoidal wave shape, sawtooth are wavy etc. vibrates.The reason making peak point current Ip carry out vibrating is as follows.When namely not making peak point current Ip carry out vibrating and being energized continuously, along with the formation of molten drop, the temperature of molten drop overheats, and produces in molten drop the phenomenon of the gas exapnsion that comprises and droplet breaks.If this fracture phenomena produces, then sputter thing and disperse from molten drop, and the formation of molten drop is also hindered.If make peak point current Ip vibrate with suitable amplitude Ws and vibration period Ts, then can suppress the overheated of molten drop, the molten drop expecting size can be formed.Expect that the molten drop of size is the size of 1.5 ~ 2.5 times of degree of the diameter of welding wire.Therefore, amplitude Ws and vibration period Ts be set to molten drop not overheated and sputtering thing not from the value that molten drop disperses.Two values are set as appropriate value according to the kind, feed speed etc. of the material of welding wire, diameter, protective gas.The molten drop of roughly desired size is formed according to Tp between this peak period.
As mentioned above, between the peak period, the length of Tp is set to appropriate value according to welding condition (material of welding wire, diameter and feed speed).This appropriate value carries out Welding experiment according in each welding condition, and the mode that the molten drop formed in Tp between the peak period stably becomes roughly same size is selected.Fig. 2 carries out illustrative figure to Tp between the peak period relative to the appropriate value of feed speed.The transverse axis of this figure represents feed speed (m/min), and the longitudinal axis represents Tp between the peak period (ms).This figure is the situation that welding wire uses the stone dead wire of diameter 1.2mm.As shown in the drawing, along with feed speed accelerates, between the peak period, Tp is also elongated.This be due to feed speed accelerate time, extend Tp between the peak period and obtain the cause that the balance between feed speed and melting speed becomes large to make the droplet size formed in Tp between the peak period.
The droplet transfer of the pulsed arc welding method of carbon oxide that above-mentioned embodiments of the present invention are correlated with is arranged, as described below.
(1) between the peak period in Tp, by making peak point current Ip vibrate, that can suppress molten drop is overheated, and prevents the sputtering from molten drop from occurring.Between the peak period, the length of Tp is set to appropriate value according to welding condition.Therefore, it is possible to stably form the molten drop of desired size.
(2) in base value period Tb, by the 1st background current Ib1 of circulation small area analysis value, the molten drop of guiding welding wire front end carries out the short circuit between fusion pool.Afterwards, molten drop carries out short circuiting transfer.Because the 1st background current Ib1 with small area analysis value is short-circuited, reducing of sputtering when therefore short circuit occurs.In addition, roughly the molten drop of fixed dimension carries out short circuiting transfer, therefore carries out transition smoothly, and the generation of sputtering when electric arc occurs again does not reach in practicality yet and becomes the such amount of problem.
(3) by the action of above-mentioned (1) and (2), a molten drop synchronously carries out transition by each pulse period Tpb.Namely, 1 droplet transfer pulse period 1 state realize, be in stable welded condition.Therefore, when welded condition easily becomes the high-speed welding in the galvanic areas of more than the 200A of instability, the high-quality welding that the generation also carrying out sputtering is few.
Below represent the numerical example of each parameter in the waveform of Fig. 1.Welding wire: the stone dead wire of diameter 1.2mm, average welding current value: 220A, feed speed (setting value): 7m/min, the 1st background current Ib1:100A of short circuit standby period, short circuit prevents period Th (setting value): 1ms again, timing period Td (setting value): 1ms, 4th background current Ib4:100A, high peak current value HIp (setting value): 450A, amplitude Ws (setting value): 350A, vibration period Ts (setting value): 2.0ms, dutycycle Ds (setting value): 1.5/2.0=0.75, between the peak period Tp (setting value): 9.5ms.The record of (setting value) represents the value being redefined for appropriate value.Conversely, the value not being recited as (setting value) is measured value, is expressed as the value carrying out changing.
Fig. 3 is the block diagram of the source of welding current for implementing the pulsed arc welding method of carbon oxide that the embodiments of the present invention described in Fig. 1 are correlated with.Below, with reference to this figure, each module is described.
Electric power main circuit PM, using the source power supply (omitting diagram) of 3 phase 200V etc. as input, the output carrying out inversion control according to error amplification signal Ea described later controls, and exports the welding current Iw and the output voltage E that are suitable for arc welding.This electric power main circuit PM, omits diagram, but such as forms by with lower part: No. 1 rectifier source power supply being carried out to rectification; The capacitor smoothing to the direct current be rectified; To be the inverter circuit of high-frequency ac by level and smooth DC converting; It is the high frequency transformer of the magnitude of voltage being suitable for arc welding by high-frequency ac step-down; High-frequency ac after step-down is carried out to No. 2 rectifiers of rectification; Using above-mentioned error amplification signal Ea as input, carry out pulse width modulation control, based on the drive circuit that this result drives above-mentioned inverter circuit.Reactor WL is the device being wound around cable on iron core, has the inductance value of Lw (μ H), smoothing to the output of above-mentioned electric power main circuit PM.The voltage exported from electric power main circuit PM becomes output voltage E, becomes weldingvoltage Vw by the voltage after reactor WL.Therefore, weldingvoltage Vw becomes the voltage between welding wire 1 and mother metal 2.Welding wire 1 is fed by the rotating past in welding torch 4 of feed rolls 5 of silk feed arrangement (omitting diagram), produces electric arc 3 between mother metal 2.
Current detection circuit ID detects above-mentioned welding current Iw, exports welding current detection signal Id.Voltage detecting circuit VD detects above-mentioned weldingvoltage Vw, exports weldingvoltage detection signal Vd.This weldingvoltage detection signal Vd as input, is differentiated short-circuit condition according to this value, is output into the short circuit discrimination signal Sd of high level by short circuit discrimination circuit SD.Between the peak period, initialization circuit TPR exports setting signal Tpr between the predetermined peak period.Setting signal Tpr between this peak period, as mentioned above, is set as appropriate value according to welding condition.Short circuit prevents period initialization circuit THR from exporting predetermined short circuit again and prevents period setting signal Thr again.Timing period initialization circuit TDR exports predetermined timing period setting signal Tdr.Period control switching circuit ST is by setting signal Tpr between the above-mentioned peak period, above-mentioned short circuit again prevents period setting signal Thr, above-mentioned timing period setting signal Tdr and above-mentioned short circuit discrimination signal Sd is as input, at the end of during being determined by setting signal Tpr between the peak period, this value was changed to for 1 (short circuit standby period), when in this period, short circuit judgment signal Sd becomes high level (short-circuit condition), this value becomes 2 (during short circuits), when short circuit discrimination signal Sd becomes low level (electric arc generation state) afterwards, during this time point prevents period setting signal Thr from determining by short circuit again, this value becomes 3 (short circuit prevents period Th again), next during being determined by timing period setting signal Tdr, this value becomes 4 (timing period Td), next during being determined by setting signal Tpr between the peak period, this value becomes 5 (between the peak period Tp), switch-over control signal St between period of output.Switch-over control signal St during this period, in FIG, 1 is become in the short circuit standby period of moment t1 ~ t2,2 are become in during the short circuit of moment t11 ~ t12, the short circuit again of moment t12 ~ t13 prevents from becoming 3 in period Th, become 4 in the timing period Td of moment t13 ~ t2, between the peak period of moment t2 ~ t3, in Tp, become 5.
Electronic inductor control circuit ERC, using switch-over control signal St and above-mentioned welding current detection signal Id during above-mentioned as input, period switch-over control signal St be 2 (during short circuits) or 3 (again short circuit prevent period) time welding current detection signal Id is carried out to differential and is multiplied by predetermined magnifying power Lr, output current differential signal Bi=LrdId/dt, when period, switch-over control signal St was the value beyond this value, output current differential signal Bi=0.This magnifying power Lr is positive value, for determining the constant of the inductance value of the reactor formed by Electronic Control.Therefore, as described later, this magnifying power Lr determine the welding current during short circuit increment rate and again short circuit prevent the slip of the welding current in period Th.Output voltage initialization circuit ER exports predetermined output voltage setting signal Er.Subtraction circuit SUB deducts above-mentioned current differential signal Bi from this output voltage setting signal Er, output voltage control setting signal Ecr=Er-Bi.Output voltage detecting circuit ED detects above-mentioned output voltage E and exports voltage sense signal Ed.Voltage error amplifying circuit EV amplifies the error between above-mentioned Control of Voltage setting signal Ecr and this voltage sense signal Ed, output voltage error amplifying signal Ev.This electronic inductor controls, and as shown in patent document 5, is the technology be in the past widely used.Its summary is as follows.If during becoming the short circuit of the moment t11 ~ t12 shown in Fig. 1, then load condition is in short circuit load, by Isobarically Control, therefore welding current Iw increases hastily.Now, magnifying power Lr > 0, dId/dt > 0, therefore current differential signal Bi > 0.Its result, Control of Voltage setting signal Ecr=Er-Bi becomes the value of the value of specific output voltage setting signal Er small area analysis differential signal Bi, slows down gathering way of welding current Iw.If the short circuit being again in moment t12 ~ t13 prevents period Th, then load condition becomes arc load, and therefore welding current Iw reduces.Now, welding current Iw is also controlled by electronic inductor and reduces lentamente.Its result, the electric current of large value when short circuit prevents in period Th the 3rd above-mentioned background current Ib3 roughly pilot arc occurs again again.If become the timing period Td of moment t13, then the action that electronic inductor controls is prohibited, and therefore welding current Iw is die-offed and becomes the 4th background current Ib4 of little value.In this electronic inductor controls, form the reactor with the inductance value of Lr (μ H) electronically.Therefore, be added with the inductance value Lw of above-mentioned reactor WL, the built-in equivalent reactance device with the inductance value of Lw+Lr of the source of welding current.Such as be set to Lw=30 μ H, Lr=200 μ H.Lw be the reason of little value be the change accelerating peak point current Ip can to welding in stable conditionization.On the other hand, during short circuit and again short circuit prevents in period Th, and that slows down the change of welding current Iw can enough make welded condition stabilisation, and the electronic inductor being therefore used in the Lr forming large value controls to carry out action.
High peak current initialization circuit HIPR exports predetermined high peak current setting signal HIpr.Amplitude setting circuit WSR exports predetermined amplitude setting signal Wsr.Vibration period initialization circuit TSR exports predetermined vibration period setting signal Tsr.Dutycycle initialization circuit DSR exports predetermined dutycycle setting signal Dsr.Peak point current initialization circuit IPR using above-mentioned high peak current setting signal HIpr, above-mentioned amplitude setting signal Wsr, above-mentioned vibration period setting signal Tsr, above-mentioned dutycycle setting signal Dsr and above-mentioned during switch-over control signal St as input, export the wavy peak point current setting signal Ipr of rectangle shown in Fig. 1 synchronously starting to vibrate from being changed to the time point of period switch-over control signal St=5 (between the peak period Tp).Current error amplifying circuit EI amplifies the error between this peak point current setting signal Ipr and above-mentioned welding current detection signal Id, output current error amplification signal Ei.Commutation circuit SW using switch-over control signal St, above-mentioned current error amplifying signal Ei during above-mentioned and above-mentioned voltage error amplifying signal Ev as input, a side is switched to when period switch-over control signal St=1 ~ 4 (base value period Tb), output voltage error amplifying signal Ev is as error amplification signal Ea, be switched to b side time St=5 (between the peak period Tp), output current error amplification signal Ei is as error amplification signal Ea.Thus, between the peak period, in Tp, become current constant control, in base value period Tb, become Isobarically Control.Afterwards, consist of above-mentioned circuit, the welding current Iw of circulation Fig. 1, exports weldingvoltage Vw.
According to above-mentioned embodiment; in the pulsed arc welding method of carbon oxide adopting with carbon dioxide the protective gas being principal component; arrange between the peak period with base value during; vibrate by making the peak point current between the peak period; molten drop is formed as roughly desired size, in can making the molten drop of this formation during base value, carries out short circuiting transfer.Therefore, it is possible to realize 1 pulse period 1 droplet transfer state, therefore, it is possible to the high-quality welding that the generation carrying out sputtering is few.During high-speed welding especially in the galvanic areas of more than 200A, the generation sputtered can be suppressed compared with connecing method with the CO2 welding of direct current further, also can improve welding bead outward appearance.
Claims (8)
1. a pulsed arc welding method of carbon oxide; use the protective gas using carbon dioxide as principal component; feeding welding wire; and weld between the peak period of circulation peak point current and during the base value of circulation background current repeatedly as 1 pulse period; the feature of this pulsed arc welding method of carbon oxide is
In between the above-mentioned peak period, current constant control is carried out to above-mentioned peak point current, and forms molten drop by making above-mentioned peak point current carry out vibrating in the front end of welding wire,
Make the molten drop of this formation to fusion pool transition by short circuiting transfer in during above-mentioned base value,
Electric welding arc control is carried out by carrying out Isobarically Control to the weldingvoltage in during above-mentioned base value,
Above-mentioned carry out the peak point current vibrated amplitude and the vibration period be set to suppress the overheated of molten drop and the molten drop of sputtering thing not from the formed value of dispersing.
2. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
The above-mentioned waveform carrying out the peak point current vibrated is that rectangle is wavy.
3. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
Between the above-mentioned peak period for the feed speed according to welding wire and during setting.
4. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
For during continuing before carrying out short circuiting transfer during above-mentioned base value.
5. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
Formed during the molten drop of the short circuit standby period before being occurred by short circuit during above-mentioned base value and then this short circuit standby period carries out the short circuit of short circuiting transfer,
Above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, in during above-mentioned short circuit circulation from the value of above-mentioned 1st background current along with the time through and the 2nd background current that increases gradually.
6. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
During short circuit standby period before being occurred by short circuit during above-mentioned base value, during then the molten drop of this short circuit standby period carries out the short circuit of short circuiting transfer and then this short circuit prevent electric arc again occur after the predetermined short circuit again that is again short-circuited prevent period from being formed
Above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, the 2nd background current that in during above-mentioned short circuit, circulation increases gradually along with time process from the value of above-mentioned 1st background current, above-mentioned short circuit again prevents the 3rd background current that in period, circulation is larger than the value of above-mentioned 1st background current.
7. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
Predetermined timing period during short circuit standby period before being occurred by short circuit during above-mentioned base value, during then the molten drop of this short circuit standby period carries out the short circuit of short circuiting transfer and then this short circuit is formed,
Above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, the 2nd background current that in during above-mentioned short circuit, circulation increases gradually along with time process from the value of above-mentioned 1st background current, the 4th background current that in above-mentioned timing period, circulation is less than the value of above-mentioned 2nd background current of the end time point during above-mentioned short circuit.
8. pulsed arc welding method of carbon oxide according to claim 1, is characterized in that,
Short circuit standby period before being occurred by short circuit during above-mentioned base value, during then the molten drop of this short circuit standby period carries out the short circuit of short circuiting transfer, then during this short circuit prevent electric arc again occur after the predetermined short circuit again that is again short-circuited prevent period and then this again short circuit prevent the predetermined timing period of period from being formed
Above-mentioned short circuit is circulated in standby period the 1st background current determined by arc load, the 2nd background current that in during above-mentioned short circuit, circulation increases gradually along with time process from the value of above-mentioned 1st background current, above-mentioned short circuit again prevents the 3rd background current that in period, circulation is larger than the value of above-mentioned 1st background current, the 4th background current that in above-mentioned timing period, circulation is less than the value of above-mentioned 2nd background current of the end time point during above-mentioned short circuit.
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