CN102107323A - Resistance welding nugget quality control method - Google Patents

Resistance welding nugget quality control method Download PDF

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Publication number
CN102107323A
CN102107323A CN 201010611997 CN201010611997A CN102107323A CN 102107323 A CN102107323 A CN 102107323A CN 201010611997 CN201010611997 CN 201010611997 CN 201010611997 A CN201010611997 A CN 201010611997A CN 102107323 A CN102107323 A CN 102107323A
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welding
current
nugget
coefficient
peak
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CN102107323B (en
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赵继华
聂兰民
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Tianjin commercial CNC technology Limited by Share Ltd
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TIANJIN SUNKE NUMERICAL CONTROL EQUIPMENT CO Ltd
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Abstract

The invention relates to a resistance welding nugget quality control method, which comprises the following steps of: connecting a three-phase supply to a controller, rectifying through a current-limiting resistance rectifier diode and a full-wave half-controlled rectification circuit, filtering a capacitor through a control circuit, and converting alternating current into direct current; and inputting the direct current into an H bridge circuit consisting of insulated gate bipolar translators (IGBT), and outputting positive and negative half-wave alternating current from a UV end according to a main control circuit and a program. The key point is that: a welding parameter, namely a nugget coefficient c, is increased on the basis of an original welding parameter, and the current output waveform in each welding and heating period can be accurately controlled through two independent parameters, so that the welding current waveform control mode is radically changed, the regulation difficulty of the welding machine is reduced in the welding process, the depth of the nugget is increased, the splash is reduced, the sensitivity of a resistance welding machine to material change, power grid fluctuation and pressure change is reduced, and stable welding quality is easily obtained by adjusting the nugget coefficient c; moreover, the efficiency of the resistance welding machine is effectively improved.

Description

Electric resistance welding nugget method of quality control
Technical field
The present invention relates to a kind of electric resistance welding welding parameter setting method, particularly a kind of electric resistance welding nugget method of quality control.
Background technology
At present, traditional electric resistance welding nugget forming process is by adjusting t weld interval, welding current i (uses the single-phase of SCR control electric current, the three-phase electricity welding resistance, electric current triggers angle adjustment size by adjusting controllable silicon, the electric resistance welding that uses IGBT inverter controller control electric current is by adjusting dutycycle control welding current size), welding pressure p reaches the purpose (welding frequency f immobilizes) that control forms weld nugget; Conventional method at total welding heat Q one regularly, be i, t, p is certain, and current i has determined the welding current waveform uniqueness, as long as welding current is set back (controllable silicon triggers setting back, angle or the IGBT dutycycle is set the back), the output welding current waveform immobilizes, like this when the welding material composition changes, electrical network fluctuates, when pressure changes, then be difficult to form to weld examine or splash, very easily cause fusion penetration change or weld seam overheated, reduce welding quality.
In force, since traditional welding parameter establishing method to some special process, as spot welding thermoforming steel, when stitching the welding steel bucket at a high speed, adjust quite difficulty of welding machine, make welding machine bigger, very easily cause poor welding spots the variation sensitiveness of the fluctuation of the variation of welding material composition, electrical network, pressure; In order to reduce the fraction defective of solder joint, generally be to increase welding heat, this very easily causes the workpiece burning, and generation is splashed, and directly influences welding work pieces interior quality and exterior quality.
Therefore, especially to some more special welding material and technology, providing a kind of easy and simple to handle, obvious results electric resistance welding nugget method of quality control, is one of these those skilled in the art problem that should address.
Summary of the invention
The objective of the invention is to overcome above-mentioned weak point, provide that a kind of technology is simple, reasonable in design, dependable performance, effect significantly, use easy electric resistance welding nugget method of quality control.
The technical solution adopted in the present invention is for achieving the above object: a kind of electric resistance welding nugget method of quality control is characterized in that implementation step is as follows:
With the three phase mains access controller,, alternating current is become direct current through current-limiting resistance commutation diode and the rectification of all-wave half control rectification circuit, capacitor filtering control circuit; Again direct current is imported in the H bridge loop of being made up of IGBT the alternating current that under the control of main control circuit, alternately changes from the positive and negative half-wave of U.V end output; Carry out the setting of following welding parameter:
(1) weld interval t,
(2) welding current i,
(3) nugget coefficient c,
(4) welding pressure p,
(5) welding frequency f;
Described nugget coefficient C definition: C=(t1-t0)/t1, scope 0-50%;
T1: the time that period of change is shared; 0.1 millisecond to 500 milliseconds of scope;
T0: a shared time of period of change IGBT work; 0.1 millisecond to 500 milliseconds of scope;
Welding frequency f=1/2t1 scope 1-5000HZ;
According to formula Q=I 2RT, C=(t1-t0)/t1, heat one timing, nugget coefficient c changes;
The relation of peak point current (i peak) and virtual value electric current (i is effective):
I effectively=K*i peak * √ (1-c),
K is correction factor: 0.5≤K<1, detects feedback by primary current transformer and secondary current and obtains;
Carrying out electric resistance welding, accurately controlling each weld heating cycle 2t1 electric current output waveform with two independent parameter i and c; When total welding heat Q is constant, i.e. i, t, p is certain, and by adjusting nugget coefficient c to 0-50%, welding current waveform showed as peak point current (i peak) and increased this moment, and conduction time, (t0) shortened; The easy weldering nuclear that forms shortened and then reduce the possibility that generation is splashed conduction time (t0) when peak point current increased.
It is by at t1 in the time that nugget coefficient c changes, send instruction through DSP, by the IGBT gate driver circuit, IGBT is with 5KHZ or 10KHZ pulse width modulation mode in control, in t0 IGBT work in the time, t1-t0 time IGBT does not work, referring to Fig. 1 (in actual application, find to work as c=0-50%, welding quality is had good effect.
The invention has the beneficial effects as follows: this method to some more special welding materials and technology when total welding heat is constant, owing to increase a welding parameter (nugget coefficient c), fundamentally changed welding current waveform, improve the welding peak point current and increased the degree of depth that weldering is examined, reducing conduction time has prevented to splash, reduced welding machine to the variation of material composition, the fluctuation of electrical network, the variation sensitiveness of pressure, be easier to obtain long-time stable welding quality, effectively reduce fraction defective by adjusting nugget coefficient c; Improved simultaneously the efficient of adjusting resistance welder effectively.
Description of drawings
Fig. 1 is an electrical resistance weld controller electric current output waveform schematic diagram of the present invention;
Fig. 2 is a traditional electrical welding resistance controller electric current output waveform schematic diagram;
Fig. 3 is a fusion penetration control method electrical schematic diagram of the present invention; Range of application: controller output 1-5000 hertz.
The specific embodiment
Below in conjunction with accompanying drawing and preferred embodiment, to according to the specific embodiment provided by the invention, structure, details are as follows for feature:
As shown in Figure 3, a kind of electric resistance welding nugget method of quality control, concrete implementation step is as follows:
With the three phase mains access controller, at first through current-limiting resistance R (165-330 Europe, 100 watts) commutation diode D (2.5 peaces, 1200 volts), be charged to 200 volts-250 volts with little electric current to electric capacity, switch giving all-wave half control rectification circuit again is pulsating direct current (circuit of being made up of the controllable silicon SCR and the commutation diode D of 50-3000 ampere) with AC rectification, by the filtering of capacitor group (a plurality of capacitor connection in series-parallel), import then in the H bridge loop of forming by 50-3000 ampere IGBT, instruction drives IGBT by the main control circuit that with DSP is core through gate driver circuit, the alternating current that alternately changes from the positive and negative half-wave of U.V end output (size of current i wherein, weld interval t, welding frequency f, each parameter of nugget coefficient c is set through programmable device), core point of the present invention is to introduce nugget coefficient c, two independent parameters are accurately controlled each weld heating periodic current output waveform, thereby, c increased the possibility that forms weldering nuclear when having improved the welding peak point current when 0-50% changes, and reduce conduction time and prevented to splash, improved the weld nugget quality; Electrical resistance weld controller output waveform of the present invention is referring to Fig. 1.Thereby reduced welding machine, thereby by adjusting nugget coefficient c control weld nugget quality to the variation of welding material composition, the fluctuation of electrical network, the variation sensitiveness of pressure.
The electrical principle explanation:
(1) input power supply: by single-phase. the input of three-phase 110V-440V electrical network.
(2) bridge-type all-wave half control rectification circuit: form by controllable silicon and commutation diode, electric current 50-3000 peace, withstand voltage 1200-2000 volt, function is that interchange is become pulsating direct current.
(3) filter circuit: by many withstand voltage 400-475 volts, the capacitor connection in series-parallel of capacity 330-10000 microfarad is formed, and function is that pulsating dc voltage is become stable DC voltage.
(4) inverter circuit: by the H bridge circuit that IGBT forms, IGBT is withstand voltage 1200-2000 volt, electric current 50-2000 peace, function be with direct current through IGBT by the pulsewidth modulating mode from U, V end output Variable Waveform, the alternating current of variable frequency.
(5) power supply and IGBT drive circuit: the work of generation control device+5V, ± 15V ,+24V power supply, the triggering signal of guard signal and the charging of control controllable silicon when control IGBT opens shutoff and IGBT fault.
(6) governor circuit: with DSP (digital signal processor) is the sequence circuit that core is formed, and by digital input/output control circuit, the simulation trial amplifying circuit is controlled welding current, weld interval, current waveform, input/output signal.
(7) first electrode current detects: is made up of current transformer, size by detecting output current and variable quantity feed back to governor circuit and reach and control output current of high accuracy (error 2%).
(8) programmable device: the man-machine interface that welding data is inputed to controller.
This nugget quality control method welding parameter setting means:
(1) weld interval t,
(2) welding current i,
(3) nugget coefficient c,
(4) welding pressure p,
(5) welding frequency f (can change);
At total welding heat Q one regularly, i.e. i, t, p is certain, changes nugget coefficient c, and welding current waveform changes, and the welding peak point current increases, and forms nugget easily, shortens conduction time and prevents to splash generation;
Specify:
Nugget quality control method nugget coefficient C definition: C=(t1-t0)/t1, theory setting scope 0-90%;
T1: the time that period of change is shared; 0.1 millisecond of scope is seen Fig. 1 to 500 milliseconds;
T0: shared time of energising in the one-period; 0.1 millisecond of scope is seen Fig. 1 to 500 milliseconds;
Welding frequency f=1/2t1 scope 1-5000HZ.
The relation of nugget quality control method peak point current (i peak) and virtual value electric current (i is effective);
According to formula Q=I 2RT, C=(t1-t0)/t1, heat one regularly c changes;
I effectively=K*i peak * √ (1-c), wherein √ (1-c) is expressed as the square root of (1-c); K is that correction factor (0.5≤K<1) detects the feedback acquisition by primary current transformer and secondary current.
The span 0-50% of Fig. 1: C; C1=0.35, C2=0.20, C3=0.
Application example
In stitching the production of welding steel bucket at a high speed, when total amount of heat immobilizes (the welding current virtual value is constant).Utilize the inventive method, set i effectively=14500 amperes (i peak=18600 ampere), K=0.97; The t1=10 millisecond, preferable nugget coefficient c=35%, (scope 0-50%), pressure 0.3mpa; 2800 buckets of sequential welding do not take place to leak and splash, and welding quality is all qualified.
And utilize conventional method, set i effectively=14500 amperes (i peak=15000 ampere), t1=10 millisecond, pressure 0.3mpa; 980 buckets of sequential welding leak and press 7.Traditional electrical welding resistance controller electric current output waveform is referring to Fig. 2.
By above contrast, the effect highly significant of electric resistance welding nugget method of quality control of the present invention.
Above-mentioned with reference to embodiment to the detailed description that electric resistance welding nugget method of quality control carries out, be illustrative rather than determinate; Therefore in the variation and the modification that do not break away under the general plotting of the present invention, should belong within protection scope of the present invention.

Claims (1)

1. electric resistance welding nugget method of quality control is characterized in that implementation step is as follows:
With the three phase mains access controller,, alternating current is become direct current through current-limiting resistance commutation diode and the rectification of all-wave half control rectification circuit, capacitor filtering control circuit; Again direct current is imported in the H bridge loop of being made up of IGBT the alternating current that under the control of main control circuit, alternately changes from the positive and negative half-wave of U.V end output; Carry out the setting of following welding parameter:
(1) weld interval t,
(2) welding current i,
(3) nugget coefficient c,
(4) welding pressure p,
(5) welding frequency f;
Described nugget coefficient C definition: C=(t1-t0)/t1, scope 0-50%;
T1: the time that period of change is shared; 0.1 millisecond to 500 milliseconds of scope;
T0: a shared time of period of change IGBT work; 0.1 millisecond to 500 milliseconds of scope;
Welding frequency f=1/2t1 scope 1-5000HZ;
According to formula Q=I 2RT, C=(t1-t0)/t1, heat one timing, nugget coefficient c changes;
The relation of peak point current (i peak) and virtual value electric current (i is effective):
I effectively=K*i peak * √ (1-c),
K is correction factor: 0.5≤K<1, detects feedback by primary current transformer and secondary current and obtains;
Carrying out electric resistance welding, accurately controlling each weld heating cycle 2t1 electric current output waveform with two independent parameter i and c; When total welding heat Q is constant, i.e. i, t, p is certain, and by adjusting nugget coefficient c to 0-50%, welding current waveform showed as peak point current (i peak) and increased this moment, and conduction time, (t0) shortened; Form weldering nuclear when peak point current increases easily, shorten conduction time (t0) then to reduce to produce and splash.
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103008865A (en) * 2012-12-31 2013-04-03 天津商科数控设备有限公司 Process method for pulse width-adjustable AC (Alternating Current)-DC (Direct Current) inverter resistance welding
CN103394801A (en) * 2013-08-16 2013-11-20 天津商科数控设备有限公司 Non-splashing dynamically heating self-adaptive resistance welding method for automobile metal sheets
CN103944411A (en) * 2014-04-10 2014-07-23 重庆瑜欣平瑞电子有限公司 Generator frequency converter
EP2954970A1 (en) * 2014-06-12 2015-12-16 Serra Soldadura, Sau Method of optimizing welding parameters in resistance welding processes and computer program thereof
CN107931811A (en) * 2017-11-23 2018-04-20 西北工业大学 Nugget formation in resistance spot welding method for predicting diameter
WO2018192038A1 (en) 2017-04-20 2018-10-25 天津商科数控技术股份有限公司 Direct contact- and alternating current trapezoidal wave-based electric resistance welding process method of aluminum
US20180304397A1 (en) * 2017-04-20 2018-10-25 Tianjin Sunke Digital Control Technology Co., Direct-contact type alternating current trapezoidal wave aluminum resistance welding process method
CN112548295A (en) * 2020-12-05 2021-03-26 钟丽慧 Resistance spot welding method for automobile aluminum alloy

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DE4203190C1 (en) * 1992-02-05 1993-05-13 Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung Ev, 8000 Muenchen, De Regulation and quality assessing of welding esp. spot welding - has ultrasonic detecting probe attached to welding electrode to record noise emission level at weld location
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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103008865A (en) * 2012-12-31 2013-04-03 天津商科数控设备有限公司 Process method for pulse width-adjustable AC (Alternating Current)-DC (Direct Current) inverter resistance welding
CN103008865B (en) * 2012-12-31 2015-02-04 天津商科数控设备有限公司 Process method for pulse width-adjustable AC (Alternating Current)-DC (Direct Current) inverter resistance welding
CN103394801A (en) * 2013-08-16 2013-11-20 天津商科数控设备有限公司 Non-splashing dynamically heating self-adaptive resistance welding method for automobile metal sheets
CN103394801B (en) * 2013-08-16 2015-11-04 天津商科数控设备有限公司 Automobile metal thin plate is without the method for splashing dynamic heat self adaptation electric resistance welding
CN103944411A (en) * 2014-04-10 2014-07-23 重庆瑜欣平瑞电子有限公司 Generator frequency converter
EP2954970A1 (en) * 2014-06-12 2015-12-16 Serra Soldadura, Sau Method of optimizing welding parameters in resistance welding processes and computer program thereof
WO2018192038A1 (en) 2017-04-20 2018-10-25 天津商科数控技术股份有限公司 Direct contact- and alternating current trapezoidal wave-based electric resistance welding process method of aluminum
US20180304397A1 (en) * 2017-04-20 2018-10-25 Tianjin Sunke Digital Control Technology Co., Direct-contact type alternating current trapezoidal wave aluminum resistance welding process method
CN107931811A (en) * 2017-11-23 2018-04-20 西北工业大学 Nugget formation in resistance spot welding method for predicting diameter
CN107931811B (en) * 2017-11-23 2019-10-22 西北工业大学 Nugget formation in resistance spot welding method for predicting diameter
CN112548295A (en) * 2020-12-05 2021-03-26 钟丽慧 Resistance spot welding method for automobile aluminum alloy

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Address after: 300000 Yixian Science Industrial Park in Tianjin economic and Technological Development Zone Qing Ling Road No. 17

Patentee after: Tianjin commercial CNC technology Limited by Share Ltd

Address before: 300170 Tianjin Yixian Wuqing economic and Technological Development Zone Science Industrial Park Qing Ling Road No. 17

Patentee before: Tianjin Sunke Numerical Control Equipment Co.,Ltd.