CN102126077A - Plasma metal inert gas arc welding method - Google Patents
Plasma metal inert gas arc welding method Download PDFInfo
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- CN102126077A CN102126077A CN2011100094683A CN201110009468A CN102126077A CN 102126077 A CN102126077 A CN 102126077A CN 2011100094683 A CN2011100094683 A CN 2011100094683A CN 201110009468 A CN201110009468 A CN 201110009468A CN 102126077 A CN102126077 A CN 102126077A
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Abstract
In a plasma metal insert gas arc welding method which causes a metal insert gas arc (3a) and a plasma arc (3b) to generate from a welding torch (WT), even a welding torch height (Lp) changes, a stable fused drop transition state of the metal insert gas arc can be kept. For this purpose, a plasma welding current (Iwp) is applied between a plasma electrode (1b) and a mother plate (2) for generating the plasma arc (3b). Additionally, a peak current in a peak period and a reference current in a reference period are applied between a welding wire (1a) and the mother plate (2). Furthermore, the peak period and/or the peak current is changed according to the heated length of the welding wire (1a), which is heated by the plasma arc (3b). Thus, even the welding torch height (Lp) is changed, the unit pulse condition can be optimized correspondingly, and the stability of the fused drop transition state can be always kept.
Description
Technical field
The present invention relates to a kind of plasma metal arc inert gas welding and connect (plasma MIG welding) method, it produces Metallic Inert Gas (MIG:Metal Inert Gas) electric arc and plasma-arc with a welding torch simultaneously, welds.
Background technology
In the prior art, motion article on plasma welding method and metal arc inert gas welding connect the plasma metal arc inert gas welding that method makes up and connect method (reference example such as patent documentation 1).Connect in the method at this plasma metal arc inert gas welding,, plasma-arc is produced by plasma welding current on logical between plasma electrode in being disposed at welding torch and the mother metal.Simultaneously, plasma electrode is arranged to hollow shape, pass the welding wire that above-mentioned hollow shape inside comes feeding to be powered via being configured in the power supply chip (chip) in the above-mentioned plasma electrode, and connect electric current by metal arc inert gas welding on logical between welding wire and the mother metal, Metallic Inert Gas electric arc is produced.Therefore, Metallic Inert Gas electric arc is the state that is surrounded by plasma-arc.Welding wire is as the electrode performance function that Metallic Inert Gas electric arc is produced, and its front end fusion becomes molten drop, the joint of auxiliary mother metal.Therefore, the plasma metal arc inert gas welding connects the many uses of method in the high efficiency welding of slab, the high-speed welding of thin plate etc.
Connect electric current about above-mentioned metal arc inert gas welding, in order to suppress to splash the generation of (sputter) and stably supply with molten drop, the general impulse waveforms of using direct current more.Therefore, to connect method be general Metallic Inert Gas electric arc pulse welding method to metal arc inert gas welding.Comprising Metallic Inert Gas electric arc pulse welding method in interior consumable electrode type arc-welding method, it is very important that the electric arc length in the welding is maintained in an appropriate value, so will carry out the long control of electric arc.Above-mentioned plasma welding electric current uses direct current or DC pulse waveform.In the explanation afterwards, when only having put down in writing electric arc length, its electric arc that refers to Metallic Inert Gas electric arc is long.Below, connect method about above-mentioned plasma metal arc inert gas welding and describe.
Figure 10 is the oscillogram that expression plasma metal arc inert gas welding of the prior art connects method.Meet electric current I wm with figure (A) expression metal arc inert gas welding, meet voltage Vwm, with figure (C) expression plasma welding electric current I wp, with figure (D) expression plasma welding voltage Vwp with figure (B) expression metal arc inert gas welding.Below, describe with reference to FIG..
Shown in figure (A), logical going up by peak point current Ip among the Tp during peak value (peak) and the background current Ib among the Tb forms during base value (base) metal arc inert gas welding meets electric current I wm.Between this peak period during Tp and the base value Tb be impulse duration Tf altogether.And it is corresponding that metal arc inert gas welding connects the energising of electric current I wm therewith, shown in figure (B), among the Tp, applies crest voltage Vp between welding wire and mother metal, and among the Tb, apply base value voltage Vb during base value between the peak period.
In Metallic Inert Gas electric arc pulse welding,, carry out electric arc length is maintained in the long control of electric arc of appropriate value in order to obtain good welding quality.Usually, the long control of this electric arc utilizes metal arc inert gas welding to meet voltage Vwm and grows up with electric arc and cause the relation that is directly proportional, and in the control impuls cycle, equals predefined voltage setting value so that metal arc inert gas welding connects the mean value of voltage Vwm.Metal arc inert gas welding connects the mean value of voltage Vwm, makes metal arc inert gas welding meet voltage Vwm and generates by low pass filter.The mode of the long control of this electric arc is called the frequency modulation(PFM) mode.In this case, Tp, peak point current Ip and background current Ib between the peak period are set at setting, it becomes pulse parameter.Peak point current Ip is set in more than the critical value, and Tp combines the unit of being known as (unit) impulsive condition between itself and peak period.This unit pulse condition enactment is for to carry out 1 time the droplet transfer in 1 pulse period.Background current Ib is set at less than the little current value about tens of A of critical value.According to the material of welding wire, diameter, feed speed etc. unit pulse condition and background current Ib are set at appropriate value.
On the other hand, shown in figure (C), article on plasma welding current Iwp implements constant current control, makes it become the dc waveform of predefined steady state value.In addition, shown in figure (D), between plasma electrode and mother metal, apply plasma welding voltage Vwp.Therefore, plasma-arc is produced by the energising of the plasma welding electric current I wp of steady state value.
Patent documentation 1:JP spy opens the 2008-229641 communique
In the plasma metal arc inert gas welding connects, between 1 welding torch and mother metal, produce two electric arcs of Metallic Inert Gas electric arc and plasma-arc simultaneously.And Metallic Inert Gas electric arc is to produce under the state that is surrounded by plasma-arc.Therefore, the welding wire of Metallic Inert Gas electric arc will be heated from plasma-arc.According to the thickness of mother metal, joint geometry, operability etc. the distance between welding torch front end and the mother metal (torch height) is set at appropriate value.Therefore, even torch height also can change by the welding position difference or in welding.If this torch height changes, then the distance between the distance between plasma electrode front end and the mother metal and power supply chip front end and the mother metal will change, and the length of being heated of pretending the length of the part of being heated from plasma-arc for welding wire will change.If this length variations of being heated changes thereby the heat then from the plasma-arc to the welding wire can change preheat mode,, the temperature of the extension of welding wire will change so rising.Consequently, the droplet transfer state will change, and also can produce from 1 droplet transfer of 1 pulse period state to break away from the situation that becomes unsure state.
Summary of the invention
The length variations of being heated of the length of the part of being heated from plasma-arc as welding wire, the objective of the invention is to for this reason, provides a kind of plasma metal arc inert gas welding to connect method, even also can be kept stable droplet transfer state.
In order to solve above-mentioned problem, the invention of claim 1 is that a kind of plasma metal arc inert gas welding connects method, it is by applying plasma welding voltage and leading to the plasma welding current between plasma electrode in being disposed at welding torch and the mother metal, thereby plasma-arc is produced, and, described plasma electrode is arranged to hollow shape, pass the welding wire that described hollow shape inside comes feeding to be powered via being configured in the power supply chip in the described plasma electrode, and by between described power supply chip and mother metal, apply metal arc inert gas welding connect voltage and logical on the peak period between in peak point current and base value during in background current connect electric current as the metal arc inert gas welding of 1 pulse period, thereby Metallic Inert Gas electric arc is produced
Wherein, make between the described peak period and/or described peak point current changes according to the length of being heated of the length of the part of being heated from described plasma-arc as described welding wire.
The invention of claim 2, the plasma metal arc inert gas welding of putting down in writing according to claim 1 connects method, it is characterized in that front end that the described length of being heated is described plasma electrode and the distance between the described mother metal.
The invention of claim 3, plasma metal arc inert gas welding according to claim 2 record connects method, it is characterized in that, according to described plasma welding electric current and described plasma are welded voltage as input and predefined function, calculate the front end of described plasma electric and the distance between the described mother metal.
The invention of claim 4, plasma metal arc inert gas welding according to claim 1 record connects method, it is characterized in that the described length of being heated is to deduct the value that obtains after the electric arc length of described Metallic Inert Gas electric arc from the front end of described plasma electrode and the distance between the described mother metal.
The invention of claim 5, plasma metal arc inert gas welding according to claim 4 record connects method, it is characterized in that, the mean value that connects voltage according to feed speed and described metal arc inert gas welding with welding wire is as input and predefined function, and it is long to calculate described electric arc.
According to the present invention, by the length of being heated metal arc inert gas welding is connect between peak period in the electric current and/or peak point current changes according to welding wire, can compensate the variation of preheat mode of the welding wire of the variation of following the length of being heated.Therefore, though variations such as torch height, thus the length variations of being heated of welding wire also can be kept the state of 1 droplet transfer of 1 pulse period, so welded condition is with all-the-time stable.
Further, according to the invention of claim 4 and claim 5, the value that the length of being heated obtains after long as the electric arc that deducts Metallic Inert Gas electric arc from the distance between plasma electrode front end and the mother metal is calculated.Therefore, change, also can correctly calculate the length of being heated even the electric arc of Metallic Inert Gas electric arc is long.Consequently, can compensate the variation of preheat mode of the welding wire of the variation of following the length of being heated more accurately.
Description of drawings
Fig. 1 is the pie graph that the plasma metal arc inert gas welding that is used to implement embodiments of the present invention 1 connects the welder of method.
Fig. 2 is be heated the length L h and the figure of the relation between Tp and the peak point current Ip between the peak period when being illustrated in plasma welding electric current I wp and being 50A.
Fig. 3 is be heated the length L h and the figure of the relation between Tp and the peak point current Ip between the peak period when being illustrated in plasma welding electric current I wp and being 100A.
Fig. 4 is be heated the length L h and the figure of the relation between Tp and the peak point current Ip between the peak period when being illustrated in plasma welding electric current I wp and being 150A.
Fig. 5 is the figure of the arc characteristic of expression plasma-arc.
Fig. 6 is the module map that the metal arc inert gas welding of the welder of pie graph 1 meets power ps M.
Fig. 7 is the module map that the plasma of the welder of pie graph 1 welds power ps P.
Fig. 8 is the figure of arc characteristic of the Metallic Inert Gas electric arc of expression embodiments of the present invention 2.
Fig. 9 is the module map that the metal arc inert gas welding of the formation welder of embodiments of the present invention 2 meets power ps M.
Figure 10 is the oscillogram that the plasma metal arc inert gas welding of expression prior art connects method.
Symbol description:
1a: welding wire
1b: plasma electrode
2: mother metal
3a: Metallic Inert Gas electric arc
3b: plasma-arc
4: power supply chip
51: plasma nozzle
52: the protective gas nozzle
61: center gas
62: plasma gas
63: protective gas
7: feed rolls
EI: current error amplifying circuit
Ei: current error amplifying signal
EV: voltage error amplifying circuit
Ev: voltage error amplifying signal
FC: feeding control circuit
Fc: feeding control signal
FR: feed speed initialization circuit
Fr: feed speed setting signal
Fw: feed speed
Ib: background current
IBR: background current initialization circuit
Ibr: background current setting signal
ID: current detection circuit
Id: current detection signal
Ip: peak point current
IPR: peak point current initialization circuit
Ipr: peak point current setting signal
IPR2: the second peak point current initialization circuit
IRC: current settings control circuit
Irc: current settings control signal
Iwm: metal arc inert gas welding connects electric current
Iwp: plasma welding electric current
IWPR: plasma welding current setting circuit
Iwpr: plasma welding current settings signal
La: the electric arc of Metallic Inert Gas electric arc is long
LAR: the long initialization circuit of Metallic Inert Gas electric arc
Lar: the long setting signal of Metallic Inert Gas electric arc
Lh: the length of being heated
LHC: the length computation of being heated circuit
Lhc: length signals is heated
Lp: the distance between torch height, plasma electrode front end and the mother metal
Lpa: the electric arc of plasma-arc is long
LPC: between plasma electrode front end mother metal apart from counting circuit
Lpc: between plasma electrode front end mother metal apart from signal
Lw: the distance between power supply chip front end and the mother metal
Lx: stretch out length
PM: electric power main circuit
PSM: metal arc inert gas welding connects power supply
PSP: plasma welding power supply
Tb: during the base value
Tf: pulse period (signal)
TP: timing (Timer) circuit between the peak period
Tp: between the peak period (signal)
TPR: initialization circuit between the peak period
Tpr: setting signal between the peak period
TPR2: initialization circuit between second peak period
VAV: average voltage counting circuit
Vav: average voltage signal
Vb: base value voltage
VD: voltage detecting circuit
Vd: voltage detection signal
VF: voltage/frequency translation circuit
Vp: crest voltage
VR: voltage setting circuit
Vr: voltage setting signal
Vwm: metal arc inert gas welding connects voltage
Vwp: plasma welding voltage
WM: feed motor
WT: welding torch
The specific embodiment
Below, with reference to accompanying drawing, describe about embodiments of the present invention.
[embodiment 1]
Fig. 1 is the pie graph that the plasma metal arc inert gas welding that is used to implement embodiments of the present invention 1 connects the welder of method.Below, with reference to FIG., constitute thing about each and describe.
This welder comprises that welding torch WT, the metal arc inert gas welding by dotted line meets power ps M and plasma welding power ps P.Welding torch WT is the structure that in protective gas nozzle 52 plasma nozzle 51, plasma electrode 1b and power supply chip 4 is configured on the concentric shafts.From the gap between protective gas nozzle 52 and the plasma nozzle 51, supply with the protective gas 63 of the mist etc. of for example argon gas, argon gas and carbon dioxide.Between plasma nozzle 51 and plasma electrode 1b, supply with the plasma gas 62 of the mist etc. of for example argon gas, argon gas and carbon dioxide.Between plasma electrode 1b and power supply chip 4, supply with center (center) gas 61 of the mist etc. of for example argon gas, argon gas and carbon dioxide.
Plasma electrode 1b forms hollow shape.Insulation ground configuration power supply chip 4 in the hollow shape of this plasma electrode 1b.Then, come feeding welding wire 1a from the through hole that is arranged on this power supply chip 4.4 couples of welding wire 1a of power supply chip carry out conducting.But insulate between welding wire 1a and the plasma electrode 1b.Welding wire 1a is by being that the rotation of the feed rolls (feed roll) 7 of drive source comes feeding with feed motor WM.Plasma electrode 1b is made up of for example copper or copper alloy, carries out water cooling indirectly by the cooling water through the outer path of figure.Plasma nozzle 51 is made up of for example copper or copper alloy, makes the stream of cooling water process by formation, directly cools off.Under the state that welding torch WT is kept by robot (diagram is omitted) usually, make it to move relative to mother metal 2.Between the front end of welding wire 1a and mother metal 2, produce Metallic Inert Gas electric arc 3a.Between plasma electrode 1b and mother metal 2, produce by plasma gas 62 and carry out the plasma-arc 3b that heat is restrained.Therefore, Metallic Inert Gas electric arc 3a is the state that is surrounded by plasma-arc 3b.Thereby, the effect that plasma-arc 3b has the shape of contained Metallic Inert Gas electric arc 3a to enlarge.
Shown in figure, the distance between the front end of plasma electrode 1b and the mother metal 2 is Lp (mm), and the distance between the front end of power supply chip 4 and the mother metal 2 is Lw (mm), and the electric arc of Metallic Inert Gas electric arc 3a is long to be La (mm).And Lp＜Lw, La＜Lp.Therefore, the electric arc of plasma-arc 3b is long is above-mentioned Lp (mm).In addition, welding wire 1a's stretches out long Lx=Lw-La.Shown in figure, because the part of the extension of welding wire 1a is surrounded by plasma-arc 3b, temperature rises so be heated.This effect is known as pre-heat effect.In addition, the length of the welding wire 1a part of being heated from plasma-arc 3b is known as the length L h that is heated.About the length L h that is heated, correctly be Lh=Lp-La (situation of embodiment 2).Under situation about simplifying, can regard the length L h=Lp that is heated (situation of embodiment 1) as.Welding wire 1a changes according to the plasma welding electric current I wp and the length L h that is heated from the heat that plasma-arc 3b is subjected to.Even plasma welding electric current I wp is identical value, if the length L h that is heated changes, then heat also can change.At this, if torch height is defined as the front end of above-mentioned plasma electrode 1b and the distance L p between the mother metal 2, then if torch height changes, the front end and the distance L w between the mother metal of then above-mentioned power supply chip 4 also can change.That is, if torch height changes, the length L of then being heated h also can change.Consequently, the temperature of the extension of welding wire 1a can change, thereby can produce the influenced unsettled situation that becomes of droplet transfer state.In order to prevent this situation, in the present embodiment,, shown in the aftermentioned of Fig. 2～Fig. 4, make unit pulse condition (Tp and peak point current Ip between the peak period) be varied to appropriate value according to the variation of the length L h that is heated.Like this, even thereby torch height changes the length L h that is heated to be changed, also can keep stable droplet transfer state.
Metal arc inert gas welding meets power ps M and is used for by meeting voltage Vwm and lead to the power supply that metal arc inert gas welding meets electric current I wm applying metal arc inert gas welding between welding wire 1a and the mother metal 2 via power supply chip 4.Meet power ps M from metal arc inert gas welding feed motor WM is sent feeding control signal Fc, thus the feed speed of control welding wire 1a.When metal arc inert gas welding meets power ps M and applies metal arc inert gas welding and meet voltage Vwm, make welding wire 1a in "+" side.Metal arc inert gas welding connects the power supply that power ps M is the constant voltage characteristic, it is controlled, so that metal arc inert gas welding connects the value that voltage Vwm equals predefined voltage setting signal Vr (diagram is omitted).In addition, metal arc inert gas welding connects the feed speed of electric current I wm according to welding wire 1a, decides its value.
Plasma welding power ps P is used for by applying the power supply that plasma welding voltage Vwp leads to plasma welding current Iwp between plasma electrode 1b and the mother metal 2.When applying plasma welding voltage Vwp from plasma welding power ps P, make plasma electrode 1b in "+" side.Plasma welding power ps P is the power supply of constant current characteristic, it is controlled, so that plasma welding electric current I wp is a setting.
Plasma welding current setting circuit IWPR outputs to metal arc inert gas welding with predefined plasma welding current settings signal Iwpr and meets power ps M and plasma welding power ps P.This plasma welding current setting signal Iwpr is the signal that is used to set above-mentioned plasma welding electric current I wp.Plasma welding current setting circuit IWPR under for the situation of robot welding, is arranged in the robot controller.
Metal arc inert gas welding meets electric current I wm, metal arc inert gas welding, and to connect the oscillogram of voltage Vwm, plasma welding electric current I wp and plasma welding voltage Vwp identical with above-mentioned Figure 10.As mentioned above, in the present embodiment, change according to the length L h that is heated of welding wire 1a as Tp between the peak period of unit pulse condition and peak point current Ip.This point unlike the prior art.Below, describe about this point.
Fig. 2 is be heated length L h and as the figure of the relation between Tp between the peak period of unit pulse condition and the peak point current Ip of expression.With the transverse axis of the figure length L h (mm) that represents to be heated, represented in practicality, to use the scope of 15 more～25mm.The longitudinal axis has been represented Tp between the peak period (ms) and peak point current Ip (A).In with figure, solid line is represented the variation of Tp between the peak period, and dotted line is represented the variation of peak point current Ip.With figure is the situation of plasma welding current value I wp=50A.For welding wire uses the aluminum-alloy wire of diameter 1.2mm, the situation of feed speed=9m/min.Background current Ib is the steady state value of 30A.
Shown in figure, when being heated length L h=15mm, be set at Tp=1.0ms and peak point current Ip=340A between the peak period.Length L h is elongated along with being heated, and Tp and peak point current Ip all diminish between the peak period.This be because, long more because of the length L h that is heated, welding wire is big more from the heat that plasma-arc is subjected to, thus can be little by the unit pulse condition is established, keep 1 pulse period, 1 droplet transfer state.And, if be heated length L h=20mm, then be set at Tp=0.8ms and peak point current Ip=330A between the peak period.If become the length L h=25mm that is heated, then Tp=0.6ms and peak point current Ip=320A between the peak period.
Fig. 3 is the length L h and as the figure of the relation between Tp between the peak period of unit pulse condition and the peak point current Ip of being heated when being illustrated in plasma welding current value I wp=100A.With the transverse axis of the figure length L h (mm) that represents to be heated, represented in practicality, to use the scope of 15 more～25mm.The longitudinal axis has been represented Tp between the peak period (ms) and peak point current Ip (A).In with figure, solid line is represented the variation of Tp between the peak period, and dotted line is represented the variation of peak point current Ip.Corresponding with above-mentioned Fig. 2 with figure, the welding condition except that plasma welding current value I wp is identical.
Shown in figure, when being heated length L h=15mm, be set at Tp=1.0ms and peak point current Ip=310A between the peak period.Length L h is elongated along with being heated, and Tp and peak point current Ip all diminish between the peak period.This be because, long more because of the length L h that is heated, welding wire is big more from the heat that plasma-arc is subjected to, thus can be little by the unit pulse condition is established, keep 1 pulse period, 1 droplet transfer state.And, if be heated length L h=20mm, then be set at Tp=0.8ms and peak point current Ip=300A between the peak period.If become the length L h=25mm that is heated, then Tp=0.6ms and peak point current Ip=290A between the peak period.In addition, if will compare with figure and above-mentioned Fig. 2, then Tp and peak point current Ip between the peak period when the length L h that is heated is same value with comparing with Fig. 2 among the figure, are less relatively value.This be because, become big in order to make with the plasma among figure welding current value I wp, the heat that welding wire is subjected to from plasma-arc will become greatly, so in order to keep 1 pulse period, 1 droplet transfer state, reduced Tp and peak point current Ip between the peak period.
Fig. 4 is the length L h and as the figure that concerns between Tp between the peak period of unit pulse condition and the peak point current Ip of being heated when being illustrated in plasma welding current value I wp=150A.With the transverse axis of the figure length L h (mm) that represents to be heated, represented in practicality, to use the scope of 15 more～25mm.The longitudinal axis has been represented Tp between the peak period (ms) and peak point current Ip (A).In with figure, solid line is represented the variation of Tp between the peak period, and dotted line is represented the variation of peak point current Ip.Corresponding with above-mentioned Fig. 2 and Fig. 3 with figure, the welding condition except that plasma welding current value I wp is identical.
Shown in figure, when being heated length L h=15mm, be set at Tp=1.0ms and peak point current Ip=290A between the peak period.Length L h is elongated along with being heated, and Tp and peak point current Ip all diminish between the peak period.This be because, long more because of the length L h that is heated, welding wire is big more from the heat that plasma-arc is subjected to, thus can be little by the unit pulse condition is established, keep 1 pulse period, 1 droplet transfer state.And, if be heated length L h=20mm, then be set at Tp=0.8ms and peak point current Ip=280A between the peak period.If become the length L h=25mm that is heated, then Tp=0.6ms and peak point current Ip=270A between the peak period.In addition, if will compare with figure and above-mentioned Fig. 2 and Fig. 3, then Tp and peak point current Ip between the peak period when the length L h that is heated is same value are with among the figure being less relatively value.This be because, become big in order to make with the plasma among figure welding current value I wp, the heat that welding wire is subjected to from plasma-arc will become greatly, so in order to keep 1 pulse period, 1 droplet transfer state, reduced Tp and peak point current Ip between the peak period.
In Fig. 2～Fig. 4, the variation of the length L h that is heated that Tp between the peak period is above-mentioned relatively is called computing function between the peak period.In addition, peak point current Ip is heated the relatively variation of length L h is called peak point current and calculates function.These functions are set appropriate value for according to the material of plasma welding current value I wp, welding wire, diameter, feed speed etc.This setting is carried out by experiment.In addition, in Fig. 2～Fig. 4, the situation that two parameters of unit pulse condition (Tp and peak point current Ip between the peak period) all change according to predefined function has been described when the length L h that is heated changes.Yet, also can only make one of them variation in the unit pulse condition.This is owing to welding wire when the length L h that is heated changes also can change from the heat that plasma-arc is subjected to, so the unit pulse condition is changed, compensates the variation to the heat of welding wire.Therefore, there is no need for this compensates two aspects of unit pulse condition all to be changed, side variation gets final product and only need wherein.That is, corresponding with the variation of the length L h that is heated, Tp and/or peak point current Ip are changed get final product.
Next, the detection method about the length L h that is heated describes.In the present embodiment, as mentioned above, because the length L h that will be heated regards the distance L p between plasma electrode front end and the mother metal as, so the detection of the length L h that is heated is equivalent to detect the distance L p between plasma electrode front end and the mother metal.As this detection method, two kinds of methods shown below are arranged.
(1) method that sends from robot controller
In the welding of having used robot, when the teaching sealing wire, be that the mode of appropriate value is carried out according to making torch height.As mentioned above, because torch height is the distance L p between plasma electrode front end and the mother metal, so when teaching, make and in operation sequence, write this value.And, when welding, send these data (distance between plasma electrode front end and the mother metal) from robot controller and get final product to source of welding current PSM.
(2) carry out Calculation Method according to plasma welding voltage Vwp and plasma welding electric current I wp
Plasma-arc is non-consumable electrode type electric arc, so long Lpa of the electric arc of plasma-arc and plasma electrode front end are consistent with the distance L p between the mother metal.The long Lpa of electric arc is if be set to plasma welding current value I wp, then with the proportional relation of plasma welding magnitude of voltage Vwp.This proportional relation is known as arc characteristic.Therefore, in welding, detect plasma welding voltage Vwp, can calculate the corresponding with it long Lpa of electric arc according to arc characteristic.In this method, weld the long Lpa of electric arc that magnitude of voltage Vwp calculates plasma-arc according to plasma welding current value I wp and plasma, the long Lpa of electric arc equals the distance L p between plasma electrode front end and the mother metal, further, the length L h that equals to be heated of the distance L p between plasma electrode front end and the mother metal.Therefore, can calculate the length L h that is heated according to arc characteristic.In Fig. 1, this calculates in plasma welding power ps P and carries out, and meets power ps M so output to metal arc inert gas welding apart from signal Lpc from plasma welding power ps P between plasma electrode front end mother metal.
Fig. 5 is the figure of the arc characteristic of the above-mentioned plasma-arc of expression.Represent plasma welding voltage Vwp (V) with the transverse axis of figure, the longitudinal axis is represented the long Lpa of the electric arc of plasma-arc (mm).In with figure, the situation when solid line has been represented plasma welding current value I wp=50A, the situation when dotted line has been represented Iwp=100A, the situation when chain-dotted line has been represented Iwp=150A.
Shown in figure, Vwp is big more for plasma welding magnitude of voltage, and the long Lpa of electric arc is long more.In addition, when plasma welding magnitude of voltage Vwp was same value, wp was big more for plasma welding current value I, and the long Lpa of electric arc is short more.For example, when plasma welding current value I wp=100A, under the situation of plasma welding magnitude of voltage Vwp=31A, the long Lpa of electric arc is 20mm.Like this, the long Lpa of electric arc of plasma-arc can be calculated, and,, the distance L p between plasma electrode front end and the mother metal can be calculated so study carefully its result because the long Lpa of electric arc equals the distance L p between plasma electrode front end and the mother metal.Below, will be called plasma electric arc length computing function with the arc characteristic shown in the figure.Plasma is welded current value I wp to the long computing function of this electric arc and plasma welds magnitude of voltage Vwp as input, and the long Lpa of electric arc of output plasma-arc.The long computing function of this plasma-arc is set at appropriate value according to the kind of plasma gas 62 and protective gas 63, the shape of plasma electrode 1b etc.This setting is carried out by experiment.In with figure, when plasma welding current value I wp=70A, carry out interpolation according to the arc characteristic of Iwp=50A and the arc characteristic of Iwp=100a, calculate plasma electric arc length Lpa.
Fig. 6 is the module map that the metal arc inert gas welding of the above-mentioned Fig. 1 of formation meets power ps M.With figure, as mentioned above, be between plasma welding power ps P input plasma electrode front end mother metal apart from the situation of signal Lpc.Below, describe about each module with reference to FIG..
Electric power main circuit PM with source power supplies such as 3 phase 200V (diagram omit) as importing, carry out the output control of inversion control etc. according to current error amplifying signal Ei described later, the output metal arc inert gas welding meets voltage Vwm and metal arc inert gas welding meets electric current I wm.This electric power main circuit PM, though diagram is omitted, it is made of following: a rectification circuit, it carries out rectification to source power supply; Capacitor, it makes the direct current after the rectification level and smooth; Inverter (inverter) circuit, it becomes high-frequency ac with the DC converting after level and smooth; It becomes to be fit to the magnitude of voltage of arc welding contravariant transformer (inverter transformer) with the high-frequency ac step-down; Secondary rectification circuit, its high-frequency ac after to step-down carries out rectification; Reactor (reactor), it makes the direct current after the rectification level and smooth; And drive circuit, it carries out PWM modulation control according to current error amplifying signal Ei described later, and drives inverter circuit based on this result.Welding wire 1a passes power supply chip 4 inside, implements feeding by the feed rolls 7 that combines with feed motor WM, and and mother metal 2 between produce Metallic Inert Gas electric arc 3a.The structure of welding torch is identical with Fig. 1, illustrates but simplify at this.
Voltage detecting circuit VD detects metal arc inert gas welding and meets voltage Vwm, and voltage sense signal Vd.Average voltage counting circuit VAV calculates the mean value of this voltage detection signal Vd, and output voltage average value signal Vav.
In Fig. 1, as mentioned above, be arranged on the plasma welding current setting circuit IWPR that metal arc inert gas welding connects the outside of power ps M and export predefined plasma welding current settings signal Iwpr.Feed speed initialization circuit FR exports predefined feed speed setting signal Fr.Feeding control circuit FC as input, and will be used for this feed speed setting signal Fr to come the feeding control signal Fc of feeding welding wire 1a to output to feed motor WM with the feed speed Fw that the value according to feed speed setting signal Fr determines.
Voltage setting circuit VR exports predefined voltage setting signal Vr.Voltage error amplifying circuit EV amplifies the error between this voltage setting signal Vr and the above-mentioned average voltage signal Vav, and output voltage error amplifying signal Ev.Voltage/frequency translation circuit VF output has the pulse-period signal Tf of the frequency of the value correspondence of voltage error amplifying signal Ev therewith.This pulse-period signal Tf is that only the short time is the triggering signal of high level (High level) in each pulse period.
Between the peak period initialization circuit TPR will between the plasma electrode front end mother metal of above-mentioned plasma welding current settings signal Iwpr and plasma welding power ps P apart from signal Lpc as input, based on computing function between the predefined peak period above-mentioned among Fig. 2～Fig. 4, export setting signal Tpr between the peak period.Signal Tp between the timing circuit TP output peak period between the peak period, signal Tp is a high level in during only the value of setting signal Tpr determines between according to the above-mentioned peak period when above-mentioned pulse-period signal Tf is high level between this peak period.Be between the peak period when signal Tp is for high level between this peak period, and during for low level (Low level) time, being base value.
Background current initialization circuit IBR exports predefined background current setting signal Ibr.Peak point current initialization circuit IPR will between the plasma electrode front end mother metal of above-mentioned plasma welding current settings signal Iwpr and plasma welding power ps P apart from signal Lpc as input, calculate function based on peak point current above-mentioned among Fig. 2～Fig. 4, export peak point current setting signal Ipr.Current settings control circuit IRC, when signal Tp is low level between the above-mentioned peak period, above-mentioned background current setting signal Ibr is exported as current settings control signal Irc, and when being high level, above-mentioned peak point current setting signal Ipr is exported as current settings control signal Irc.
Current detection circuit ID detects metal arc inert gas welding and meets electric current I wm, and output current detection signal Id.Current error amplifying circuit EI amplifies the error between above-mentioned current settings control signal Irc and the above-mentioned current detection signal Id, and output current error amplification signal Ei.By carry out the output control of the source of welding current according to this current error amplifying signal Ei, in Figure 10 (A), logical above-mentioned metal arc inert gas welding meets electric current I wm.Above-mentioned metal arc inert gas welding is met power ps M, change according to the pulse period and export control, so that metal arc inert gas welding connects the value that the mean value of voltage Vwm equals voltage setting signal Vr, so it is the power supply of constant voltage characteristic.
Fig. 7 is the module map that constitutes the plasma welding power ps P of above-mentioned Fig. 1.Represented plasma to be welded current value I wp and plasma welding magnitude of voltage Vwp calculate the length L h that is heated as the plasma electric arc length computing function of input situation with figure according to the method for above-mentioned (2).Below, with reference to FIG., describe about each module.
Electric power main circuit PM as input, carry out the output control of inversion control etc. according to current error amplifying signal Ei described later, and the output plasma welds electric current I wp with source power supplies such as 3 phase 200V (diagram omit).This plasma welding current Iwp switches on by plasma electrode 1b, plasma-arc 3b, mother metal 2.The structure of welding torch is identical with above-mentioned Fig. 1, illustrates but simplify at this.
In Fig. 1, as mentioned above, the plasma welding current setting circuit IWPR that is arranged on the outside of plasma welding power ps P exports predefined plasma welding current settings signal Iwpr.Current detection circuit ID detects above-mentioned plasma welding electric current I wp, and output current detection signal Id.Current error amplifying circuit EI amplifies the error between above-mentioned plasma welding current settings signal Iwpr and the above-mentioned current detection signal Id, and output current error amplification signal Ei.By carry out the output control of the source of welding current according to this current error amplifying signal Ei, in Figure 10 (C), the logical plasma welding electric current I wp that above-mentioned direct current.Plasma welding power ps P to above-mentioned exports control, so that plasma welding electric current I wp equals the value of plasma welding current settings signal Iwpr, so it is the power supply of constant current characteristic.
Voltage detecting circuit VD detects above-mentioned plasma welding voltage Vwp, and voltage sense signal Vd.Between plasma electrode front end mother metal apart from counting circuit LPC with above-mentioned plasma welding current settings signal Iwpr and above-mentioned voltage detection signal Vd as input, long according to the electric arc that predefined plasma electric arc length computing function above-mentioned among Fig. 5 calculates plasma-arc, and meet power ps M as outputing to metal arc inert gas welding apart from signal Lpc between plasma electrode front end mother metal.
In the present embodiment, illustrated that plasma welding electric current I wp is the situation of direct current.When plasma welding electric current I wp is impulse waveform, as the input that computing function, peak point current between the above-mentioned peak period calculate function and plasma electric arc length computing function, use the mean value of plasma welding electric current I wp and the mean value of plasma welding voltage Vwp to get final product.
According to above-mentioned embodiment 1, by the length of being heated metal arc inert gas welding is connect between peak period of electric current and/or peak point current changes according to welding wire, can compensate the variation of preheat mode of the welding wire of the variation of following the length of being heated.Therefore, even thereby the length variations of being heated of variation welding wires such as torch height also can be kept 1 pulse period, 1 droplet transfer state, so the welded condition all-the-time stable.
[embodiment 2]
Embodiments of the present invention 2 are the situations of length L h=Lp-La of being heated.At this, as mentioned above, Lp is the distance between plasma electrode front end and the mother metal, and La is that the electric arc of Metallic Inert Gas electric arc is long.About the detection method of the distance L p between plasma electrode front end and the mother metal, identical with embodiment 1.As the establishing method of the long La of electric arc, 3 kinds of methods shown below are arranged.
(1) preestablishes the situation of the long La of electric arc
The proper range that is used to carry out the long La of electric arc of good welding is about 3～5mm.Therefore, the long La of electric arc is set at predefined constant (for example 4mm).Like this, though and can produce error about 1mm between the long La of the electric arc of reality, so long as it is the error of this degree, just little to the influence of the calculated value of the length L h that is heated.If make in this way, the simple advantage of computational methods of the length L h that is heated is arranged.
(2) set the situation of the long La of electric arc based on voltage setting signal Vr
In Fig. 6, the value that above-mentioned metal arc inert gas welding meets the voltage setting signal Vr in the power ps M is the desired value of the long control of electric arc of Metallic Inert Gas electric arc.That is, carry out the long control of electric arc, so that become the long La of the electric arc corresponding with the value of voltage setting signal Vr.Therefore, according to this voltage setting signal Vr as the input and the long computing function of the predefined first Metallic Inert Gas electric arc, calculate the long La of electric arc.For example, making the long computing function of this first Metallic Inert Gas electric arc is La=aVr+b.At this, a and b are constant, decide by experiment.Constant a and b are set at appropriate value by experiment according to the material of the kind of center gas, plasma gas and protective gas, welding wire and diameter etc.
(3) connecing voltage Vwm and metal arc inert gas welding according to metal arc inert gas welding meets electric current I wm and carries out Calculation Method
Because Metallic Inert Gas electric arc is consumable electrode type electric arc, so the front end of the welding wire of fusion always and the distance between the mother metal are the long La of electric arc.If set the feed speed Fw (metal arc inert gas welding connects the mean value of electric current I wm) of welding wire, it is proportional that then long La of electric arc and metal arc inert gas welding connect the mean value of voltage Vwm.This proportional relation is known as arc characteristic.Therefore, can in welding, detect the mean value that metal arc inert gas welding meets voltage Vwm, and calculate the corresponding with it long La of electric arc according to arc characteristic.In this method, according to the mean value that feed speed Fw and metal arc inert gas welding is met voltage Vwm as input and the long computing function of the predefined second Metallic Inert Gas electric arc calculates the long La of electric arc.In Fig. 1, this calculating is carried out in metal arc inert gas welding meets power ps M.
Fig. 8 is the figure of the arc characteristic of the above-mentioned Metallic Inert Gas electric arc of expression.Represent that with the transverse axis of figure metal arc inert gas welding connects the mean value of voltage Vwm (V), the longitudinal axis is represented the long La of the electric arc of Metallic Inert Gas electric arc (mm).In with figure, solid line has been represented the feed speed Fw=9m/min (situation when metal arc inert gas welding connects the mean value of electric current I wm=70A), dotted line has represented that (situation when metal arc inert gas welding connects the mean value of electric current I wm=105A), chain-dotted line have been represented the Fw=14m/min (situation when metal arc inert gas welding connects the mean value of electric current I wm=135A) to Fw=12m/min.Wherein, the metal arc inert gas welding in () connects the situation that the mean value of electric current I wm is plasma welding current value I wp=100A.
Shown in figure, the mean value that metal arc inert gas welding meets voltage Vwm is big more, and the long La of electric arc is long more.In addition, when the mean value that meets voltage Vwm when metal arc inert gas welding was identical value, feed speed Fw was big more, and the long La of electric arc is short more.For example, when feed speed Fw=12m/min, connect at metal arc inert gas welding under the situation of mean value=17V of voltage Vwm, the long La of electric arc is 5mm.Like this, can calculate the long La of electric arc of Metallic Inert Gas electric arc.With the arc characteristic shown in the figure is the long computing function of the second Metallic Inert Gas electric arc.The mean value that the long computing function of this second Metallic Inert Gas electric arc meets voltage Vwm with feed speed Fw and metal arc inert gas welding is as input, and the long La of electric arc of output Metallic Inert Gas electric arc.The long computing function of this second Metallic Inert Gas electric arc is set at appropriate value according to the material of the kind of above-mentioned center gas 61, plasma gas 62 and protective gas 63, welding wire 1a and diameter etc.This setting is carried out by experiment.
The pie graph of welder that the plasma metal arc inert gas welding that is used to implement embodiment 2 connects method is identical with above-mentioned Fig. 1.But the metal arc inert gas welding that will constitute this welder connects the module map (Fig. 6) of power ps M and changes over Fig. 9 described later.In addition, about be heated length L h and of expression, also identical as the above-mentioned Fig. 2～Fig. 4 that concerns between Tp between the peak period of unit pulse condition and the peak point current Ip.About these identical items, omit its explanation.
Fig. 9 is the module map that the metal arc inert gas welding of the pie graph 1 of embodiments of the present invention 2 meets power ps M.With figure, as mentioned above, be between plasma welding power ps P input plasma electrode front end mother metal apart from the situation of signal Lpc.Corresponding with figure with above-mentioned Fig. 6, same module is paid same mark, omit its explanation.With figure is the length computation circuit LHC that is heated that appends the long initialization circuit LAR of the Metallic Inert Gas electric arc that dots and dot in Fig. 6, initialization circuit TPR between the peak period of Fig. 6 is replaced as initialization circuit TPR2 between second peak period that dots, and the peak point current initialization circuit IPR of Fig. 6 is replaced as the second peak point current initialization circuit IPR2 that dots.Below, with reference to FIG., describe about these modules.
The long initialization circuit LAR of Metallic Inert Gas electric arc with feed speed setting signal Fr and average voltage signal Vav as input, according to the long computing function of the predefined second Metallic Inert Gas electric arc above-mentioned among Fig. 8, the electric arc that calculates Metallic Inert Gas electric arc is long, and it is exported as the long setting signal Lar of Metallic Inert Gas electric arc.The length computation of being heated circuit LHC in the future since then among the long setting signal Lar of Metallic Inert Gas electric arc and Fig. 7 above-mentioned plasma weld between the plasma electrode front end mother metal of power ps P apart from signal Lpc as input, the calculating length signals Lhc=Lpc-Lar that is heated, the line output of going forward side by side.
Initialization circuit TPR2 welds current settings signal Iwpr and the above-mentioned length signals Lhc that is heated as input with plasma between second peak period, based on computing function between the predefined peak period above-mentioned among Fig. 2～Fig. 4, exports setting signal Tpr between the peak period.The second peak point current initialization circuit IPR2 welds current settings signal Iwpr and the above-mentioned length signals Lhc that is heated as input with plasma, calculates function based on predefined peak point current above-mentioned among Fig. 2～Fig. 4, exports setting signal Tpr between the peak period.
In with figure, be the situation of the long setting of Metallic Inert Gas electric arc of carrying out with the method for above-mentioned (3), and the situation of using the method for (1) and (2) to carry out, for shown below.
(1) preestablishes the situation of the long La of electric arc
The long initialization circuit LAR of Metallic Inert Gas electric arc exports the long setting signal Lar of predefined Metallic Inert Gas electric arc.
(2) set the situation of the long La of electric arc based on voltage setting signal Vr
The long initialization circuit LAR of Metallic Inert Gas electric arc with voltage setting signal Vr as input, the electric arc that calculates Metallic Inert Gas electric arc according to the above-mentioned long computing function of the predefined first Metallic Inert Gas electric arc is long, and it is exported as the long setting signal Lar of Metallic Inert Gas electric arc.
According to above-mentioned embodiment 2, the value that the length of being heated obtains after long as the electric arc that deducts Metallic Inert Gas electric arc from the distance between plasma electrode front end and the mother metal is calculated.Therefore, change, also can correctly calculate the length of being heated even the electric arc of Metallic Inert Gas electric arc is long.Consequently, can compensate the variation of preheat mode of the welding wire of the variation of following the length of being heated more accurately.
Claims (5)
1. a plasma metal arc inert gas welding connects method, it is by applying plasma welding voltage and leading to the plasma welding current between plasma electrode in being disposed at welding torch and the mother metal, thereby plasma-arc is produced, and, described plasma electrode is arranged to hollow shape, pass the welding wire that described hollow shape inside comes feeding to be powered via the power supply chip that is configured in the described plasma electrode, and by between described power supply chip and mother metal, apply metal arc inert gas welding connect voltage and logical on the peak period between in peak point current and base value during in background current connect electric current as the metal arc inert gas welding of 1 pulse period, thereby Metallic Inert Gas electric arc is produced
These ionic metal inert gas arc weldings connect method and are characterised in that, make between the described peak period and/or described peak point current changes according to the length of being heated of the length of the part of being heated from described plasma-arc as described welding wire.
2. plasma metal arc inert gas welding as claimed in claim 1 connects method, it is characterized in that,
Front end that the described length of being heated is described plasma electrode and the distance between the described mother metal.
3. plasma metal arc inert gas welding as claimed in claim 2 connects method, it is characterized in that,
According to described plasma welding electric current and described plasma are welded voltage as input and predefined function, calculate the front end of described plasma electrode and the distance between the described mother metal.
4. plasma metal arc inert gas welding as claimed in claim 1 connects method, it is characterized in that,
The described length of being heated is to deduct the value that obtains after the electric arc length of described Metallic Inert Gas electric arc from the front end of described plasma electrode and the distance between the described mother metal.
5. plasma metal arc inert gas welding as claimed in claim 4 connects method, it is characterized in that,
The mean value that connects voltage according to feed speed and described metal arc inert gas welding with welding wire is as input and predefined function, and it is long to calculate described electric arc.
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