CN102380691B - Necking detecting and controlling method for melted-electrode arc welding - Google Patents
Necking detecting and controlling method for melted-electrode arc welding Download PDFInfo
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- CN102380691B CN102380691B CN201110226462.1A CN201110226462A CN102380691B CN 102380691 B CN102380691 B CN 102380691B CN 201110226462 A CN201110226462 A CN 201110226462A CN 102380691 B CN102380691 B CN 102380691B
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Abstract
The invention provides a necking detecting and controlling method for melted-electrode arc welding. During the melted-electrode arc welding, an electric arc can be smoothly regenerated even if molten drop necking is wrongly detected. Through the change in a voltage value (Vw) or a resistance value (Vw/Iw) of a welding wire and a base material, the premonitory phenomena of electric arc regeneration under the short-circuit state, i.e., molten drop necking, is detected according to a necking detection reference value. The welding current (Iw) which powers on a short-circuit load is reduced from the necking detection time (t2), so as to enable the regeneration (t3) of the electric arc. If the electric arc is regenerated, then the welding current is increased. When the self-necking detection period of time reaches the reference time (Tt) before the regeneration of the electric arc (t21), the necking detection is judged to be wrong. The welding wire is reversely moved at a set reverse feeding speed (Frr) so as to be far away from the base material, so that the electric arc is smoothly regenerated. If the electric art is regenerated, then the welding wire is moved at a set forward feeding speed (Ffr).
Description
Technical field
The present invention relates to necking for detection of the molten drop in during short circuit so that welding current reduces the Neckdown detection control method of the sacrificial electrode arc welding that improves welding quality.
Background technology
Fig. 5 represents current-voltage waveform in the sacrificial electrode arc welding of Ts and arc period Ta during repetition short circuit and the figure of droplet transfer.Fig. 5 (A) illustrates sacrificial electrode (following, be called welding wire 1) energising welding current Iw time change, the time that Fig. 5 (B) is illustrated in the weldingvoltage Vw applying between welding wire 1 and mother metal 2 changes, Fig. 5 (C)～(E) illustrate state of molten drop 1a transition.Below, describe with reference to Fig. 5.
During the short circuit of moment t1～t3 in Ts, the molten drop 1a of welding wire 1 front end in the state of mother metal 2 short circuits, as shown in Fig. 5 (A), welding current Iw increases gradually, as shown in Fig. 5 (B), due in short-circuit condition, therefore weldingvoltage Vw is the lower value of several V left and right.As shown in Fig. 5 (C), at moment t1, molten drop 1a contacts with mother metal 2 and enters short-circuit condition.Then,, as shown in Fig. 5 (D), because of the electromagnetic contractile force that the welding current Iw of molten drop 1a energising is caused, and produce necking down 1b on molten drop 1a top.The value of this electromagnetic contractile force and welding current Iw increases pro rata.Therefore, by increase of weld current Iw, and increase electromagnetic contractile force, promoted the formation of necking down 1b.Then, this necking down 1b develops rapidly, and at moment t3, as shown in Fig. 5 (E), molten drop 1a is from welding wire 1 to molten bath 2a transition, then produces electric arc 3.
If produce above-mentioned necking,, after the short time of hundreds of μ s left and right, short circuit is open, then produces electric arc 3., this necking is the open premonitory phenomenon of short circuit.If produce necking down 1b, the power-on circuit of welding current Iw narrows at necking section, so the resistance value of necking section increases.Along with the development of necking down, it is narrower that necking section becomes, and it is larger that the increase of this resistance value just becomes.Therefore, during short circuit, in Ts, by detecting the variation of the resistance value between welding wire 1 and mother metal 2, can detect generation and the development of necking.The variation of this resistance value can be calculated divided by welding current Iw by weldingvoltage Vw.In addition, compared with the variation of the welding current Iw in Ts during short circuit, the variation of the resistance value after necking down forms is larger.Therefore, also can replace the variation of resistance value, and detect the generation of necking by the variation of weldingvoltage Vw.As concrete necking down detection method, there is following method: calculate during short circuit the resistance value in Ts or the rate of change (differential value) of welding voltage value Vw, reached according to this differential value the method that predetermined this situation of necking down detection reference value Vtn is carried out necking down detection.In addition, as additive method, as shown in Fig. 5 (B), there is following method: the voltage rising value Δ V that calculates the stable short-circuit voltage value Vs before producing apart from the necking down in Ts during short circuit, at moment t2, reach according to this voltage rising value Δ V the method that predetermined this situation of necking down detection reference value Vtn is carried out necking down detection.In the following description, necking down detection method is the explanation of carrying out according to the situation of above-mentioned voltage rising value Δ V, but can be also the various additive methods that in the past proposed.Can differentiate more than weldingvoltage Vw becomes electric arc discriminant value Vta, thereby carry out simply the detection that the electric arc of moment t3 produces again.Wherein, during Vw < Vta, for Ts during short circuit, during Vw >=Vta, be arc period Ta.Below, the time producing again to electric arc is called to necking down Tn detection time after the necking down that detects moment t2～t3 produces.If produce electric arc at moment t3,, as shown in Fig. 5 (A), welding current Iw reduces reposefully again, and as shown in Fig. 5 (B), weldingvoltage Vw becomes the arc voltage value of 20～30V left and right.Therefore, above-mentioned electric arc discriminant value Vta is set to 10～15V left and right.In the arc period Ta of moment t3～t4, welding wire 1 front end melts and forms molten drop 1a.After, repeat the action during moment t1～t4.
During repeating above-mentioned short circuit in the sacrificial electrode arc welding of Ts and arc period Ta, have that Arcosarc welding connects, metal utmost point metal active gas arc welding connects, pole noble gas protection arc welding, with pulse electric arc welding of short circuit etc.Connect at Arcosarc welding, metal utmost point metal active gas arc welding connects and pole noble gas protection arc welding in the situation that; transfer manner of droplet; in the galvanic areas of not enough 200A left and right, being short circuiting transfer form, if current value greatly, is orbicule transitional form.In addition, the in the situation that of pulse electric arc welding, transfer manner of droplet is spray transfer form.Even if in these orbicule transitional forms and spray transfer form, because carrying out in the situations such as high-speed welding, electric arc length being set very shortly, so produce short circuit.Therefore,, for open this short circuit, as described above, form necking down 1b.
In the welding with above-mentioned short circuit, if current value I a is large current value when the electric arc in the time that moment t3 electric arc 3 produces again produces again, sharply increase to the arc force of molten bath 2a from electric arc 3, produce a large amount of sputters.When, sputter generation and electric arc produce again, the value of current value I a roughly increases pro rata.Therefore, in order to suppress the generation of sputter, current value I a need to reduce this electric arc and produce again time.As the method that reduces current value I a, the various sources of welding current that add Neckdown detection control method have been proposed all the time, that is: check the generation of above-mentioned necking, welding current Iw is reduced, thus current value I a when reducing electric arc and producing again.Below, the prior art (for example,, with reference to patent documentation 1) is described.
Fig. 6 is the block diagram that has carried the welder of the Neckdown detection control method of prior art.Source of welding current PS is the source of welding current that general sacrificial electrode arc welding is used, output weldingvoltage Vw and welding current Iw, and will output to feeding motor WM for the feeding control signal Fc that controls feeding motor WM rotation corresponding to feed speed setting signal Fr described later.Transistor T R series connection is inserted in output, and that be connected in parallel with it is reducing resister R.Welding wire 1, the rotation of the feed rolls 5 by the combination of feeding motor WM institute, carries out feeding through in welding torch (welding torch) 4, and mother metal 2 between produce electric arc 3.Feed speed initialization circuit FR, will output to source of welding current PS for the predetermined feed speed setting signal Fr that the feed speed of welding wire 1 is set.Welding wire 1, with the feed speed being specified by the feed speed setting signal Fr feeding of advancing.
Voltage detecting circuit VD, detects weldingvoltage Vw voltage sense signal Vd.Current detection circuit ID, detects welding current Iw output electric current measure signal Id.Necking down detection reference value initialization circuit VTN, exports predetermined necking down detection reference value signal Vtn.Necking down testing circuit ND, using this necking down detection reference value signal Vtn, above-mentioned voltage detection signal Vd and above-mentioned current detection signal Id as input, export following necking down detection signal Nd, that is: the voltage rising value Δ V in as mentioned above during short circuit has reached the moment of the value of necking down detection reference value signal Vtn, become High level, make the value of voltage detection signal Vd become the moment more than electric arc discriminant value Vta producing again electric arc, become the necking down detection signal Nd of Low level.Therefore, this necking down detection signal Nd becomes above-mentioned necking down Tn detection time during High level.As mentioned above, the differential value of the voltage detection signal Vd in also can be during short circuit has reached the moment of the value of necking down detection reference value signal Vtn, makes necking down detection signal Nd be changed to High level.In addition, also the value of voltage available detection signal Vd calculates the resistance value of molten drop divided by the value of current detection signal Id, and reached moment of the value of necking down detection reference value signal Vtn at the differential value of this resistance value, make necking down detection signal Nd be changed to High level.Drive circuit DR, in the time that this necking down detection signal Nd is Low level (when non-necking down detects), output makes the driving signal Dr that above-mentioned transistor T R is conducting state.Therefore, above-mentioned transistor T R, in the time that above-mentioned necking down detection signal Nd is High level, (when necking down detects) becomes cut-off state.
Fig. 7 is the time diagram of each signal of above-mentioned welder.Fig. 7 (A) illustrates that the time of welding current Iw changes, Fig. 7 (B) illustrates that the time of weldingvoltage Vw changes, Fig. 7 (C) illustrates the time variation of necking down detection signal Nd, and Fig. 7 (D) illustrates and drives the time of signal Dr to change.Below, describe with reference to Fig. 7.
In Fig. 7, beyond necking down Tn detection time of moment t2～t3 during, as shown in Fig. 7 (C), because necking down detection signal Nd is Low level, so as Fig. 7 (D) as shown in, driving signal Dr becomes High level.Consequently, transistor T R becomes conducting state, so become the identical action of welder of using with common sacrificial electrode arc welding.
At moment t2, as shown in Fig. 7 (B), if detect during short circuit in Ts that weldingvoltage Vw rises and more than voltage rising value Δ V become predetermined necking down detection reference value Vtn, produce necking down and differentiate for molten drop,, as shown in Fig. 7 (C), necking down detection signal Nd becomes High level.Correspondingly, as shown in Fig. 7 (D), because drive signal Dr to become Low level, so transistor T R becomes cut-off state.Consequently, reducing resister R is inserted in the power-on circuit of welding current Iw.The value of this reducing resister R, is set to 10 times of above large values (0.5～3 Ω left and right) of short circuit load (0.01～0.03 about Ω).For this reason, the energy of storing in the direct current reactance coil in the source of welding current and the reactance coil of cable is by deep discharge, and as shown in Fig. 7 (A), welding current Iw sharply reduces, and becomes little current value.Here, the output voltage of establishing source of welding current PS is 50V, and reducing resister R is 1 Ω, and this little current value is 50A.At moment t3, if electric arc is opened and produced in short circuit, as shown in Fig. 7 (B), more than weldingvoltage Vw becomes predetermined electric arc discriminant value Vta.It is detected, and as shown in Fig. 7 (C), necking down detection signal Nd becomes Low level, as shown in Fig. 7 (D), drives signal Dr to become High level.Consequently, transistor T R becomes conducting state, becomes the control of common sacrificial electrode arc welding.At moment t3, if produce electric arc, transistor T R becomes conducting state again, and, as shown in Fig. 7 (A), welding current Iw, after being increased to the high level of regulation, converges to the value being specified by feed speed.By this action, because current value I a when the electric arc of (moment t3) produces again can reduce electric arc and produce time, so can suppress the generation of sputter.In the time detecting necking down, as the method for quick minimizing welding current Iw, in above narration, the method that reducing resister R is inserted into power-on circuit is described.As method in addition, also have between the lead-out terminal of welder, via the switch element capacitor that is connected in parallel, if detect necking down, switch element is set to conducting state, from capacitor energization discharge current, reduce fast the method (for example,, with reference to patent documentation 2) of welding current Iw.
In above-mentioned Neckdown detection control method, for the inhibition of larger performance sputter generation, the generation that correctly detects necking down becomes very important.The generation of necking down and state of development thereof, change according to welding conditions such as the feed speed of the kind of the kind of protective gas, welding wire, welding point, welding wire, welding postures., be necessary according to welding condition the sensitivity that optimum detection necking down produces for this reason.The sensitivity that this necking down detects, can adjust by increasing and decreasing above-mentioned necking down detection reference value Vtn.That is, if necking down detection reference value Vtn is increased, sensitivity step-down, if make on the contrary necking down detection reference value Vtn reduce, sensitivity uprises.If Vtn is excessive for necking down detection reference value, sensitivity is just too low, and above-mentioned necking down Tn detection time just becomes too short, before electric arc produces again, can not reduce fully welding current, so the inhibition of sputter generation just diminishes.On the contrary, if necking down detection reference value Vtn is too small, sensitivity is just too high, and above-mentioned necking down Tn detection time just becomes long, because electric arc cannot produce again, so that welded condition becomes is unstable.Therefore, can say necking down Tn detection time stating and reach 50～1000 μ s left and right scope time, be exactly, that necking down detection reference value Vtn is configured in appropriate value.
As noted above, necking down detection reference value Vtn is set as appropriate value according to welding condition.But even if according to variables such as the deviations of the irregular movement in the variation of feed speed, molten bath, droplet shape, necking down detection reference value Vtn is optimized, necking down Tn detection time also can produce deviation.The scope of this deviation, as noted above, in the time of 50～1000 μ s left and right, the generation to sputter and the stability of welded condition can not brought too large harmful effect.In addition, even if necking down Tn detection time is less than 50 μ s once in a while, the problem that the degree of a small amount of sputter increasing neither be large.On the other hand, if necking down Tn detection time exceedes 1000 μ s, more than particularly becoming 2000 μ s, welded condition just becomes unstable, and the state that electric arc cannot produce again even occurs., reached while also not producing electric arc again fiducial time in the elapsed time that certainly detects the necking down moment, usual is that compensation is controlled for this reason, and it strengthens electromagnetic contractile force by increasing welding current Iw, promotes the development of necking down, the producing again of pilot arc.Below, this compensation control (for example,, with reference to patent documentation 3) is described.
Fig. 8 is the time diagram for compensation being controlled to the each signal corresponding with above-mentioned Fig. 7 describing.Fig. 8 (A) illustrates that the time of welding current Iw changes, Fig. 8 (B) illustrates that the time of weldingvoltage Vw changes, Fig. 8 (C) illustrates the time variation of necking down detection signal Nd, and Fig. 8 (D) illustrates and drives the time of signal Dr to change.In Fig. 8, the action during moment t21～t3, all the other are all identical with Fig. 7, therefore omit the explanation of these same sections.Below, with reference to Fig. 8, the action during moment t21～t3 is described.
The elapsed time t that detects the moment from the necking down of moment t2 has reached fiducial time when Tt in moment t21, as shown in Fig. 8 (B), because the not enough electric arc discriminant value of weldingvoltage Vw Vta, so electric arc does not also produce again.Therefore,, as shown in Fig. 8 (D), make to drive signal Dr to be changed to High level.If drive signal Dr to become High level, the transistor T R of Fig. 6 becomes conducting state, so as shown in Fig. 8 (A), welding current Iw increases and become setting.If it is large that welding current Iw becomes, electromagnetic contractile force also becomes greatly, so promoted the development of necking down, at moment t3, then produces electric arc.At moment t3, if electric arc produces again,, as shown in Fig. 8 (B), weldingvoltage Vw becomes arc voltage value more than electric arc discriminant value Vta, and as shown in Fig. 8 (A), welding current Iw steadily reduces after that, converges on stationary value.As shown in Fig. 8 (C), necking down detection signal Nd, it is all High level that the electric arc that detects moment to moment t3 from the necking down of moment t2 produces again.As shown in Fig. 8 (D), drive signal Dr, from moment t21, become High level.Above-mentioned Tt fiducial time is set to 1000 μ s left and right.
Patent documentation 1: TOHKEMY 2006-281219 communique
Patent documentation 2: TOHKEMY 2005-288540 communique
Patent documentation 3: TOHKEMY 2006-116585 communique
As described above, reach while also not producing electric arc again fiducial time detecting elapsed time in moment from necking down, prevented that by increasing welding current welded condition from becoming unstable.But if carry out such compensation control,, as shown in Fig. 8 (A), the current value in the time that moment t3 electric arc produces again becomes large value, so can produce the sputter of large grain.In addition, because (during moment t2～t21) is longer during electric current is reduced, the temperature of molten bath and molten drop declines, so even if increase electric current, the generation again of electric arc can not be carried out, and can produce the situation of welding bead degraded appearance unobstructedly.
Summary of the invention
Therefore, the object of the invention is to, provide a kind of and reached while also not producing electric arc again fiducial time detecting elapsed time in moment from necking down, can not increase the generation of sputter and the Neckdown detection control method that carries out the sacrificial electrode arc welding that electric arc produces again unobstructedly.
In order to solve above-mentioned problem, the invention of technical scheme 1 is a kind of Neckdown detection control method of sacrificial electrode arc welding, it is characterized in that, advanced feeding welding wire and repeating in sacrificial electrode arc welding that electric arc produces state and short-circuit condition between welding wire and mother metal by welding torch, reach necking down detection reference value by the variation of the magnitude of voltage between welding wire and mother metal or resistance value and detected the premonitory phenomenon that produces again electric arc from short-circuit condition, it is the necking down of molten drop, from detecting the moment, this necking down with the state that reduces the welding current to short circuit load energising, electric arc is produced again, if producing again, electric arc increases welding current, in the time that the elapsed time of detecting the moment from described necking down had reached predetermined fiducial time before producing electric arc again, produce again electric arc by making welding wire retreat mobile away from mother metal, if electric arc produces described in stopping again and retreats movement.
The invention of technical scheme 2 is according to the Neckdown detection control method of the sacrificial electrode arc welding described in technical scheme 1, it is characterized in that, make described welding current increase and described in retreat the mobile moment that stops producing again from described electric arc and only postpone predetermined time delay.
The invention of technical scheme 3 is according to the Neckdown detection control method of the sacrificial electrode arc welding described in technical scheme 1～2 any one, it is characterized in that, describedly retreat the mobile feeding that retreats that refers to welding wire, described in retreat mobile stopping refer to retreat feeding described in stopping and turning back to described in the feeding of advancing.
The invention of technical scheme 4 is according to the Neckdown detection control method of the sacrificial electrode arc welding described in technical scheme 1～2 any one, it is characterized in that, described to retreat movement be to instigate described welding torch to retreat the mobile torch height that increases, and makes described welding torch advance mobile and described torch height is turned back to original height described after retreating mobile stopping.
According to the present invention, in the time that the elapsed time of detecting the moment from necking down had reached fiducial time before electric arc produces again, produce again electric arc by making welding wire retreat mobile away from mother metal.Accordingly, because can keep little current value state, produce again reliably electric arc, so can not increase the generation of sputter, carry out producing again of electric arc unobstructedly.
Brief description of the drawings
Fig. 1 is the block diagram of the welder of the Neckdown detection control method for implementing the related sacrificial electrode arc welding of embodiments of the present invention 1.
Fig. 2 is the time diagram of the each signal in the welder of Fig. 1.
Fig. 3 is the block diagram of the welder of the Neckdown detection control method for implementing the related sacrificial electrode arc welding of embodiments of the present invention 2.
Fig. 4 is the time diagram of the each signal in the welder of Fig. 3.
Fig. 5 represents in the prior art, the current-voltage waveform during repetition short circuit in the sacrificial electrode arc welding of Ts and arc period Ta and the figure of droplet transfer.
Fig. 6 is the block diagram that has carried the welder of the Neckdown detection control method of prior art.
Fig. 7 is the time diagram of the each signal in the welder of Fig. 6.
Fig. 8 is the time diagram of the each signal corresponding with above-mentioned Fig. 7 for compensation control of the prior art is described.
1-welding wire; 1a-molten drop; 1b-necking down; 2-mother metal; 2a-molten bath; 3-electric arc; 4-welding torch; 5-feed rolls; DR-drive circuit; Dr-drives signal; DR2-the 2nd drive circuit; Fc-feeding control signal; Advance feed speed setting value of Ffr-; Advance feed speed setting value of Ffr2-the 2nd; FR-feed speed initialization circuit; Fr-feed speed setting signal; FR2-the 2nd feed speed initialization circuit; FR3-the 3rd feed speed initialization circuit; Frr-retreats feed speed setting value; Current value when Ia-electric arc produces again; ID-current detection circuit; Id-current detection signal; Iw-welding current; LT-torch height (power supply tip front end and mother metal spacing); Lt0-altitude datum; ND-necking down testing circuit; Nd-necking down detection signal; NDD-delay circuit; Ndd-necking down detects inhibit signal; The PS-source of welding current; R-reducing resister; RC-retreats mobile control circuit; Rc-retreats mobile control signal; RC2-the 2nd retreats mobile control circuit; RCE-robot (robot) control device; RM-robot body; The t-elapsed time; Ta-arc period; Td-time delay; Tn-necking down detection time; TR-transistor; During Ts-short circuit; Tt-fiducial time; VD-voltage detecting circuit; Vd-voltage detection signal; Vs-short-circuit voltage value; Vta-electric arc discriminant value; VTN-necking down detection reference value initialization circuit; Vtn-necking down detection reference value (signal); Vw-weldingvoltage; WM-feeding motor; Δ V-voltage rising value.
Detailed description of the invention
Below, with reference to accompanying drawing, embodiments of the present invention are described.
Embodiment 1
The related invention of embodiment 1 is, before producing again, electric arc reaches predetermined fiducial time when Tt detecting the elapsed time t in moment from necking down, it is mobile and away from mother metal by welding wire is retreated, keep the state of little current value to produce again electric arc, stop the aforementioned movement that retreats if produce again electric arc.In embodiment 1, carry out the movement that retreats of above-mentioned welding wire by retreating feeding.Therefore, above-mentioned what is called retreats mobile stopping, and refers to and stops the meaning that retreats feeding and turn back to the common feeding of advancing.Below, this embodiment 1 is described.
Fig. 1 is the block diagram of the welder of the Neckdown detection control method for implementing the related sacrificial electrode arc welding of embodiments of the present invention 1.In Fig. 1, to picture frame mark identical meet identical with above-mentioned Fig. 6, and the explanation of omitting these same sections.Fig. 1, append the delay circuit NDD being shown in dotted line, the drive circuit DR of Fig. 6 is replaced as to the 2nd drive circuit DR2 being shown in dotted line, append the mobile control circuit RC that retreats being shown in dotted line, the feed speed initialization circuit FR of Fig. 6 has been replaced as to the 2nd feed speed initialization circuit FR2 being shown in dotted line.Below, with reference to Fig. 1, these picture frame contents are described.
Delay circuit NDD, using necking down detection signal Nd as input, output make this signal only with predetermined time delay Td turn-off delay necking down detect inhibit signal Ndd.This necking down detects inhibit signal Ndd becomes High level in the necking down detection moment, becomes the signal of Low level in the moment that has only postponed Td time delay from producing again the moment of electric arc.The 2nd drive circuit DR2, this necking down is detected to inhibit signal Ndd as input, in the time that this signal is High level (between necking down detection period), stopping driving signal Dr and making transistor T R is cut-off state, in the time being Low level (between non-necking down detection period), output drive signal Dr to make transistor T R be conducting state.
Retreat mobile control circuit RC, above-mentioned necking down detection signal Nd and above-mentioned necking down are detected to inhibit signal Ndd as input, the moment of having passed through predetermined fiducial time of Tt in the moment that has become High level (between necking down detection period) from necking down detection signal Nd is during still for High level, to retreat mobile control signal Rc set is High level, in the moment that is changed to Low level at necking down detection inhibit signal Ndd, will retreat mobile control signal Rc and be reset to Low level.Therefore, this retreats mobile control signal Rc, has reached while also not producing electric arc again when Tt fiducial time detecting elapsed time in moment from necking down, becomes High level, only postpone the moment of Td time delay in the moment from having produced again electric arc, become the signal of Low level.The 2nd feed speed initialization circuit FR2, this is retreated to mobile control signal Rc as input, in the time that this signal is Low level, using predetermined on the occasion of the feed speed setting value Ffr that advances export as feed speed setting signal Fr, in the time being High level, the feed speed setting value Frr that retreats of predetermined negative value is exported as feed speed setting signal Fr.Source of welding current PS, using feed speed setting signal Fr as input, in the time that the value of this signal sets value Ffr for the feed speed of advancing, output is for the feeding control signal Fc of the feeding welding wire 1 that advances, when retreating feed speed setting value Frr, output is for retreating the feeding control signal Fc of feeding welding wire 1.
Fig. 2 is the time diagram of each signal of welder described in Fig. 1.Fig. 2 (A) illustrates that the time of welding current Iw changes, Fig. 2 (B) illustrates that the time of weldingvoltage Vw changes, Fig. 2 (C) illustrates that the time of necking down detection signal Nd changes, Fig. 2 (D) illustrates and drives the time of signal Dr to change, Fig. 2 (E) illustrates that necking down detects the time variation of inhibit signal Ndd, Fig. 2 (F) illustrates the time variation that retreats mobile control signal Rc, and Fig. 2 (G) illustrates that the time of feed speed setting signal Fr changes.Fig. 2 represents that detecting elapsed time in moment from necking down has reached fiducial time Tt and also do not produce the time diagram in the situation of electric arc again.Fig. 2 is corresponding with above-mentioned Fig. 7 and Fig. 8, the action difference during moment t21～t31.Action except is during this period identical, so description thereof is omitted.Below, with reference to Fig. 2, to describing during difference action.
At moment t2, if detect necking down,, as shown in Fig. 2 (C), necking down detection signal Nd is changed to High level, and correspondingly, as shown in Fig. 2 (E), necking down detects inhibit signal Ndd and is also changed to High level.If this necking down detects inhibit signal Ndd and is changed to High level,, as shown in Fig. 2 (D), drive signal Dr to be changed to Low level, so transistor T R becomes cut-off state, reducing resister R is inserted in power-on circuit.Therefore, as shown in Fig. 2 (A), welding current Iw reduces, and becomes little current value (10～100A left and right).The detection method of necking down is identical with above-mentioned prior art.In addition, the value of reducing resister R is also identical with above-mentioned prior art.
As shown in Fig. 2 (C), elapsed time the moment that is changed to High level from necking down detection signal Nd (necking down detect moment) reaches the moment t21 of Tt fiducial time, as shown in Fig. 2 (F), retreat mobile control signal Rc and become High level.Correspondingly, as shown in Fig. 2 (G), feed speed setting signal Fr, from predetermined on the occasion of the feed speed setting value Ffr that advances switch to predetermined negative value retreat feed speed setting value Frr, welding wire is along retreating feeding away from the direction of mother metal.At moment t3, if because this retreats feeding, welding wire, away from mother metal, produces electric arc again.If produce electric arc,, as shown in Fig. 2 (B), weldingvoltage Vw sharply rises to arc voltage value more than electric arc discriminant value Vta again.The value of welding current Iw when the electric arc of moment t3 produces again, as shown in Fig. 2 (A), is keeping little current value, so the generation of sputter is little.In addition, make welding wire front end produce electric arc away from mother metal owing to retreating feeding, produce again so can realize stable electric arc.
As shown in Fig. 2 (B), at moment t3, become electric arc discriminant value Vta above and determined producing again of electric arc if determine the value of weldingvoltage Vw,, as shown in Fig. 2 (C), necking down detection signal Nd is changed to Low level.And, as shown in Fig. 2 (E), necking down detect inhibit signal Ndd from moment t3 only turn-off delay Td time delay, become Low level at moment t31.Correspondingly, at moment t31, as shown in Fig. 2 (D), drive signal Dr to be changed to High level, so transistor T R becomes conducting state, reducing resister R is by short circuit.Correspondingly, as shown in Fig. 2 (A), welding current Iw is increased to high level.Meanwhile, at moment t31, as shown in Fig. 2 (F), retreat mobile control signal Rc and become Low level, so as shown in Fig. 2 (G), feed speed setting signal Fr, from negative value retreat feed speed setting value Frr switch on the occasion of the feed speed setting value Ffr that advances.Consequently, welding wire is according to the feeding of conventionally advancing like that.
Above-mentioned action is arranged as follows.As shown in Fig. 2 (A), welding current Iw detects moment minimizing since the necking down of moment t2, produces electric arc again until passed through the state that the moment of Td time delay maintains little current value always at moment t3.As shown in Fig. 2 (G), the elapsed time that welding wire detects the moment in necking down from moment t2 reaches the moment t21 of Tt fiducial time, switches to and retreats feeding, through the moment t31 after time delay Td, turns back to the feeding of advancing.
Said reference time T t is set to 500～1500 μ s left and right.Fiducial time, Tt, according to kind of the kind of the mean value of welding current, protective gas, welding wire etc., was configured to appropriate value by experiment.This is because according to welding condition, cause being carved into the deviation difference of the time that electric arc produces again in the time that necking down detects.Deviation larger fiducial time of Tt will be set as larger value.Time delay, Td was set at 0～2000 μ s left and right.Td=0 refers to the situation that does not produce delay.In embodiment 1, Td time delay can be set as to 0.The reasons are as follows of this time delay of Td is set., because electric arc produces again, electric arc is long afterwards becomes very short at once, so the feeding vibration of the vibration in molten bath, welding wire etc. can cause producing short circuit again.If produce short circuit again, can produce sputter, it is unstable that welded condition also becomes.Therefore, after electric arc produces again, also to maintain and retreat feeding, by welding current being maintained to little current value, prevent the generation of short circuit again.This time delay, Td, according to the mean value of welding current, welding point, speed of welding etc., was configured to appropriate value by experiment.This is because according to welding condition, produce the difficulty difference of short circuit again.The feed speed of advancing setting value Ffr, identical with general sacrificial electrode arc welding, be to be configured to appropriate value according to the thickness of slab of mother metal, welding point, speed of welding etc.Its setting range is 2～20m/min left and right.Retreat feed speed setting value Frr, for making as far as possible promptly to produce again electric arc after retreating feeding and starting, and be set as about 30～50m/min.In addition, in order to accelerate from the draw back switching of feeding and from retreating the march forward switching of feeding of feeding of the feeding of advancing, feeding motor WM preferably uses the servomotor that indicial response is good etc.In addition because the length from feeding motor WM to welding torch front end more short transition time response is better, so below 2m better, preferably below 1m.
In embodiment 1, reach in the elapsed time of detecting the moment from necking down produce electric arc fiducial time again time diagram under normal circumstances before Tt, above-mentioned Fig. 7 is identical for fundamental sum., do not carry out the retreating feeding of welding wire and be only fixed the feeding of advancing of speed.Wherein, the moment that welding current Iw starts to increase is through after time delay Td.
According to above-mentioned embodiment 1, detecting elapsed time in moment from necking down reached fiducial time before electric arc produces again time, mobile and away from mother metal by welding wire is retreated, then produce electric arc.Accordingly, keep can producing again reliably electric arc under little current value state, so can not increase the generation of sputter, carry out producing again of electric arc unobstructedly.In addition, welding wire retreat feeding, only reached in fiducial time and just carried out in the elapsed time of detecting the moment from necking down, so retreat the number of times of feeding, to account for the frequency of short circuit number of times lower.Therefore, force superfluous load can to feeding motor, so just improved the reliability of feeding motor yet.
Embodiment 2
The invention that embodiment 2 is related, identical with embodiment 1, before producing electric arc again, reach predetermined fiducial time when Tt detecting the elapsed time t in moment from necking down, it is mobile and away from mother metal by welding wire is retreated, keep the state of little current value to produce again electric arc, stopping the aforementioned movement that retreats if produce again electric arc.In embodiment 2, make welding torch retreat movement by retreating of above-mentioned welding wire is mobile, torch height Lt is increased.Then, retreating after mobile stopping, making the welding torch movement of advancing, torch height Lt is being turned back to original height.During retreating movement, the feeding of advancing of welding wire still continues.Below, this embodiment 2 is described.
Fig. 3 is the block diagram of the welder of the Neckdown detection control method for implementing the related sacrificial electrode arc welding of embodiments of the present invention 2.In Fig. 3, the picture frame identical with above-mentioned Fig. 6 and Fig. 1 marked to identical symbol, and omit the explanation of these same sections.Fig. 3 compared to Figure 1, the robot controller RCE and the robot body RM that are shown in dotted line are appended, by mobile retreating of Fig. 1 control circuit RC be replaced as be shown in dotted line the 2nd retreat mobile control circuit RC2, the 2nd feed speed initialization circuit FR2 of Fig. 1 is replaced as to the 3rd feed speed initialization circuit FR3 displacement being shown in dotted line.Below, with reference to Fig. 3, these picture frame contents are described.
The 2nd retreats mobile control circuit RC2, necking down detection signal Nd and necking down are detected to inhibit signal Ndd as input, the moment of having passed through predetermined fiducial time of Tt in the moment that has become High level (between necking down detection period) from necking down detection signal Nd is during still for High level, to retreat mobile control signal Rc set is High level, be changed to the moment of Low level at necking down detection inhibit signal Ndd, to retreat mobile control signal Rc and be reset to Low level, this is retreated to mobile control signal Rc and outputs to the 3rd feed speed initialization circuit FR3 and robot controller RCE.Therefore, this retreats mobile control signal Rc, has reached while also not producing electric arc again when Tt fiducial time detecting elapsed time in moment from necking down, becomes High level, only postpone the moment of Td time delay in the moment from having produced again electric arc, become the signal of Low level.The 3rd feed speed initialization circuit FR3, this is retreated to mobile control signal Rc as input, in the time that this signal is Low level, using predetermined on the occasion of the feed speed setting value Ffr that advances export as feed speed setting signal Fr, in the time being High level, the 2nd of predetermined more than 0 value the feed speed setting value Ffr2 that advances is exported as feed speed setting signal Fr.Here, 0≤Ffr2≤Ffr., the 2nd feed speed setting value Ffr2, the advance identical value of feed speed setting value Ffr or than its little value of the feed speed while being set to stable welding.Source of welding current PS, using feed speed setting signal Fr as input, in the time that the value of this signal sets value Ffr for the feed speed of advancing, output is for making welding wire 1 to be equivalent to the advance feeding control signal Fc of feeding of the feed speed of this value, being the 2nd while advancing feed speed setting value Ffr2, output is for making welding wire 1 to be equivalent to the feed speed of this value feeding feeding control signal Fc of (comprising that feeding stops) that advances.
Robot controller RCE, retreats mobile control signal Rc as input using above-mentioned, by for making the action control signal Mc that the welding torch 4 that is installed on robot body RM moves according to the operation procedure of one-tenth prepared in advance output to robot body RM.In common welding, the distance between power supply tip front end and mother metal 2 (following, to be called torch height Lt) is maintained predetermined altitude datum Lt0 by welding torch 4 always, moves along sealing wire with predetermined speed of welding.But, in the present embodiment, welding torch 4 moves along sealing wire, if the above-mentioned mobile control signal Rc that retreats is changed to High level, the direction that welding torch 4 uprises along torch height Lt simultaneously retreats movement, if be changed to Low level, welding torch 4 advances and moves and revert to above-mentioned altitude datum Lt0 along the direction of torch height Lt step-down simultaneously.In Fig. 4, the detailed process of this action is described in detail.Have advancing angle or receding angle in the posture of welding torch 4, torch height Lt is along its height of welding wire feeding direction detection.Robot body RM is joint type manipulator, drives installed multiple servomotors by above-mentioned action control signal Mc.On robot body RM, carrying the feed arrangement and the welding torch 4 that comprise feeding motor WM.
Fig. 4 is the time diagram of each signal of the welder described in Fig. 3.Fig. 4 (A) illustrates that the time of welding current Iw changes, Fig. 4 (B) illustrates that the time of weldingvoltage Vw changes, Fig. 4 (C) illustrates that the time of necking down detection signal Nd changes, Fig. 4 (D) illustrates and drives the time of signal Dr to change, Fig. 4 (E) illustrates that necking down detects the time variation of inhibit signal Ndd, Fig. 4 (F) illustrates that the time that retreats mobile control signal Rc changes, Fig. 4 (G) illustrates the time variation of feed speed setting signal Fr, and Fig. 4 (H) illustrates that the time of torch height Lt changes.Fig. 4 detects elapsed time in moment from necking down to have reached fiducial time Tt and also do not produce the time diagram in the situation of electric arc again.Fig. 4 is corresponding with above-mentioned Fig. 1, appends the torch height Lt of Fig. 4 (H).Fig. 4 and Fig. 1 compare, the action difference during moment t21～t32.Because the action during except is during this period identical, so omit the explanation during identical.Below, with reference to Fig. 4, to describing during difference action.
At moment t2, if detect necking down,, as shown in Fig. 4 (C), necking down detection signal Nd is changed to High level, and correspondingly, as shown in Fig. 4 (E), necking down detects inhibit signal Ndd and is also changed to High level.If this necking down detects inhibit signal Ndd and is changed to High level,, as shown in Fig. 4 (D), drive signal Dr to be changed to Low level, so transistor T R becomes cut-off state, reducing resister R is inserted in power-on circuit.Therefore, as shown in Fig. 4 (A), welding current Iw reduces, and becomes little current value (10～100A left and right).The detection method of necking down is identical with above-mentioned prior art.In addition, the value of reducing resister R is also identical with above-mentioned prior art.
As shown in Fig. 4 (C), elapsed time the moment that is changed to High level from necking down detection signal Nd (necking down detect moment) reaches the moment t21 of Tt fiducial time, as shown in Fig. 4 (F), retreat mobile control signal Rc and become High level.Correspondingly, as shown in Fig. 4 (G), feed speed setting signal Fr, from predetermined on the occasion of the feed speed setting value Ffr that advances switch to predetermined on the occasion of the 2nd feed speed setting value Ffr2 that advances, the welding wire feeding (comprising that feeding stops) of proceeding to advance.Because what represent in Fig. 4 is the situation of Ffr2 < Ffr, the feed speed of the feeding of advancing of welding wire is slowed down.Meanwhile, at moment t21, robot controller RCE has started the movement that retreats of welding torch, so as shown in Fig. 4 (H), torch height Lt uprises gradually from the altitude datum Lt0 before that.Making welding torch retreat mobile speed here, is set sooner than the above-mentioned the 2nd feed speed setting value Ffr2 that advances.Like this, welding wire front end retreats movement.
At moment t3, if make welding wire away from mother metal by retreating of above-mentioned welding torch is mobile, electric arc produces again.If produce electric arc,, as shown in Fig. 4 (B), weldingvoltage Vw sharply rises to arc voltage value more than electric arc discriminant value Vta again.The value of welding current Iw when the electric arc of moment t3 produces again, as shown in Fig. 4 (A), is keeping the state of little current value, so sputter produces less.In addition, because make welding wire front end produce electric arc away from mother metal by retreating of welding torch is mobile, produce again so can realize stable electric arc.
As shown in Fig. 4 (B), at moment t3, become electric arc discriminant value Vta above and determined producing again of electric arc if determine the value of weldingvoltage Vw,, as shown in Fig. 4 (C), necking down detection signal Nd is changed to Low level.And, as shown in Fig. 4 (E), necking down detect inhibit signal Ndd from moment t3 only turn-off delay Td time delay, become Low level at moment t31.Correspondingly, at moment t31, as shown in Fig. 4 (D), drive signal Dr to be changed to High level, so transistor T R becomes conducting state, reducing resister R is by short circuit.Correspondingly, as shown in Fig. 4 (A), welding current Iw is increased to high level.Simultaneously, at moment t31, as shown in Fig. 4 (F), retreat mobile control signal Rc and become Low level, so as shown in Fig. 4 (G), feed speed setting signal Fr, from the occasion of the 2nd advance feed speed setting value Ffr2 switch on the occasion of the feed speed setting value Ffr that advances.Consequently, welding wire is to fix feed speed (feed speed of the advancing setting value Ffr) feeding of advancing.Meanwhile, at moment t31, robot controller RCE starts the movement of advancing of welding torch, so as shown in Fig. 4 (H), torch height Lt step-down gradually.Then, as shown in Fig. 4 (H), return to the moment (moment t32) of above-mentioned altitude datum Lt0 at torch height Lt, mobile the stopping that advancing of welding torch.Wherein, as noted above, welding torch moves along sealing wire, and retreating of welding torch moved or advance mobile irrelevant.The advancing mobile and retreat and mobilely carry out for lifting in welding wire feeding direction of welding torch.
Above-mentioned action is arranged as follows.As shown in Fig. 4 (A), welding current Iw detects moment minimizing since the necking down of moment t2, produces electric arc again until passed through the state that the moment of Td time delay maintains little current value always at moment t3.As shown in Fig. 4 (G), welding wire reaches the moment t21 of Tt fiducial time in the elapsed time in the necking down detection moment from moment t2, switch to the 2nd feed speed of advancing, through the moment t31 after time delay Td, turn back to the feed speed of advancing (fixing feed speed).As shown in Fig. 4 (H), torch height Lt, the elapsed time of detecting the moment in necking down from moment t2 reaches the moment t21 of Tt fiducial time, start to retreat movement, through the moment t31 after time delay Td, start the movement of advancing, at moment t32, turn back to altitude datum Lt0.
Above-mentioned Tt fiducial time, time delay, the establishing method of Td and the feed speed of advancing setting value Ffr was identical with embodiment 1.Welding torch retreat mobile speed, for shortening the time of moment t21～t3 and promptly producing again electric arc, within the scope of 30～70m/min left and right, be configured to by experiment appropriate value.(welding wire front end retreat mobile speed)=(welding torch retreat mobile speed)-(the 2nd advance feed speed).Therefore, at the feed speed setting value Ffr that advances during for large value, by the 2nd feed speed of advancing is set value to Ffr2 and is set as the value less than Ffr, thereby can accelerate the mobile speed of retreating of welding wire front end and promptly produce again electric arc.The 2nd feed speed setting value Ffr2 that advances sets within the scope of 0≤Ffr2≤Ffr.That is, the 2nd feed speed setting value Ffr2 that advances, if be set to 0 feed-disabling, if be set to the value identical with Ffr in welding with the definite value feeding of the feed speed setting value Ffr that advances.The mobile speed of advancing of welding torch is configured to by experiment appropriate value within the scope of 1～5m/min left and right.(the mobile speed of advancing of welding wire front end)=(feed speed of advancing)+(the mobile speed of advancing of welding torch).Therefore, if the mobile speed of advancing of welding torch is very fast, can cause the mobile excessive velocities of advancing of welding wire front end, it is unstable that conditions at the arc become.Determining of the mobile speed of advancing of welding torch, makes to shorten the time of moment t31～t32 and promptly converges to stable state and can avoid again conditions at the arc to become unstable.
In embodiment 2, reach in the elapsed time of detecting the moment from necking down produce electric arc fiducial time again time diagram generally before Tt, substantially identical with above-mentioned Fig. 7.That is, welding wire is not switched to the 2nd feed speed, and is only fixed the feeding of advancing of speed.Do not carry out mobile and the movement of advancing of retreating of welding torch yet.Wherein, the moment that welding current Iw starts to increase is after having passed through Td time delay.
According to above-mentioned embodiment 2, by the mobile movement that retreats of carrying out welding wire of retreating of welding torch, can reach the effect identical with embodiment 1.Because the movement that retreats of welding torch is undertaken by robot, so there is no need to use the good feeding motor of indicial response as Embodiment 1, reduce cost.And, because there is no need to shorten as Embodiment 1 the length of welding torch, improve operability.
Claims (4)
1. the Neckdown detection control method of a sacrificial electrode arc welding, it is characterized in that, advanced feeding welding wire and repeating in sacrificial electrode arc welding that electric arc produces state and short-circuit condition between welding wire and mother metal by welding torch, having reached necking down detection reference value by the variation of the magnitude of voltage between welding wire and mother metal or resistance value, to detect the premonitory phenomenon that produces again electric arc from short-circuit condition be the necking down of molten drop, from detecting the moment, this necking down with the state that reduces the welding current to short circuit load energising, electric arc is produced again, if producing again, electric arc increases welding current
Before producing electric arc again, in the time that the elapsed time of detecting the moment from described necking down has reached predetermined fiducial time, produce again electric arc by making welding wire retreat mobile away from mother metal, if producing described in stopping again, electric arc retreats movement.
2. the Neckdown detection control method of sacrificial electrode arc welding according to claim 1, is characterized in that,
Make described welding current increase and described in retreat the mobile moment that stops producing again from described electric arc and only postpone predetermined time delay.
3. according to the Neckdown detection control method of the sacrificial electrode arc welding described in claim 1～2 any one, it is characterized in that,
Describedly retreat the mobile feeding that retreats that refers to welding wire, described in retreat mobile stopping refer to retreat feeding described in stopping and turning back to described in the feeding of advancing.
4. according to the Neckdown detection control method of the sacrificial electrode arc welding described in claim 1～2 any one, it is characterized in that,
Described to retreat movement be to instigate described welding torch to retreat the mobile torch height that increases, and makes described welding torch advance mobile and described torch height is turned back to original height described after retreating mobile stopping.
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| JP6154672B2 (en) * | 2013-06-13 | 2017-06-28 | 株式会社ダイヘン | Necking detection control method for welding power source |
| JP6555825B2 (en) * | 2014-05-19 | 2019-08-07 | 株式会社ダイヘン | Arc welding control method |
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