CN102601492A - Arc-welding molten drop necking formation detection method and control method after necking formation - Google Patents
Arc-welding molten drop necking formation detection method and control method after necking formation Download PDFInfo
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- CN102601492A CN102601492A CN2012100535905A CN201210053590A CN102601492A CN 102601492 A CN102601492 A CN 102601492A CN 2012100535905 A CN2012100535905 A CN 2012100535905A CN 201210053590 A CN201210053590 A CN 201210053590A CN 102601492 A CN102601492 A CN 102601492A
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Abstract
The invention discloses an arc-welding molten drop necking formation detection method and a control method after necking formation. The instantaneous power of welding and the variation rate of the instantaneous power of the welding are calculated through the real-time detection for welding current and welding voltage, and the necking is formed when the variation rate of the instantaneous power is more than a certain critical value. After the necking formation, the output instantaneous power is controlled to be the some critical value, so as to control the energy when in electric exploding. The arc-welding molten drop necking formation detection method has predictability and compensates the time delay of a detection circuit, so that a welding system can perform the timely action in the aspect of control, so as to avoid the violent electric exploding; meanwhile, due to the factor of the current, the erroneous judgment caused by the over-fast rising rate of the current can be avoided.
Description
[technical field]
The present invention relates to consumable electrode gas shield welding, relate in particular to the control method after a kind of arc welding molten drop necking down generation detection method and molten drop necking down take place.
[background technology]
Shown in Figure 1 is gas metal-arc welding electric current, voltage and sketch map of droplet transfer when the droplet transfer being in the short circuiting transfer state when connecing.Wherein Ts representes the arc short circuit time, and Ta representes the electric arc arc time, and Iw representes the instantaneous value of welding current, and Vw representes the instantaneous value of weldingvoltage, and Pw representes the bonding power instantaneous value, interior molten drop form of cycle droplet transfer of Fig. 1 (b) expression.Describe with reference to Fig. 1 below.
Be the short circuiting transfer period of molten drop between the t1-t4 constantly, shown in Fig. 1 (b), molten drop 2 forms and beginning contact workpiece 4 in the end of welding wire 1 gradually.The t1 that weldingvoltage Vw begins in short circuit reduces rapidly constantly and remains on lower value.During short circuit, welding current Iw at first is controlled so as to and remains unchanged, to guarantee wetting between molten drop 2 and the workpiece 4.After after a while, welding current Iw begins to rise gradually to form electromagnetic contractile force and electric arc thrust, promotes molten drop necking down 2a to form gradually, and to workpiece 4 quick transition.At t3 constantly, molten drop necking down 2b forms gradually, and quick-fried disconnected until t4 necking down constantly, molten drop 2 breaks away from the end of welding wire 1 fully, and electric arc 3 forms again.
Above-mentioned necking down formation time is very short; Arrive between the hundreds of microsecond about tens microseconds greatly; Welding current Iw is because the existence of true inductance or electronic inductance; Can not undergo mutation and maintain bigger value,, prevent that molten drop 2 transition direction under other external force effect from deflecting to keep bigger electromagnetic push.Narrow gradually owing to bottleneck current path cross section simultaneously, be accumulated in the energy moment increase of bottleneck, because of overheated or gasification quick-fried breaking taken place until bottleneck, this phenomenon is the one of the main reasons of generation spatter phenomenon.
Prior art forms through the necking down of judgement during the droplet transfer, distinguishes the droplet transfer process and comes back to the arcing state from short-circuit condition, and switch the control mode of welding system whereby, to obtain better welding quality.Because the control object when electric current is short circuiting transfer, therefore existing method mainly judge that through detecting voltage necking down forms.Necking down is when forming gradually, and the cross-sectional area of current path reduces gradually, causes current path resistance to increase.Because the utmost point that forms in necking down is in the short time, electric current changes less, so the increase of current path resistance promptly shows as the increase of weldingvoltage instantaneous value Vw, and until the necking down fracture, electrode drop and arc space form again.Simply judge whether weldingvoltage instantaneous value Vw can judge that greater than certain critical voltage value the droplet transfer process comes back to the arcing state from short-circuit condition.The another kind of method of judging that necking down forms is to calculate the rate of change of weldingvoltage Vw through hardware detecting circuit or microprocessor; Think that necking down forms when the rate of change of Vw during greater than a certain critical value, the droplet transfer process begins to switch to the arcing state from short-circuit condition.Compare with preceding method,, therefore increased the foresight that necking down is judged, can control the probability that electric current splashes and takes place with reduction in advance owing to added the differentiation element of voltage detecting.
Since in the detection loop of weldingvoltage Vw, added for filtering from welding system inside and the filter circuit of welding system external disturbance with the acquisition smooth waveform; Thereby inevitably introduced bigger time-delay; Therefore use above-mentioned first method to judge that necking down forms; When judging that weldingvoltage Vw is higher than a certain critical value and switches the welding system control method in view of the above, necking down discharge-induced explosion and forming is splashed more greatly.
Above-mentioned second method is judged the rate of change of weldingvoltage Vw through adding differentiation element, anticipation the generation of necking down; Compensated and detected the influence that time-delay brings; And according to this welding current is controlled, reduced the probability of discharge-induced explosion during the necking down, reduced and splashed.But the method has been ignored the influence of welding current Iw.In molten drop short circuit process; In order to accelerate the progress that necking down forms; Perhaps, usually need control different current slope, under the acting in conjunction of this current slope and short circuit equivalent resistance, obtain the rate of change of weldingvoltage Vw in order to regulate the diverse location arc force in when welding.As shown in Figure 2; Welding current Iw undergos mutation and short circuit equivalent resistance when constant; Be that the current path cross-sectional area is not when changing very greatly; Weldingvoltage rate of change Vw (A position among the figure) still possibly surpass the critical value that is used to judge necking down formation, thereby causes erroneous judgement disconnected, influences the normal transient of molten drop.
The essence of necking down discharge-induced explosion is energy accumulation rapidly in necking down, above forcing necking down fracture or gasification behind the certain value, causes and splashes.Therefore detect and control this energy and can satisfy the requirement that necking down is judged, and improve the proportioning of energy under short circuit and arcing state in the welding process.Prior art has no idea directly to detect and control is shorted to the energy in the arcing transfer process, and it is not good therefore possibly to cause erroneous judgement or welding energy to distribute.
[summary of the invention]
The technical problem that the present invention will solve provides a kind ofly can accurately be declared necking down and take place, with the reduction detection method that the arc welding molten drop necking down of incidence takes place of splashing.
Another technical problem that will solve of the present invention provides the control method after a kind of necking down takes place, to suppress short circuiting transfer splashing because of the discharge-induced explosion generation when electric arc arcing again change.
In order to solve the problems of the technologies described above; The technical scheme that the present invention adopts is that a kind of arc welding molten drop necking down generation detection method is when arc welding; Through real-time detection welding current and weldingvoltage; Calculate welding instantaneous power and welding instantaneous power rate of change, when the instantaneous power rate of change surpasses a certain critical value, judge that necking down takes place.
Above-described arc welding molten drop necking down generation detection method; Detect the weldingvoltage between welding wire end and the workpiece through voltage detection unit; Detect the welding current that flows through welding wire and workpiece through current detecting unit, the voltage and current sampled signal is obtained weldingvoltage sampled signal and welding current sampling signal through the filter circuit filtering interference signals; Current detection signal and voltage detection signal are sent into power calculation unit and are calculated welding instantaneous power and instantaneous power rate of change, when the rate of change of instantaneous power reaches threshold value, then judge necking down formation
The technical scheme of the control method after a kind of molten drop necking down takes place is, judge that according to above-mentioned arc welding molten drop necking down generation detection method necking down takes place after, the instantaneous power of control output is in a certain setting value, the energy during with the control discharge-induced explosion.
Control method after above-described molten drop necking down takes place; Judge necking down take place after through a certain preset time; System judges that molten drop breaks away from welding wire fully; Increase the bonding power setting value this moment, obtains the preset initial value of current adjustment unit after the equivalent circuit resistance calculations with the bonding power setting value of this increase and the output of power calculation unit, with this initial value of controlling as arcing constant voltage in period.
Control method after above-described molten drop necking down takes place; Detect the weldingvoltage between welding wire end and the workpiece through voltage detection unit; Detect the welding current that flows through welding wire and workpiece through current detecting unit, the voltage and current sampled signal is obtained weldingvoltage sampled signal and welding current sampling signal through the filter circuit filtering interference signals; Current detection signal and voltage detection signal are sent into power calculation unit and are calculated welding instantaneous power and instantaneous power rate of change, when the rate of change of instantaneous power reaches threshold value, then judge necking down formation; Current detection signal also is admitted to current adjustment unit as the current feedback amount, and voltage detection signal also is admitted to voltage-adjusting unit as voltage feedback signal; After judging that necking down takes place; The output signal of multiplexer power switched adjuster gets into current adjustment unit; Current adjustment unit is through the adjustment dutycycle, and the high-frequency inversion unit of control main circuit makes instantaneous power follow the trail of set-point; Realization prevents the necking down heavy explosion to the control of instantaneous power.
Control method after above-described molten drop necking down takes place; Judge necking down take place after through a certain preset time; The bonding power setting value is increased; Obtain the setting value of current adjustment unit after the equivalent circuit resistance calculations of electric current loop initial value setup unit with the set value of the power after increasing and the output of power calculation unit, and the initial value of controlling as arcing constant voltage in period with the setting value of this current adjustment unit.
Control method after above-described molten drop necking down takes place is set after the described initial value, and multiplexer switches to current adjustment unit with the output signal of voltage regulator again.
Arc welding molten drop necking down generation detection method of the present invention has anticipation property; Compensated the time-delay of testing circuit, welding system control can in time be moved, acutely taken place to avoid discharge-induced explosion; Because considered the factor of electric current, avoided the too fast necking down erroneous judgement that causes of current-rising-rate disconnected simultaneously.
[description of drawings]
Below in conjunction with the accompanying drawing and the specific embodiment the present invention is done further detailed explanation.
Fig. 1 is prior art molten drop electric current, voltage and sketch map of droplet transfer when being in the short circuiting transfer state.
When Fig. 2 was the sudden change of prior art welding current, the weldingvoltage rate of change surpassed critical value, caused the sketch map of necking down erroneous judgement.
Fig. 3 is the sequential chart of each signal in the welding system of the present invention.
Fig. 4 is consumable electrode arc welding necking down detection of the present invention and control principle block diagram.
Fig. 5 is the flow chart of arc welding molten drop necking down generation detection method of the present invention,
[specific embodiment]
Fig. 4 is that the present invention is about necking down detection of arc welding molten drop and control principle block diagram.Main circuit is controlled by DSP, and DSP comprises detecting circuit, power calculation unit, current adjustment unit, voltage-adjusting unit VR, power governor PR, state switching circuit SW, electric current loop initial value setup unit Ia_init and multiplexer Mux.
The wire-feed motor constant speed wire feed of welding machine; Detect the weldingvoltage Vw between welding wire end and the workpiece through voltage detection unit Vd; Detect the welding current Iw that flows through welding wire and workpiece through current detecting unit Id; With the voltage and current sampled signal through the filter circuit filtering wherein from obtaining weldingvoltage sampled signal Vs and welding current sampling signal Is after the inside and outside interfering signal of welding system, proportional on these signal amplitudes, and time-delay to some extent on phase place with actual signal.Current detection signal Is is admitted to current adjustment unit CR (electric current loop) as the current feedback amount, also is admitted to power calculation unit simultaneously as the parameter of calculating outputs such as bonding power.Voltage detection signal Vs also is admitted to voltage-adjusting unit VR as voltage feedback signal, also is admitted to power calculation unit simultaneously as the parameter of calculating outputs such as bonding power.
Power calculation unit with voltage detection signal Vs and current detection signal Is as input quantity;, as output quantity the handoff procedure that is shorted to arcing is controlled with instantaneous power Pc (instantaneous voltage multiply by transient current), instantaneous power rate of change Δ Pc/ Δ t (instantaneous power is carried out differential), equivalent circuit resistance R c (instantaneous voltage is divided by transient current).
Fig. 3 is the sequential chart of each signal in the welding system.Uppermost first curve is represented the variation of welding current Iw, and second curve is represented the variation of weldingvoltage Vw, and the 3rd curve representes to weld the variation of instantaneous power, figure (b) expression droplet transfer situation.In t1 to t3 zone, welding system output is in short-circuit condition, molten drop from the welding wire end gradually to the mother metal transition; To the t3 moment, necking down forms gradually, and equivalent resistance increases rapidly; Because have physics inductance and electronic inductance, electric current I w maintains the higher position, and instantaneous power increases rapidly.At t 4 constantly; The rate of change Δ Pc/ Δ t of the instantaneous power that power calculation unit calculates reaches threshold value, and state switching circuit SW judges that necking down this moment forms, and the input of multiplexer Mux switches to rapidly in the output of power governor PR; The output signal of power governor PR is sent into current adjustment unit CR through multiplexer Mux; Current adjustment unit CR is through the adjustment dutycycle, and the high-frequency inversion unit of control main circuit makes instantaneous power follow the trail of set-point; Realization prevents the necking down heavy explosion to the control of instantaneous power.
Judge necking down take place after through after a certain preset time; The control system judges that molten drop has broken away from welding wire fully; At this moment; Rapidly the bonding power setting value is increased, obtain the setting value of current adjustment unit after electric current loop initial value setup unit Ia_init calculates with the equivalent circuit resistance R c of this set value of the power and the output of power calculation unit, the initial value of controlling as arcing constant voltage in period with the setting value of this current adjustment unit.Because Rc can reflect the arc length information of electric arc, can adapt to the situation that arc length changes faster with the method.Set after the initial value, multiplexer Mux switches to current adjustment unit CR with the output signal of voltage regulator VR again.
The selection of power governor PR bonding power setting value can either guarantee that necking down can quick-break, and necessary electromagnetic force of droplet transfer, again excessive discharge-induced explosion can not be arranged simultaneously.
The above embodiment of the present invention has anticipation property to the judgement that the molten drop necking down produces; Compensated the time-delay of testing circuit, welding system control can in time be moved, acutely taken place to avoid discharge-induced explosion; Because considered the factor of electric current, avoided the too fast necking down erroneous judgement that causes of current-rising-rate disconnected simultaneously.
After the molten drop necking down produces; Through detecting and control the energy in the necking down, the energy in the time of can more directly controlling discharge-induced explosion has reduced only relying on the control electric current; Thereby possibly destroy the molten drop stress balance, the necking down that perhaps can not in time fuse causes the long probability of short circuit duration.
Welding wire during arcing, is set some performance numbers stage power initial value for this reason again.From the calculating of previous stage, obtain the welding system equivalent resistance, can obtain the given initial value of this stage current regulator through initial gain value and this equivalent resistance value.Because equivalent resistance can reflect arc length information, thus this method can each droplet transfer process of dynamic adjustments in arc length during arcing, improve the stability of electric arc.
Claims (7)
1. an arc welding molten drop necking down generation detection method is characterized in that, during arc welding; Through real-time detection welding current and weldingvoltage; Calculate welding instantaneous power and welding instantaneous power rate of change, when the instantaneous power rate of change surpasses a certain critical value, judge that necking down takes place.
2. arc welding molten drop necking down generation detection method according to claim 1; It is characterized in that; Detect the weldingvoltage between welding wire end and the workpiece through voltage detection unit; Detect the welding current that flows through welding wire and workpiece through current detecting unit, the voltage and current sampled signal is obtained weldingvoltage sampled signal and welding current sampling signal through the filter circuit filtering interference signals; Current detection signal and voltage detection signal are sent into power calculation unit and are calculated welding instantaneous power and instantaneous power rate of change, when the rate of change of instantaneous power reaches threshold value, then judge necking down formation.
3. the control method after a molten drop necking down takes place is characterized in that, after arc welding molten drop necking down generation detection method according to claim 1 judged that necking down takes place, the instantaneous power of control output was in a certain setting value, the energy during with the control discharge-induced explosion.
4. the control method after molten drop necking down according to claim 3 takes place; It is characterized in that; Through a certain preset time, system judged that molten drop breaks away from welding wire fully after the judgement necking down took place, and increase the bonding power setting value this moment; Obtain the preset initial value of current adjustment unit after the equivalent circuit resistance calculations with the output of the bonding power setting value of this increase and power calculation unit, with this initial value as the control of arcing constant voltage in period.
5. the control method after molten drop necking down according to claim 3 takes place; It is characterized in that; Detect the weldingvoltage between welding wire end and the workpiece through voltage detection unit; Detect the welding current that flows through welding wire and workpiece through current detecting unit, the voltage and current sampled signal is obtained weldingvoltage sampled signal and welding current sampling signal through the filter circuit filtering interference signals; Current detection signal and voltage detection signal are sent into power calculation unit and are calculated welding instantaneous power and instantaneous power rate of change, when the rate of change of instantaneous power reaches threshold value, then judge necking down formation; Current detection signal also is admitted to current adjustment unit as the current feedback amount, and voltage detection signal also is admitted to voltage-adjusting unit as voltage feedback signal; After judging that necking down takes place; The output signal of multiplexer power switched adjuster gets into current adjustment unit; Current adjustment unit is through the adjustment dutycycle, and the high-frequency inversion unit of control main circuit makes instantaneous power follow the trail of set-point; Realization prevents the necking down heavy explosion to the control of instantaneous power.
6. the control method after molten drop necking down according to claim 5 takes place; It is characterized in that; Judge necking down take place after through a certain preset time; The bonding power setting value is increased, obtain the setting value of current adjustment unit after the equivalent circuit resistance calculations of electric current loop initial value setup unit with the set value of the power after increasing and the output of power calculation unit, and the initial value of controlling as arcing constant voltage in period with the setting value of this current adjustment unit.
7. the control method after molten drop necking down according to claim 5 takes place is characterized in that set after the described initial value, multiplexer switches to current adjustment unit with the output signal of voltage regulator again.
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Cited By (5)
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| CN104227184A (en) * | 2013-06-07 | 2014-12-24 | 株式会社安川电机 | Arc welding apparatus, arc welding system, and are welding method |
| CN106513935A (en) * | 2016-12-30 | 2017-03-22 | 唐山松下产业机器有限公司 | Arcing state judgment method and device and electric arc welding device |
| CN107042350A (en) * | 2017-02-22 | 2017-08-15 | 重庆理工大学 | A kind of molten drop deposition detection method manufactured applied to electric arc three-dimensional rapid forming |
| CN114160925A (en) * | 2021-12-07 | 2022-03-11 | 深圳市麦格米特焊接技术有限公司 | Current blocking method and device, welding system and welding machine |
| CN114184982A (en) * | 2021-12-29 | 2022-03-15 | 成都卡诺普机器人技术股份有限公司 | Welding arc striking explosion detection method and system and welding method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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