CN103223541B - The protecting control method of the source of welding current - Google Patents
The protecting control method of the source of welding current Download PDFInfo
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- CN103223541B CN103223541B CN201310011096.7A CN201310011096A CN103223541B CN 103223541 B CN103223541 B CN 103223541B CN 201310011096 A CN201310011096 A CN 201310011096A CN 103223541 B CN103223541 B CN 103223541B
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Abstract
The invention provides a kind of protecting control method of the source of welding current, carry out action by the utilization rate protecting control of the source of welding current and suppress welding to be interrupted suddenly and the situation of production efficiency reduction.All the time calculate in the past 10 minutes period in welding current square mean value (Si); the energising of welding current (Iw) is cut off when this mean value (Si) reaches predetermined a reference value (St); in the protecting control method of above-mentioned such source of welding current; be estimated as mean value (Si) after the stipulated time, reach a reference value (St) time, the alarm (Ar) that the sound sending " be in rear ×× second and exceed utilization rate " and so on produces.Welding operator receives this alarm, changes the countermeasure of welding condition etc. by implementing to continue to weld, thus can be in exceed utilization rate before end weld.Therefore, it is possible to suppress the reduction of production efficiency.
Description
Technical field
The present invention relates to the protecting control method of the source of welding current for protecting the source of welding current when exceeding specified utilization rate to weld.
Background technology
In the source of welding current of the arc welding for sacrificial electrode arc welding, non-consumable electrode arc welding, plasma-arc welding etc., specify specified utilization rate.Such as when the source of welding current of the relative rated welding current 350A of regulation is the specified utilization rate of 60%, if 10 minutes periods were 1 cycle, the welding of 350A amounts to carries out 6 minutes, and within remaining 4 minutes, needs stop welding.If welding current becomes 300A, then allow utilization rate=(350/300)
2× 60=82%.If welding current becomes 271A, then allow that utilization rate becomes 100%, can continuous welding.The source of welding current specifies that the reason of specified utilization rate is, if the semiconductor element, transformer and the reactor that are arranged at the transistor, diode etc. of the inside of the source of welding current exceed specified utilization rate, is heated, and can produce and burn or the reduction of durability.
In the prior art; in order to prevent from exceeding utilization rate, the welding current in the past in 10 minutes periods square mean value exceeded rated welding current square with the amassing of specified utilization rate time (the temperature rising value of source of welding current inside exceeded with specified utilization rate use time temperature rising value time) cut off the energising of welding current and stop welding to protect the source of welding current.Below, the control preventing from exceeding utilization rate is called protecting control (reference example is as patent document 1 etc.).
Patent document 1:JP Unexamined Patent 11-259149 publication
Summary of the invention
Welding operator, when welding the slab such as reinforcing bar, bridge, passes into big current to carry out the situation of welding more continuously for a long time.In this case, the state being in and exceeding specified utilization rate can also be produced.If exceed specified utilization rate, then as described above, in order to protect the source of welding current to interrupt welding forcibly.Weld by the workpiece that interrupts or discarded or again weld from interruptions halfway.In any one situation, all expend man-hour, production efficiency reduces.
At this, the object of the invention is to, provide a kind of and when having exceeded specified utilization rate, seek the protection of the source of welding current in arc welding, and the protecting control method of the source of welding current that production efficiency can be suppressed to reduce.
In order to solve above-mentioned problem; the protecting control method of the source of welding current of the invention of technical scheme 1; all the time calculate over 10 minutes period in welding current square mean value; the energising of welding current is cut off when this mean value reaches predetermined a reference value; the feature of the protecting control method of this source of welding current is; be estimated as above-mentioned mean value after the stipulated time, reach said reference value time, give the alarm.
The feature of the protecting control method of the source of welding current of the invention of technical scheme 2 is, is assumed to the value of the above-mentioned welding current under former state maintenance current point in time, carries out above-mentioned presumption like this.
The feature of the protecting control method of the source of welding current of the invention of technical scheme 3 is, carries out above-mentioned alarm by sound.
According to the present invention, be estimated as over the welding current in 10 minutes periods square mean value after the stipulated time, reach predetermined a reference value time, the alarm that the sound etc. sending " to be in second in rear ×× and to exceed utilization rate " and so on produces.Welding operator be in exceed utilization rate before predicted, therefore receive this alarm and continue welding and carry out the change of welding condition, even if weld until terminal also can not be in the state exceeding utilization rate workpiece.In addition, welding operator can interrupt welding easily restarting welding part, therefore, it is possible to successfully restart welding after making source of welding current termination.Therefore, can not the energising of welding current be cut off forcibly owing to exceeding utilization rate and welding be interrupted suddenly.Therefore, it is possible to the situation preventing discarded workpiece or expend more man-hour when restarting welding, thus protecting on the basis of the source of welding current from exceeding utilization rate, production efficiency can be suppressed to reduce.
Accompanying drawing explanation
Fig. 1 is the sequential chart of the protecting control method of the source of welding current that expression is relevant to embodiments of the present invention.
Fig. 2 is the block diagram of the source of welding current of protecting control method for implementing the source of welding current relevant to embodiments of the present invention.
Detailed description of the invention
Below, with reference to accompanying drawing, embodiments of the present invention are described.
Below protecting control side's ratio juris of the source of welding current relevant to embodiments of the present invention is described.Setting rated welding current It (A) and specified utilization rate α (%).And, by following formula definition datum value St.
St=(It)
2α ... (1) formula
At this, a reference value St has carried out the relevant value of the temperature rising value of source of welding current inside when welding to adopting the specified utilization rate α rated welding current It that is energized.Also above-mentioned α can be set as the value of setting less of specified utilization rate.
Setting constant and cycle T=600 second (10 minutes), detects welding current Iw (A), the welding current of being calculated in during 10 minutes by following formula square mean value Si.
Si=(1/T) ∫ (Iw)
2dt... (2) formula
Integration is carrying out during (10 minutes) in the past apart from current point in time for 600 seconds.
At this, if carry out sampling to carry out A/D conversion by the sampling period Ts (second) of each regulation to welding electric current I w, and be detected as welding current digital value Id (n), then above formula and following formula equivalence.
Si (n)=(D (n-k-1)+...+D (n))/k ... (3) formula
Wherein, D (n)=Id (n) Id (n), k is the data number be sampled 10 minutes periods, k=600/Ts.Can by this formula by each sampling period Ts calculate 10 minutes period in welding current square mean value Si.
Sampling period Ts is set to such as 1 second.In this case, k=600.If by sampling period Ts high speed until 100 μ s degree, then correctly welding current waveform can be detected.But, in this case, if data number k=600 ten thousand, then become googol order, therefore need the CPU using energy high-speed computation process, thus become high price.In order to prevent this situation, by welding current Iw is detected and carries out smoothing by low pass filter (cut-off frequency 1 ~ 10Hz degree), even if thus sampling period Ts postpones the computing that degree also correctly can carry out above formula in 1 second.
Setting duration T d (second).Be assumed to and light to presumption mean value Ss when maintaining the value Id (n) of the welding current Iw current point in time during this duration T d by following formula computing from current time.
Ss=(D (n-k+m)+...+D (n)+D (n) m)/k ... (4) formula
Wherein, the data number of m for sampling in duration T d, m=Td/Ts.Duration T d is in for determining the constant exceeding utilization rate from current point in time after how many seconds, such as, be set as 30 ~ 180 seconds degree.Computing presumption mean value Ss is carried out by each sampling period Ts by above formula.
The protecting control method of the source of welding current that embodiments of the present invention are correlated with is undertaken by following step.
Step 1: setting rated welding current It and specified utilization rate α, is carried out computing by above-mentioned (1) formula and is set a reference value St.
Step 2: welding electric current I w is sampled and is detected as digital value by each sampling period Ts.If the welding current digital value of n-th time is Id (n).
Step 3: by above-mentioned (3) formula, by the welding current in 10 minutes periods of each sampling period Ts computing n-th time square mean value Si (n), when mean value Si (n) of n-th time reaches a reference value St (Si (n) >=St), make energising shutoff signal As be changed to high level, cut off the energising of welding current Iw and stop welding.The process of step 4 is not carried out when the shutoff signal As that is energized is in high level.
Step 4: by presumption mean value Ss (n) of above-mentioned (4) formula by each sampling period Ts computing n-th time, when this presumption mean value Ss (n) of n-th time reaches a reference value St (Ss (n) >=St), alarm signal Ar is made to be changed to high level and to give the alarm.Alarm is undertaken by the sound of " exceeding utilization rate in latter 60 seconds " etc., identifies so that welding operator can carry out welding.Within 60 seconds, become above-mentioned duration T d.In addition, the handle portion of welding torch also can be made to vibrate give the alarm.Also can and with making abnormal show lamp light.Even if alarm signal Ar is changed to high level and also only gives the alarm and continue welding.
Fig. 1 is the sequential chart of the protecting control method of the source of welding current that expression is relevant to embodiments of the present invention.This figure (A) represents welding current Iw, this figure (B) represent 10 minutes period in welding current square mean value Si, this figure (C) represents alarm signal Ar, this figure (D) represent energising shutoff signal As.This figure is the situation becoming Ss >=St in above-mentioned step 4.Below, be described with reference to this figure.
As shown in this figure (A), it is the weld period that welding current I1 is energized during moment t1 ~ t2, during during moment t2 ~ t3 being the cold termination of welding current Iw, it is the weld period that welding current I1 is energized during moment t3 ~ t4, for during termination during moment t4 ~ t5, during moment t5 ~ t6 be welding current I2 be energized give fixed weld period, during moment t6 ~ t7 for stop during.At this, I1 < I2.If be sacrificial electrode arc welding, then welding current value changes along with the feed speed of welding wire, if be non-consumable electrode arc welding, then welding current value is changed by current constant control.Identical time span is respectively during each weld period and each termination.And weld period and the aggregate values during stopping become 10 minutes periods.
As shown in this figure (B), during before moment t5, welding current I1 is energized with identical utilization rate, and therefore mean value Si becomes fixed value Si1.Carry out the process of above-mentioned step 3, Si1 becomes Si1=I1I1 (utilization rate) according to above-mentioned (2) formula or (3) formula.This Si1 is less than a reference value St shown in dotted line.Therefore, as shown in this figure (D), energising shutoff signal As is in low level.In addition, carry out the process of above-mentioned step 4, during before moment t5, be in by the presumption mean value Ss of above-mentioned (4) formula computing the state being less than a reference value St.Therefore, as shown in this figure (C), alarm signal Ar is in low level.
As shown in this figure (A), because welding current setting value there occurs change, the welding current therefore from moment t5 is increased to I2 from I1.Therefore, as shown in this figure (B), mean value Si increases gradually from moment t5.And the moment t51 before the moment t6 that welding terminates, mean value Si is in the state being less than a reference value St shown in dotted line.On the other hand, at moment t51, presumption mean value Ss becomes more than a reference value St, and therefore as shown in this figure (C), alarm signal Ar is changed to short time high level, sends the audible alarm of " be at latter 60 seconds and exceed utilization rate " and so on.At this, exemplified with the situation of duration T d=60.
Can welding operator receive this alarm and judge carry out welding until terminal in duration T d (second), if possible then do not change welding condition and continue welding.When being judged as impossible, embodiment countermeasure as described below on the basis considering welding quality.
1) accelerate the speed (speed of welding) of mobile welding torch, and can carry out welding until terminal with the time being less than duration T d.
2) by reducing the value of welding current Iw, extending until become the time of Si >=St, and can weld until terminal.
3) welding part interruption welding is easily being restarted until have passed through duration T d.And, make the source of welding current stop after, make welding from this place successfully again.
This figure is that welding operator receives alarm, is judged as can not carrying out welding until terminal within duration T d, implements above-mentioned 1 at moment t51) shown in the situation of countermeasure of acceleration speed of welding.Therefore, as shown in this figure (A), terminate until the welding of terminal terminating the more forward moment t52 of predetermined instant t6 than original welding, therefore the energising of welding current I2 terminates at moment t52.Being the time shorter than duration T d during moment t51 ~ t52, is the time longer than duration T d during moment t51 ~ t6.As shown in this figure (B), mean value Si increases from moment t5 to moment t52, reduces to moment t6 after this, maintains this value in during the termination of moment t6 ~ t7.As shown in this figure (D), energising shutoff signal As is in low level state of all periods.Even if if receiving alarm at moment t51, when also keeping welding current I2 and do not proceed welding with not accelerating speed of welding, the shutoff signal As that is energized between moment t52 and moment t6 is being changed to high level, then the energising of welding current Iw is cut off.
Fig. 2 is the block diagram of the source of welding current of protecting control method for implementing the source of welding current that above-mentioned embodiments of the present invention are correlated with.The situation of this figure to be arc-welding process be sacrificial electrode arc-welding process.Below, with reference to this figure, each module is described.
Electric power main circuit PM inputs the source power supply (diagram is omitted) of 3 phase 200V etc., and the output carrying out inverter control etc. according to drive singal Dv described later controls, and exports output voltage E and welding current Iw.This electric power main circuit PM omits diagram, but possess to source power supply carry out rectification No. 1 rectification circuit, to the smoothing capacitor of the direct current with pulsation (ripple) be rectified, to be driven by above-mentioned drive singal Dv and by by level and smooth DC converting be high-frequency ac inverter circuit, by high-frequency ac step-down be the magnitude of voltage being suitable for arc welding high frequency transformer and to No. 2 rectification circuits being carried out rectification by the high-frequency ac of step-down.Direct current reactor DCL is smoothing to above-mentioned output voltage E.Welding wire 1 by being fed in welding torch 4, produces electric arc 3 due to the rotation of feed rolls 5 that is coupled with feed motor WM between mother metal 2.Welding torch 4 is held by welding operator.Weldingvoltage Vw is applied, energising welding current Iw between welding wire 1 and mother metal 2.
Torch switch ON is arranged in welding torch 4, if be in connection when welding operator starts to weld, is output into the welding commencing signal On of high level.
Predetermined rated welding current value It and predetermined specified utilization rate α is input to above-mentioned (1) formula and output reference value setting signal Str by reference value circuit SR.This circuit carries out the process of above-mentioned step 1.
Welding current testing circuit IWD is detected above-mentioned welding current Iw and is exported welding current detection signal Iwd by low pass filter.Electric current A/D translation circuit ID carries out A/D conversion by each predetermined sampling period Ts to this welding current detection signal Iwd, and exports welding current data signal Id.This circuit carries out the process of above-mentioned step 2.
Mean value operating circuit SIC is using above-mentioned welding current data signal Id as input, by each above-mentioned sampling period Ts by above-mentioned (3) formula come welding current in computing 10 minutes period square mean value, and to export as mean value computing signal Sic.Energising cuts off judging circuit AS using this mean value computing signal Sic and above-mentioned reference value signal Str as input, reach the time point of the value (Sic >=Str) of reference value signal Str in the value of mean value computing signal Sic, be output into the energising shutoff signal As of high level.These circuit carry out the process of the first half of above-mentioned step 3.
Duration settings circuit TDR exports predetermined duration settings signal Tdr.Presumption mean value operating circuit SSC is using this duration settings signal Tdr and above-mentioned welding current data signal Id as input, by above-mentioned each sampling period Ts by above-mentioned (4) formula computing presumption mean value, and export as presumption mean value computing signal Ssc.Alarm judging circuit AR, using this presumption mean value computing signal Ssc and above-mentioned reference value signal Str as input, compares two values, is output into the alarm signal Ar of short time high level at the time point being changed to Ssc >=Str.The alarm that the sound that this alarm signal Ar as input, if alarm signal Ar is changed to high level, then sends by circuit for alarming KH " to be in second in rear ×× and to exceed utilization rate " and so on produces.This circuit for alarming KH is arranged in the source of welding current, wire feed unit (omitting diagram), welding torch 4 etc.In addition, as described above, also give the alarm by vibration, abnormal show lamp etc.These circuit carry out the process of above-mentioned step 4.
Output voltage initialization circuit ER exports predetermined output voltage setting signal Er.Output voltage detecting circuit ED detects and exports to the primary side of high frequency transformer the pulse-like voltage and the output voltage E (voltage by before direct current reactor DCL) that have carried out rectification, this detected value is passed into low pass filter (cut-off frequency 1 ~ 10Hz degree), and export as voltage sense signal Ed.Error between above-mentioned output voltage setting signal Er and this voltage sense signal Ed is amplified by error amplifying circuit EA, and output error amplifying signal Ea.The power supply of constant-voltage characteristic is become by this error amplifying circuit EA.Drive circuit DV using this error amplification signal Ea, above-mentioned welding commencing signal On and above-mentioned energising shutoff signal As input, be high level at welding commencing signal On, and carry out pulse width modulation control according to error amplification signal Ea when the shutoff signal As that is energized is low level, export drive singal Dv for driving the inverter circuit in above-mentioned electric power main circuit PM based on this result, to weld commencing signal On be low level or energising shutoff signal As be high level time not output drive signal Dv.This circuit carries out the process of Hou half part of above-mentioned step 3.By this circuit, if energising shutoff signal As is in high level, then because the output of the source of welding current is stopped, therefore the energising of welding current is cut off.
Feed speed initialization circuit FR exports predetermined feed speed setting signal Fr.Feeding control circuit FC using this feed speed setting signal Fr, above-mentioned welding commencing signal On and above-mentioned energising shutoff signal As input, when welding commencing signal On and be high level and energising shutoff signal As being low level, the feeding control signal Fc of the feed speed feeding welding wire 1 being used for the value being equivalent to this feed speed setting signal Fr is outputted to above-mentioned feed motor WM, to weld commencing signal On be low level or energising shutoff signal As be high level time export feeding control signal Fc for feed-disabling.This circuit carries out the process of the latter half of above-mentioned step 3.By this circuit, when the shutoff signal As that is energized is high level, stop the feeding of welding wire 1.
According to above-mentioned embodiment, be estimated as over the welding current in 10 minutes periods square mean value after the predetermined duration, reach predetermined a reference value time, the alarm that the sound etc. sending " rear ×× second be in exceed utilization rate " and so on produces.Welding operator be in exceed utilization rate before predicted, therefore receive this alarm and continue welding and carry out the change of welding condition, even if weld workpiece until terminal also can be in the state exceeding utilization rate.In addition, welding operator can interrupt welding easily restarting welding part, therefore, it is possible to successfully again start welding after making source of welding current termination.Therefore, can not the energising of welding current be cut off forcibly owing to exceeding utilization rate and welding be interrupted suddenly.Therefore, it is possible to the situation preventing discarded workpiece or expend more man-hour when restarting welding, thus protecting on the basis of the source of welding current from exceeding utilization rate, production efficiency can be suppressed to reduce.
In the above-described embodiment, the situation that arc welding is sacrificial electrode arc welding is illustrated, but the present invention also can be applicable in non-consumable electrode arc welding, plasma-arc welding etc.
Symbol description:
1 welding wire
2 mother metals
3 electric arcs
4 welding torches
5 feed rolls
AR alarm judging circuit
Ar alarm signal
Judging circuit is cut off in AS energising
As is energized shutoff signal
DCL direct current reactor
DV drive circuit
Dv drive singal
E output voltage
EA error amplifying circuit
Ea error amplification signal
ED output voltage detecting circuit
Ed voltage sense signal
ER output voltage initialization circuit
Er output voltage setting signal
FC feeding control circuit
Fc feeding control signal
FR feed speed initialization circuit
Fr feed speed setting signal
I1, I2 welding current
ID electric current A/D translation circuit
Id welding current numeral (value/signal)
It rated welding current
Iw welding current
IWD welding current testing circuit
Iwd welding current detection signal
K, m data number
KH circuit for alarming
ON torch switch
On welds commencing signal
PM electric power main circuit
Si (past 10 minutes period in welding current square) mean value
SIC mean value operating circuit
Sic mean value computing signal
SR reference value circuit
Ss estimates mean value
SSC estimates mean value operating circuit
Ssc estimates mean value computing signal
St a reference value
Str reference value signal
The T cycle
The Td duration
TDR duration settings circuit
Tdr duration settings signal
The Ts sampling period
Vw weldingvoltage
WM feed motor
The specified utilization rate of α
Claims (3)
1. the protecting control method of a source of welding current; all the time calculate over 10 minutes period in welding current square mean value; cut off the energising of welding current when this mean value reaches predetermined a reference value, the feature of the protecting control method of this source of welding current is
Be estimated as above-mentioned mean value after the stipulated time, reach said reference value time, give the alarm.
2. the protecting control method of the source of welding current according to claim 1, is characterized in that,
Be assumed to the value of the above-mentioned welding current under former state maintenance current point in time, carry out above-mentioned presumption like this.
3. the protecting control method of the source of welding current according to claim 1 and 2, is characterized in that,
Above-mentioned alarm is carried out by sound.
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| JP2012012547A JP2013151000A (en) | 2012-01-25 | 2012-01-25 | Protection control method for welding power source |
| JP2012-012547 | 2012-01-25 |
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| CN103223541A CN103223541A (en) | 2013-07-31 |
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| CN105682844B (en) * | 2013-12-25 | 2019-06-07 | 株式会社达谊恒 | Arc welding control method |
| US10385967B2 (en) | 2015-11-09 | 2019-08-20 | GM Global Technology Operations LLC | Method and apparatus to control a continuously variable transmission |
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| US4658323A (en) * | 1985-06-10 | 1987-04-14 | General Electric Company | RMS calculation circuit for digital circuit interrupters |
| JP2745166B2 (en) * | 1991-05-24 | 1998-04-28 | 三菱電機株式会社 | Drive control device for servo amplifier and servo motor |
| JPH0993795A (en) * | 1995-09-21 | 1997-04-04 | Fanuc Ltd | Overload supervising of servo motor |
| JP3926463B2 (en) * | 1998-03-11 | 2007-06-06 | 日立ビアエンジニアリング株式会社 | Burnout prevention device for electrical equipment that determines the rated output by period |
| CN1178530C (en) * | 2002-06-28 | 2004-12-01 | 苏州工业园区新海宜电信发展股份有限公司 | Industrial frequency invasion detecting method and device for outside connections of main distribution frame |
| CN101425754B (en) * | 2008-12-22 | 2010-08-04 | 深圳市明微电子股份有限公司 | Method and controller for controlling output current of switch electric power |
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