Background technology
Electroslag pressure welding is that two reinforcing bars are placed into vertical or oblique (gradient is in the range of 4:1) is right
Connect form, utilize welding current to pass through two reinforcing bar gaps, under welding flux layer, form arc process and Electroslag Process,
Produce arc heat and resistance heat, melt reinforcing bar, a kind of press welding method pressurizeed.Briefly, it is simply that
Electric current is utilized to be carried out a kind of fusion welding method welded by resistance heat produced by liquid slag.But with arc welding
Comparing, its work efficiency is high, low cost, achieved with good effect in some high-building constructions.According to making
Electrode shape, electroslag welding with wire, electroslag welding with plate electrode, electroslag welding with consumable nozzle etc. can be divided into.Electroslag welding is suitable for
Welding in slab.Boiler, heavy-duty machinery, shipbuilding industry are applied more.
The welding process of electroslag pressure welding includes four-stage: arc process, arc process, Electroslag Process and
Top presses through journey.
When welding starts, first ignite between upper and lower two reinforcing bar end faces electric arc, makes solder flux around electric arc melt
Change and form hole;Welding arc burns between two reinforcing bars therewith, and arc heat is by two end reinforced fusings, molten
The metal changed forms molten bath, and melted solder flux forms slag (slag bath), is covered on molten bath, now,
Along with the burning of electric arc, upper and lower two end reinforced gradually melt, by upper reinforcing bar constantly under send, to keep electric
Stablizing of arc, continues arc process;With the continuity of arc process, two end reinforced fusing amounts increase, molten bath
Deepen with slag bath, during certain depth to be achieved, quickenings send speed under reinforcing bar so that it is end is direct and slag
Pond contact, at this moment, arc extinction and become arc process into Electroslag Process;Treat the resistance heat that Electroslag Process produces
The end making upper and lower two reinforcing bars reaches total cross-section when uniformly heat, and rapidly upper reinforcing bar is pushed up downwards pressure,
Extrude whole slag and liquid metal, cut off the source of welding current immediately, complete welding job.
Electroslag pressure welding is vertical or oblique be applicable to monolithic reinforced concrete structure, and (gradient is at 4:1 model
In enclosing) connection of reinforcing bar, especially for post, the wall reinforcing bar of skyscraper, apply the most extensive.
The welding facility of electroslag pressure welding specifically include that the source of welding current, weld jig, control chamber at present.
(1) source of welding current
Electroslag pressure welding can use the AC or DC source of welding current, and welding machine capacity should be according to the diameter of institute's welding steel muscle
Selected.Owing to the manufacturer of electroslag pressure welding machine is a lot, product design is respectively arranged with and differs, so adapted weldering
The model connecing power supply is also same, and conventional mostly is Arc Welding Power (arc welder), such as BX3-500 type, BX3-630
Type, BX3-750 type, BX3-1000 type etc..
(2) weld jig
Weld jig is made up of column, gearing, upper and lower clamp, solder flux cylinder etc., and it is provided with prison
Control device, i.e. controls switch, secondary voltage table, time display (buzzer) etc., and weld jig should have
Enough rigidity, should move flexibly under maximum allowable load, and operation is convenient;The diameter of solder flux cylinder should be with institute
Weldering bar diameter adapts;Adnexa (such as voltmeter, time display etc.) on watch-dog should be equipped with complete.
(3) control chamber
The Main Function of control chamber is to be operated by welder, makes the primary line of Arc Welding Power be switched on or switched off, control
Equipped with primary voltage table, on and off switch, display lamp, signal electric bell etc. in case front plate processed, it is possible to scribe weldering
Connect parameter list, for operator's reference.
Existing electroslag pressure welding machine welding start and at the end of, control chamber is all directly to connect the source of welding current
With the disconnection source of welding current, owing to welding current and voltage are relatively big, switching on power between weld jig and reinforcing bar
During and the process of deenergization it would appear that arc spark, so there is serious potential safety hazard.Again
Person, owing to producing arc spark between weld jig and reinforcing bar, such arc spark will burn weld jig,
It is substantially reduced the service life of weld jig.
Summary of the invention
In welding process, there is arc spark for existing electroslag pressure welding machine, cause potential safety hazard and meeting
Burn weld jig, the problem reducing the service life of weld jig, it is an object of the invention to provide one
The concret iron electroslag pressure welder of the contactless spark of steel bar flux press welding can be realized.
In order to achieve the above object, the present invention adopts the following technical scheme that:
A kind of concret iron electroslag pressure welder, it includes the source of welding current, weld jig, control chamber, described control
Case is provided with steel bar flux press welding control system, this control system:
Virtual voltage module, described virtual voltage module controls to connect welding terminal, at welding terminal one
One virtual voltage of straight output, and when welding machine output loop short circuit, virtual voltage is reduced to 0 volt;
Short-circuit detecting module, described short-circuit detecting module connects with welding terminal, in real time the output of detection welding machine
Voltage and current, and judge that welding machine output loop is the most short-circuit with this;
Power control module, described power control module controls the welding electricity connecting in concret iron electroslag pressure welder
Source, provides energy for electric arc during reinforcement welding;
Control module, described control module controls to connect virtual voltage module, short-circuit detecting module, power control
Molding block, and work of coordinating to cooperate between them, it is achieved the steel bar flux press welding mistake of contactless spark
Journey.
In a particular embodiment, described control module, after opening welding machine electric power, controls virtual voltage module
Export a virtual voltage at welding terminal always;Control short-circuit detecting module to detect welding machine in real time defeated simultaneously
The voltage and current gone out, and the output loop of welding machine is judged according to the voltage and current of short-circuit detecting module detection
The most short-circuit;Described control module judges the output of welding machine according to the voltage and current that short-circuit detecting module detects
After the short circuit of loop, control virtual voltage module and virtual voltage is reduced to 0 volt of (electric current of virtual voltage output
Less (less than 1A), the process that therefore switches on power does not produces electric arc), and after time delay a period of time, control
Power control module processed controls the source of welding current and exports a little striking current;
Described control module judges the output loop of welding machine according to the voltage and current that short-circuit detecting module detects
After non-shorting, then judge that the steel bar flux press welding starting the arc completes, control power control module and adjust the source of welding current
Output welding current;
Described control module judges the output of welding machine again according to the voltage and current that short-circuit detecting module detects
After the short circuit of loop, then judge that welding completes, control power control module and adjust the electric current fall of source of welding current output
Be 0 (this process is closed because of welding machine output, and only virtual voltage exists, and the electric current of virtual voltage output is less,
Less than 1A, therefore this process does not produce electric arc).
Further, described power control module includes input rectifying module and inversion module, and described input is whole
The input of flow module connects with the outfan of the source of welding current, the outfan of input rectifying module and inversion module
Input connect, the outfan of inversion module connects with the outfan of welding machine, simultaneously the control of inversion module
End connects with control module.
The present invention provide scenario-frame simple, it is easy to accomplish, this programme in the specific implementation, by weldering
Machine outfan exports a virtual voltage all the time, due to the fan-out capability of virtual voltage the least (less than 1A),
So during switching on power, there will not be arc spark during welding;Same, when welding completes,
Owing to output loop electric current is 0, only having virtual voltage to work during disconnection, virtual voltage fan-out capability is the least
(less than 1A), does not haves arc spark during deenergization yet.From there through this virtual voltage,
Whole welding process is produced without arc light, not only increases safety, improve work situation, and keep away
Exempt from electric arc fixture is burnt, improve the service life of fixture.
It addition, its output voltage of virtual voltage in this programme is less than safe voltage, further increase whole
The safety of welding process.
Furthermore, this programme is playing forearc, welding machine is exporting a little striking current (such as 30A), not weld
Connect electric current, make the energy between two reinforcing bars of short circuit less, so when the starting the arc, due to melting point between reinforcing bar
Minimum, the power pulling open two reinforcing bars needs is smaller, reduces labor intensity.
Detailed description of the invention
For the technological means making the present invention realize, creation characteristic, reach purpose and be easy to understand with effect,
Below in conjunction with being specifically illustrating, the present invention is expanded on further.
The concret iron electroslag pressure welder that the present invention provides, it mainly includes the source of welding current, weld jig, control
Case.Wherein the connection matching relationship between this three is same as the prior art, is not repeated here, and welds
Connect power supply and weld jig can use the source of welding current in existing concret iron electroslag pressure welder and weld jig, this
It is all that those skilled in the art knows technology, is not repeated here.
On this basis, the present invention is provided with realizing the reinforcing bar electroslag pressure of contactless spark in control chamber
The steel bar flux press welding control system of power weldering.
See Fig. 1, its show the present invention provide concret iron electroslag pressure welder control system 100 be
System block diagram.As seen from the figure, this control system 100 includes: virtual voltage module 101, short-circuit detecting module
102, power control module 103, these four parts of control module 104.
Whole control system 100 is arranged in the control chamber of concret iron electroslag pressure welder, wherein, and virtual voltage
Module 101 controls to connect welding terminal, for exporting a virtual voltage at welding terminal always, and should
Virtual voltage is less than safe voltage, and always present in the outfan of welding machine, the shortest at welding machine output loop
Lu Shi, is reduced to 0 volt by virtual voltage.
Short-circuit detecting module 102 the most also connects with welding terminal, and this module is real in whole welding process
Time detection welding machine output voltage and current, and during by the fructufy of detection, reach control module 104, and with
This judges that welding machine output loop is the most short-circuit.
Power control module 103, it controls to connect the source of welding current in concret iron electroslag pressure welder and welding machine
Outfan, whole welding process constantly regulates the output of the source of welding current, for electric arc during reinforcement welding
Corresponding energy is provided.
Concrete, this power control module 103 is with input rectifying module 103a and inversion module 103b
Composition, wherein the input of input rectifying module 103a connects with the outfan of the source of welding current, input rectifying
The outfan of module connects with the input of inversion module.By this module, the output electric current of the source of welding current is entered
Row rectification processes, it is ensured that the stability of follow-up work.
Inversion module 103b, its outfan connects with the outfan of welding machine, simultaneously the control end of inversion module with
Control module 104 connects.This inversion module 103b is under the control of control module 104, to through input
The electric current of rectification module 103a rectification carries out inversion process, to reach required operating current.
Control module 104, it is the whole control core in system, its connection virtual voltage module 101,
Short-circuit detecting module 102, power control module 103, and work of coordinating to cooperate between them, it is achieved
The steel bar flux press welding process of contactless spark.It is implemented as follows:
Control module 104, after opening welding machine electric power, first controls virtual voltage module 101 and exports at welding machine
End one virtual voltage of output always;Control short-circuit detecting module 102 simultaneously and detect the electricity of welding machine output in real time
Pressure and electric current, and accept the voltage and current of the welding machine output that short-circuit detecting module 102 detects, and according to
The output loop of this voltage and current data real-time judge welding machine is the most short-circuit.
Control module 104 judges the output of welding machine for the first time according to the voltage and current that short-circuit detecting module detects
After the short circuit of loop, control virtual voltage module 101 and virtual voltage is reduced to 0 volt, and when time delay one section
After between, control power control module 103 and work, power control module 103 control source of welding current output one
Little striking current.
According to the voltage and current that short-circuit detecting module 102 detects, control module 104 judges that the output of welding machine is returned
After road is non-shorting, then judge that the steel bar flux press welding starting the arc completes, control power control module 103 and adjust weldering
Connect power supply output welding current;
The voltage and current second time that control module 104 detects according to short-circuit detecting module 102 judges welding machine
After output loop short circuit, then judge that welding completes, control power control module 103 and adjust source of welding current output
Electric current reduce to 0.
Concret iron electroslag pressure welder in this programme is further illustrated below by way of a concrete application example
Running (techniques below content as an example, does not limit this programme and only runs following process), whole
Process is as shown in Figure 2:
1, opening welding machine electric power, control system 100 is started working, the control module 104 in control system
After opening welding machine electric power, control virtual voltage module 101 in welding terminal output less than safe voltage
Virtual voltage, this virtual voltage is present in the outfan of welding machine all the time;Simultaneously control short-circuit detecting module
The voltage and current of 102 detection welding machine outputs in real time, the most short-circuit to judge welding machine output loop.
2, on-the-spot preparation: the reinforcing bar that two is to be welded is connected together (formation short-circuit condition), adjust and install weldering
Welding fixture, and filling flux, specifically can use common scheme, not be repeated here.
3, the source of welding current connected by two reinforcing bars: welding terminal is connected to reinforcing bar two ends, now welding machine output
Terminal voltage is virtual voltage, therefore the virtual voltage of output is applied on two reinforcing bars that connect together by welding machine, shape
Become corresponding output loop;Now due to two bar connecting together, short-circuit detecting module 102 will detect
The voltage and current of welding machine output reaches control module 104, and control module 104 determines welding machine by calculating
Output loop is in short-circuit condition, and control module 104 will control virtual voltage module 101 and virtual voltage be dropped
Low to 0 volt.Due to virtual voltage fan-out capability the least (less than 1A), will not during switching on power
Arc spark (mainly not havinging contact sparking between reinforcing bar and fixture) occurs.
4, after detection determines that the output loop of welding machine is in short-circuit condition for the first time, control module 104 is prolonged
Time a period of time (such as 0.5S, this time is adjustable) after, control module 104 will control power control module
103 work, are controlled the source of welding current one small area analysis (generally 30A) of output by power control module 103,
For the starting the arc, because small area analysis can make the energy between two reinforcing bars of short circuit less, between reinforcing bar, melt point pole
Little (even without melting point).
5, two reinforcing bars pull open generation electric arc: pull open two reinforcing bars by fixture, make to produce between two reinforcing bars
Electric arc.The electric current now exported due to motor is a small area analysis (not welding current) (generally 30A),
Between reinforcing bar, melting point is minimum, and the power pulling open two reinforcing bars needs is smaller, reduces labor intensity.
6, during electric arc produces, short-circuit detecting module 102 detects voltage and the electricity of welding machine output in real time
Spread to control module 104, after electric arc produces, the welding machine output that short-circuit detecting module 102 will detect
Voltage and current reach control module 104, control module 104 determines the output loop of welding machine by calculating
Being in non-shorting state, control module 104 then judges that the steel bar flux press welding starting the arc completes, and controls power control
Molding block 103 adjusts source of welding current output welding current (the most hundreds of ampere).
7, arc stage: the electric arc that welding current produces between two reinforcing bars, and the electric arc that ignites, makes reinforcing bar two
End fusing, i.e. by the electric arc that ignites, makes solder melts around electric arc form hole, and welding arc is two therewith
Burning between reinforcing bar, two end reinforced fusings, molten metal are formed molten bath, melted solder flux by arc heat
Form slag (slag bath), be covered on molten bath.
8, the pressure period: after reinforcing bar fusing amount reaches requirement, by fixture adjust bar spacing from, make
Distance reduces, until two bar connecting are to (even if welding machine output loop is short-circuit condition) together, and passes through
Fixture adds certain pressure to two reinforcing bars.
9, in step (9), when two bar connecting are to time together, and short-circuit detecting module 102 will detect
Welding machine output voltage and current reach control module 104, control module 104 determines welding machine by calculating
Output loop be again at short-circuit condition, control module 104 then judges that welding completes, control power control
Module 103 adjusts the electric current of source of welding current output and reduces to 0A or reduce to a very small area analysis;Simultaneously by outfan
The virtual voltage of output reduces to 0 volt.
10, output loop is disconnected: welding process completes, and welding machine can disconnect output loop;Now welding machine is defeated
Going out end and still export virtual voltage, output loop electric current is 0, only has virtual voltage to act as when deenergization
With, virtual voltage fan-out capability the least (less than 1A), during deenergization, do not have electric arc fire
Flower.
11, cleaning welding slag solder flux.
From the foregoing, it will be observed that the control that this programme provides, its by the outfan of welding machine export all the time one virtual
Voltage, due to the fan-out capability of virtual voltage the least (less than 1A), so in the mistake switched on power during welding
Journey there will not be arc spark;Same, when welding completes, owing to output loop electric current is 0,
Only having virtual voltage to work during disconnection, virtual voltage fan-out capability the least (less than 1A), at deenergization
During do not have arc spark yet.From there through this virtual voltage so that whole welding process is without arc
Light produces, and not only increases safety, and avoids electric arc to burn fixture, improves the use longevity of fixture
Life.
It addition, its output voltage of virtual voltage in this programme is less than safe voltage, further increase whole
The safety of welding process.
Furthermore, this programme is playing forearc, welding machine is exporting a little striking current (such as 30A), not weld
Connect electric current, make the energy between two reinforcing bars of short circuit less, so when the starting the arc, due to melting point between reinforcing bar
Minimum, the power pulling open two reinforcing bars needs is smaller, saves muscle power, reduces labor intensity.
The ultimate principle of the present invention, principal character and advantages of the present invention have more than been shown and described.The industry
Skilled person will appreciate that, the present invention is not restricted to the described embodiments, in above-described embodiment and description
The principle that the present invention is simply described described, without departing from the spirit and scope of the present invention, the present invention
Also having various changes and modifications, these changes and improvements both fall within scope of the claimed invention.This
The claimed scope of invention is defined by appending claims and equivalent thereof.