CN104368896B - A kind of dark fusion penetration union-melt weld controller - Google Patents

Abstract

The invention relates to a deep penetration submerged arc welding controller, which belongs to the technical field of submerged arc welding equipment. The controller includes a regulated power supply, a PWM single-phase pulse width modulation circuit, a normal/pulse function switching circuit, an LED signal display circuit and a weld indicator. The advantages of the present invention are: the frequency, duty cycle and base value current parameters are solidified in the controller, which simplifies the welding operation, leaving only a single adjustment knob for the penetration depth (peak current) on the controller panel; the controller can realize low-frequency The pulse can effectively control the heat input, improve the quality of the weld seam, and increase the welding penetration; the cost of the invention is lower than that of other integrated equipment, and the same control effect can be achieved.

Description

A Deep Penetration Deep Submerged Arc Welding Controller

technical field

The invention relates to a deep penetration deep submerged arc welding controller, which belongs to the technical field of submerged arc welding equipment.

Background technique

Submerged arc welding has high production efficiency, good weld shape, and no arc radiation in factory operations. It is widely used in thick plate welding in shipbuilding, boilers, ocean engineering and other fields. At present, most of the submerged arc welding equipment used in various industries are high-power DC submerged arc welding machines, and it is difficult to control the penetration depth and deposition rate. When the current is low, the arc penetration is insufficient and the penetration depth is low When high current is used, it is easy to cause magnetic deflection blowing, excessive heat input, and cause welding quality problems. With the improvement of domestic submerged arc welding process level, customers have more stringent requirements on welding quality, so they have higher requirements on welding equipment; and the existing DC submerged arc welding machines have a very large amount of storage in the industry, such as unified replacement of equipment , the equipment will be idle and eliminated, and the cost of use is high. Therefore, it is necessary to do further improvement and research on the existing submerged arc welding machine.

The patent invention number "CN201110418499.4" is named "a submerged arc welding controller". By detecting the welding voltage and current signals, excitation current signals, and armature voltage and current signals, and simultaneously controlling the PWM pulse width drive unit, the speed of the motor can be controlled. , closed-loop control of steering. It is mainly a wire feeding controller with network communication function controlled by a dsPIC30F series single-chip microcomputer; this invention mainly performs digital control on wire feeding, and changes the welding voltage by changing the wire feeding speed. There are too many PLC control adjustment parameters, and the cost is high. In actual production, there is an urgent need for low-cost and high-efficiency integrated equipment.

Contents of the invention

The object of the present invention is to provide a deep penetration submerged arc welding controller in order to solve the technical problems of insufficient welding penetration, low welding efficiency, and expensive replacement existing in the prior art in DC submerged arc welding.

In order to solve the above-mentioned technical problems, the present invention adopts the following technical solutions:

A deep penetration deep submerged arc welding controller provided by the present invention includes a multi-mode power supply, a PWM single-phase pulse width modulation circuit, a normal/pulse function switching circuit, an LED signal display circuit and a weld seam indicator.

The deep penetration deep submerged arc welding controller is an external submerged arc welding controller, which is independently arranged on the original submerged arc welding control box, and the welding control switch of the control box does not need to be changed; if the controller function is not needed, it can be turned off The controller can be switched to normal welding mode. The deep penetration submerged arc welding controller panel has: normal/pulse switch, penetration (peak adjustment) knob, and display switch.

The multi-mode power supply is placed in the controller, adopts 120W dual-group voltage output D-120W switching power supply, inputs 220V sinusoidal alternating current, and outputs +12V and +5V (error 2%) DC stabilized voltage; the multi-mode power supply passes four The pin connectors are respectively connected with the PWM single-phase pulse width modulation circuit, the normal/pulse function switching circuit, the LED signal display circuit and the welding seam indicator.

The PWM single-phase pulse width modulation circuit is connected to the original submerged arc welding control box through the fourteen-core control line, and is connected to the normal/pulse function switching circuit and the LED signal display circuit through the connector, which is different from the existing technical features:

1. The PWM single-phase pulse width modulation circuit is based on the pulse generation chip SG3526 as the modulation pulse generator, and the chip SG3526 can realize the output of the pulse signal through the cooperation with the peripheral circuit: its constituent circuit is divided into the pulse signal generation circuit in A zone and B area pulse input signal forming circuit.

The pulse signal generating circuit is composed of chip SG3526, resistors R1, R2, R3, R4, R5, potentiometers RP1, RP2, capacitors C1, C2, filter capacitors C3, C4, C5, diodes D1, D2, and power supply Vcc, wherein Resistor R1 and potentiometer RP1 are connected in series to the eighteenth pin 18, which is connected to the user's voltage setting and voltage feedback to form a pulse width modulation output; the third pin 3 is connected in series with the voltage feedback terminal of the adjustment object through the resistor R2; the fourth Pin 4 is connected to the sixth pin 6 and seventh pin 7 in parallel and grounded through the series capacitor C1 to set the soft start time; the fifth pin 5 is positively connected to the power supply Vcc through the capacitor C2; the ninth pin 9 is connected through the resistor R3 and the potentiometer RP2 are connected to the ground to adjust the PWM pulse frequency; the thirteenth pin 13 and the sixteenth pin 16 are respectively connected in series with diodes D1 and D2 and connected in parallel to form a pulse signal generating circuit.

The pulse input signal forming circuit is composed of resistors R6, R7, capacitor C6, triode Q, diodes D3, D4, relay switch J1, and power supply Vcc, wherein the positive pole of the power supply Vcc and the relay switch J1 coil are connected in series, and the negative pole of the relay switch J1 coil is connected in series. It is connected in series with the collector of the transistor Q, the diodes D3 and D4 are connected in parallel with the transistor Q and the relay switch J1 respectively, and the capacitor C6 is connected in parallel with the base and the emitter of the transistor Q.

The diodes D1 and D2 in the pulse signal generating circuit are connected in parallel and connected in series with the resistor R7 in the pulse input signal forming circuit.

2. The maximum adjustment range of the duty ratio in the pulse signal generating circuit is 0-96%, and the adjustment range of the pulse frequency is 1-50 Hz;

3. The PWM waveform in the pulse input signal forming circuit directly drives the triode Q, and controls the generation of the pulse current input signal through the +12V Japanese Omron synchronous relay switch J1. The base value input signal is connected to the normally closed pin, and the peak value input signal is connected to the For normally open pins, the common end is connected to the signal output end.

The normal/pulse function switching circuit is composed of controller current potentiometers RP3 and RP4, the original submerged arc welding control box current potentiometer RP5, +12VDC Omron intermediate relay switches J2-1, J2-2, J2-3, The current potentiometer RP3 and RP4 of the controller can be switched with the current potentiometer RP5 of the original submerged arc welding control box; the three pins of the current potentiometer RP5 of the original submerged arc welding control box are connected to the normally closed ends of the three sets of switches The three pins of the controller current potentiometer RP3 and RP4 are respectively connected to the normally open ends of the three sets of switches.

The LED signal display circuit is composed of a display switching circuit and a signal acquisition and display part; the LED signal display circuit is composed of a BCD dial and a CD4051 analog switch. The composed signal acquisition and display part is composed; the display switching circuit can realize the switching of the base value peak value, pulse frequency and duty cycle parameters of the pulse current through the 8421 code of the dial and the CD4051 analog switch, and switch the acquisition signal The display sequence; the signal collection and display part, the duty ratio signal is collected from the duty ratio adjustment potentiometer RP1, the pulse frequency signal is collected from the potentiometer RP2, and the pulse current signal is collected from the middle lead of the controller current potentiometer RP3 and RP4 pin; obtain the signal through the voltage divider resistor to reduce the signal strength, obtain the millivolt level voltage signal, and display the value through multiple digital tubes.

The weld indicator is connected to the multi-mode power supply through a two-core wire. The weld indicator is composed of two red dot laser modules connected in parallel. The weld indicator is fixed on the welding torch by bolts, replacing the original needle-shaped indicator. The welding seam indicator emits two adjustable red light spots to correspond to the center of the welding seam, so that the offset of the welding wire can be adjusted in time during the welding process.

The present invention has the advantage that:

1. The present invention solidifies the frequency, duty cycle and base value current parameters in the controller, which simplifies the welding operation, leaving only a single adjustment knob for penetration (peak current) on the controller panel.

2. The waveform frequency of the controller of the present invention is low, which effectively controls the heat input, improves the quality of the welding seam, and increases the welding penetration.

3. The cost of the present invention is lower than that of other integrated devices, and can achieve the same control effect.

Description of drawings

Fig. 1 is a structural diagram of the deep penetration deep submerged arc welding controller of the present invention.

Fig. 2 is a schematic diagram of the panel of the deep penetration submerged arc welding controller.

Figure 3 is a PWM single-phase pulse width modulation circuit.

Fig. 4 is a schematic diagram of PWM waveform.

Figure 5 is a normal/pulse function switching circuit.

Figure 6 is the LED signal display circuit.

Fig. 7 is a schematic diagram of the centering of the weld indicator.

detailed description

The specific embodiment of the present invention is described in further detail below in conjunction with accompanying drawing:

See Figure 1, a deep penetration submerged arc welding controller, including multi-mode power supply, PWM single-phase pulse width modulation circuit, normal/pulse function switching circuit, LED signal display circuit, weld indicator, connector unit.

See Figure 2, the deep penetration submerged arc welding controller of the present invention is an external submerged arc welding controller, which is independently arranged on the original submerged arc welding control box, and the welding control switch of the control box does not need to be changed; if the controller function is not required , you can turn off the controller to switch to the normal welding mode. The deep penetration deep submerged arc welding controller panel has: normal/pulse switch, penetration (peak adjustment) knob, display switch; the controller can generate frequency, Control waveform with adjustable duty cycle, in which the three parameters of pulse current base value, waveform frequency and duty cycle are preset adjustable parameters, which are built into the controller.

The multi-mode power supply is placed in the controller, adopts 120W dual-group voltage output D-120W switching power supply, inputs 220V sinusoidal alternating current, and outputs +12V and +5V (error 2%) DC stabilized voltage; the multi-mode power supply passes four The foot connector is connected to the PWM single-phase pulse width modulation circuit, the normal/pulse function switching circuit, the LED signal display circuit and the welding seam indicator; , The welding seam indicator provides +12V DC power, and the LED display circuit provides +5V DC power; the rectified DC power is input to the PWM single-phase pulse width modulation circuit, so as to realize the pulse width and frequency of the waveform, the base value/peak value of the welding current range adjustment.

The PWM single-phase pulse width modulation circuit is connected to the original submerged arc welding control box through a fourteen-core control line, and its technical characteristics are shown in Figure 3:

The pulse generation chip SG3526 is used as a modulation pulse generator. It is a third-generation high-performance single-phase pulse width modulator designed for fixed-frequency switching regulators and other power control applications. The chip can realize pulse signals through cooperation with peripheral circuits. The output; it realizes the output of the pulse signal through the cooperation with the peripheral circuit, the A area is the pulse signal generating circuit, and the B area is the pulse input signal forming circuit.

The pulse signal generating circuit is composed of chip SG3526, resistors R1, R2, R3, R4, R5, potentiometers RP1, RP2, capacitors C1, C2, filter capacitors C3, C4, C5, diodes D1, D2, and power supply Vcc, wherein Resistor R1 and potentiometer RP1 are connected in series to the eighteenth pin 18, which is connected to the user's voltage setting and voltage feedback to form a pulse width modulation output; the third pin 3 is connected in series with the voltage feedback terminal of the adjustment object through the resistor R2; the fourth Pin 4 is connected in series with capacitor C1, sixth pin 6, and seventh pin 7 to ground in parallel to set the soft start time; fifth pin 5 is positively connected to power supply Vcc through capacitor C2; ninth pin 9 is connected to potential through resistor R3 The device RP2 is connected to the ground to adjust the PWM pulse frequency; the thirteenth pin 13 and the sixteenth pin 16 are respectively connected in series with diodes D1 and D2 and connected in parallel to form a pulse signal generating circuit.

The pulse input signal forming circuit is composed of resistors R6, R7, capacitor C6, triode Q, diodes D3, D4, relay switch J1, and power supply Vcc, wherein the positive pole of the power supply Vcc and the relay switch J1 coil are connected in series, and the negative pole of the relay switch J1 coil is connected in series. It is connected in series with the collector of the transistor Q, the diodes D3 and D4 are connected in parallel with the transistor Q and the relay switch J1 respectively, and the capacitor C6 is connected in parallel with the base and the emitter of the transistor Q.

The diodes D1 and D2 in the pulse signal generating circuit are connected in parallel and connected in series with the resistor R7 in the pulse input signal forming circuit.

The SG3526 generates a PWM waveform after the diodes D1 and D2, and the PWM waveform drives the on-off action of the triode Q. The triode Q acts as an on-off switch. The relay switch J1 is a Japanese Omron synchronous switch relay with a standard voltage of 12V. The relay switch J1 mainly controls For the generation of pulse current input signal, the base value input signal is connected to the normally closed pin, the peak voltage model is connected to the normally open pin, and the common terminal is connected to the signal output terminal; when the pulse signal is at a high level, the transistor Q is turned on, at this time The relay switch J1 starts to switch from normally closed to normally open, and the peak current and voltage control signal output; when the pulse signal is at low level, the relay switch J1 is in the normally closed state and conducts, and the base value current and voltage control signal output. After that, the pulse signal is input into the original submerged arc welding control box, passes through the signal separation circuit, and then drives the thyristor after passing through the calculation circuit to achieve pulse welding. The frequency and duty cycle of the waveform can be adjusted by adjusting the resistance values of the potentiometers RP1 and RP2, and the frequency and duty cycle of the welding pulse current can be set. The maximum adjustment range of the duty cycle in the pulse signal generating circuit is 0-96%, and the adjustment range of the pulse frequency is 1-50Hz.

The preset PWM welding waveform is shown in FIG. 4 , its duty cycle is 60%, and its frequency is 1.03 Hz, which can effectively achieve the effect of preset welding penetration.

The normal/pulse function switching circuit is shown in Figure 5, which is composed of current potentiometers RP3 and RP4, the original submerged arc welding control box current potentiometer RP5, and +12VDC Omron intermediate relay switches J2-1, J2-2 and J2-3 , where the three pins of the current potentiometer RP5 of the original submerged arc welding control box are respectively connected to the normally closed end of J2-1/2/3, the middle pin of the controller current base value potentiometer RP3 is connected to the normally closed end of J1, and the peak value The middle leg of the potentiometer RP4 is connected to the normally open end of J1, the first pin 1 of RP3, the second pin 2 of RP3 and the third pin 3 of RP4 are respectively connected to the normally open end of J2-1/2/3.

The LED signal display circuit is shown in Figure 6. It is composed of a display switching circuit composed of a BCD dial and a CD4051 output channel selection switch, and a signal acquisition and display part composed of a three-and-a-half-digit meter head ICL7107 and a digital tube.

The display switching circuit is composed of a dial, an analog switch CD4051, voltage dividing resistors R27, R31, R28, R32, R29, R33, R30, R34, R35, R37, and the starting end of the voltage dividing resistor is a signal acquisition input The end and the middle end are respectively connected to the twelfth to fifteenth pins 12, 13, 14, 15 of CD4051, and the ends are connected to the ground in parallel. The first pin 1, the fifth pin 5, the second pin 2, the fourth pin Pin 4 is connected to the ground in parallel, pin C, fourth pin 4, second pin 2, and first pin 1 of the dial are respectively connected to 5V power supply, eleventh pin 11, and tenth pin 10 of CD4051 , and the ninth pin 9 is connected; the dial can realize the switching of the base value/peak value of the pulse current, the pulse frequency, and the duty ratio, and switch the display sequence of the collected signals.

The signal acquisition shows that the duty ratio signal is collected from the duty ratio adjustment potentiometer RP1 in Figure 3, the pulse frequency signal is collected from the potentiometer RP2, and the pulse current signal is collected from the middle pins of the controller current potentiometer RP3 and RP4 in Figure 5 ; Obtain the signal through the voltage divider resistor to reduce the signal strength, obtain the millivolt level voltage signal, and display the value through multiple digital tubes. The LED display circuit facilitates the digitalization of the signal, and the parameter adjustment is more convenient.

The weld seam indicator is shown in Figure 7. It is connected to the multi-mode power supply through a two-core wire. The weld seam indicator is composed of double red dot laser modules connected in parallel. The weld seam indicator is fixed on the welding torch by bolts, replacing the original Needle-shaped indicator; the welding seam indicator emits two beams of adjustable red light spots to correspond to the center of the welding seam, so that the offset of the welding wire can be adjusted in time during the welding process.

The following is an actual engineering application as an implementation case:

For butt welding of 18mm thick marine grade B boards, this controller is used in combination with Weiteli MZ-1000R automatic submerged arc welding machine, and the welding steps are as follows:

1. Turn on the power of the controller, switch to pulse adjustment, and adjust the penetration knob to adjust the peak value of the pulse current. The pulse current base value, waveform frequency and duty cycle are fixed values;

2. Adjust the welding voltage on the submerged arc welding control box to the specified value of the process, the welding speed to the specified value of the process and the dry elongation of the welding wire. At this time, the parameter adjustment is completed.

3. Power on the welding seam indicator, adjust the size and distance of the light spots of the two welding seam indicators, corresponding to the center line of the welding seam.

Compared with the prior art, the deep penetration deep submerged arc welding controller of the present invention realizes the integration of deep penetration deep submerged arc welding equipment; under the premise of the same welding speed, the heat input is effectively reduced, and the stirring at the bottom of the molten pool is improved at the same time Therefore, without clearing the root, the penetration depth of the weld is increased, the requirements for welding operators are reduced, the welding efficiency is improved, and the production efficiency of the enterprise is promoted.

Claims (7)

1. a dark fusion penetration union-melt weld controller, comprise multimode power supply, the single-phase pulse-width modulation circuit of PWM, common/pulse function switching circuit, LED signal display circuit and weld seam telltale, it is characterized in that: the single-phase pulse-width modulation circuit of described PWM is using pulse generation chip SG3526 as modulation pulse generator, pulse generation chip SG3526 process coordinates, with peripheral circuit, the output that can realize pulse signal: the single-phase pulse-width modulation circuit of described PWM is divided into A district pulse signal generation circuit and B district pulse input signal to form circuit; Described pulse generation chip SG3526 produces PWM waveform after diode D1 and diode D2, PWM waveform drives triode Q break-make action, this triode Q is as switch on and off, relay1 switch J1 is Japan's Omron synchro-switch rly., standard voltage 12V, the wherein generation of relay1 switch J1 major control pulsed current input signal, base value input signal is connected to normally closed pin, peak value input signal is in often opens pin, public end connection signal output terminal; When pulse signal is in high level, triode Q conducting, now relay1 switch J1 starts often to open by normally closed being switched to, and peak point current voltage control signal exports; When pulse signal is in lower level, relay1 switch J1 is in normally off conducting, and background current voltage control signal exports; Pulse signal is input to through demultiplexing circuit in original union-melt weld controlling box afterwards, then through arithmetical circuit rear drive thyristor, reaches pulse welding; By regulating frequency and the dutycycle of the resistance of potentiometer RP1 and potentiometer RP2 and adjustable waveform, just the frequency and dutycycle welding pulsed current can be set;

Described pulse signal generation circuit is by pulse generation chip SG3526, resistance R1, resistance R2, resistance R3, resistance R4, resistance R5, potentiometer RP1, potentiometer RP2, electric capacity C1, electric capacity C2, filter capacitor C3, filter capacitor C4, filter capacitor C5, diode D1, diode D2, power Vcc is formed, wherein resistance R1 and potentiometer RP1 series connection the 18 pin (18), connect that user's voltage is given and voltage feedback, form width modulation and export; 3rd pin (3) is connected by resistance R2 and is connected with the pressure feedback port of controlled plant; 4th pin (4) by series capacity C1 again and ground connection in parallel with the 6th pin (6) and the 7th pin (7) soft-start time is set; 5th pin (5) is just connected with power Vcc by electric capacity C2; 9th pin (9) is connected with ground with potentiometer RP2 by resistance R3, regulates pwm pulse frequency; 13 pin (13), the 16 pin (16) are in parallel after series diode D1, diode D2 respectively thus form pulse signal generation circuit;

Described pulse input signal forms electricity routing resistance R6, resistance R7, electric capacity C6, triode Q, diode D3, diode D4, relay1 switch J1, power Vcc is formed, the wherein positive pole series connection of power Vcc and relay1 switch J1 coil, the negative pole of relay1 switch J1 coil and the series connection of triode Q collector electrode, diode D3, D4 are in parallel with triode Q, relay1 switch J1 respectively, electric capacity C6 and triode Q base stage, emtting electrode parallel connection;

In described pulse signal generation circuit after diode D1, diode D2 parallel connection and pulse input signal form resistance R7 in circuit and be in series.

2. a kind of dark fusion penetration union-melt weld controller as claimed in claim 1, it is characterised in that: in described pulse signal generation circuit, largest duty cycle regulation range is 0��96%, and the regulation range of pulse-repetition is 1��50Hz.

3. a kind of dark fusion penetration union-melt weld controller as claimed in claim 1, it is characterised in that: described multimode power supply is positioned in controller, adopts two group voltage to export D-120W switch power supply, and input 220V sinusoidal ac, exports+12V and+5V voltage of direct-flow voltage regulation; This multimode power supply is connected by four pin connector pulse-width modulation circuits single-phase with PWM, common/pulse function switching circuit, LED signal display circuit and weld seam telltale; Described switching mode power supply transformer, provides+12V direct current to the single-phase pulse-width modulation circuit of PWM, common/pulse function switching circuit, weld seam telltale, provides+5V direct current to LED display circuit; Direct current after rectification is input in the single-phase pulse-width modulation circuit of PWM, thus realizes the range regulation to the pulsewidth of waveform and frequency, welding current base value/peak value.

4. a kind of dark fusion penetration union-melt weld controller as claimed in claim 1, it is characterised in that: described LED signal display circuit, is made up of display switching circuit and signals collecting display section; Display switching circuit can switch in pulsed current, waveform frequency and dutycycle three, the signal input terminus of signals collecting part is the middle pin of described controller electric current potentiometer RP3 and RP4, frequency potentiometer RP2, dutycycle potentiometer RP1, the power input of Signal aspects part is provided by multimode power supply, it is achieved the digitizing display of multiple signal.

5. a kind of dark fusion penetration union-melt weld controller as claimed in claim 1, it is characterised in that: the display switching circuit that described LED signal display circuit is made up of BCD dial and CD4051 analog switch and the signals collecting display section being made up of three and half digital watch ICL7107 and charactron form;

Described display switching circuit, can realize the switching of the base value peak value of pulsed current, pulse-repetition, each parameter of dutycycle by the 8421 of dial yards and CD4051 analog switch, the shown sequence of switching acquired signal;

Described signals collecting display section, duty cycle signals picks up from duty cycle adjustment potentiometer RP1, and pulse duration frequency signal picks up from potentiometer RP2, and pulsed current signal picks up from the middle pin of controller electric current potentiometer RP3 and RP4; Obtaining signal and reduce strength of signal by a point compressive resistance, obtain millivolt magnitude voltage signals, display numerical value is by multiple numeral method.

6. a kind of dark fusion penetration union-melt weld controller as claimed in claim 1, it is characterized in that: described common/pulse function switching circuit, it is made up of controller electric current potentiometer RP3 and RP4, union-melt weld controlling box electric current potentiometer RP5 ,+12VDC Omron intermediate relay switch J2-1, J2-2, J2-3 so that controller electric current potentiometer RP3 and RP4 and union-melt weld controlling box electric current potentiometer RP5 can switch; Union-melt weld controlling box electric current potentiometer RP5 tri-pins connect the normal-closed end of intermediate relay switch J2-1, intermediate relay switch J2-2, intermediate relay switch J2-3 tri-groups of switches respectively, and controller electric current potentiometer RP3 and RP4 tri-pins meet the Chang Kaiduan of intermediate relay switch J2-1, intermediate relay switch J2-2, intermediate relay switch J2-3 tri-groups of switches respectively.

7. a kind of dark fusion penetration union-melt weld controller as claimed in claim 1, it is characterized in that: described weld seam telltale, it is connected with multimode power supply by two heart yearns, weld seam telltale is made up of two red point-like laser modules in parallel, weld seam telltale is secured by bolts on welding gun, replaces needle-like telltale; Described weld seam telltale sends the adjustable red hot spot of two bundles so that it is corresponding with Weld pipe mill, can regulate the skew amount of welding wire in welding process in time.