CN105382377A - Arc welding method - Google Patents
Arc welding method Download PDFInfo
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- CN105382377A CN105382377A CN201510526599.7A CN201510526599A CN105382377A CN 105382377 A CN105382377 A CN 105382377A CN 201510526599 A CN201510526599 A CN 201510526599A CN 105382377 A CN105382377 A CN 105382377A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract
The invention provides an arc welding method which can increase the depth of fusion in spray transfer welding. In a first period, T1 outputs a first output voltage E1 and a first welding current Iw1; in a second period, T2 outputs a first output voltage E2 and a first welding current Iw2; in a third period, T3 outputs a third output voltage E3 and a third welding current Iw3, wherein 0<E2<E3<E1, and 0<Iw2<Iw3<Iw1. When a rate of change of the welding currents is less than a reference rate of change, the first output voltage E1 is raised, or/and the first output voltage E2 is reduced. Through the T1 in the first period, molten metal right below a welding wire is made to be relatively thin. Through the T2 in the second period, electric arcs are made to gather right below the welding wire. Through the T3 in the third period, centralized heating is carried out in a molten pool so as to make the molten pool to be smoother. By means of correcting the output voltages E1 and E2, inductances of a cable for welding will not be influenced so as to form a relatively-large depth of fusion and reach purposes of high quality.
Description
Technical field
The present invention relates to feeding welding wire and the high quality of the arc-welding method welded by spray transfer state.
Background technology
Using the mist of argon gas and carbon dioxide as protective gas and use the MAG of solid welding wire to weld, using carbon dioxide as protective gas and in using the arc welding of filling flux welding wire, do not use protective gas and use the self-shielded arc welding of self-shield filling flux welding wire to connect etc., transfer manner of droplet becomes spray transfer form.Under spray transfer form, due to arc heat, welding wire front end is melted and becomes particulate to molten bath transition.Under spray transfer form, molten drop is not short circuiting transfer, and carrys out transition by free-falling.
Based on spray transfer form arc welding (hereinafter referred to as spray transfer welding) in, use the source of welding current of constant-voltage characteristic, welding wire is by constant speed feed.In spray transfer welding, the generation with splashing is few and welding bead outward appearance also becomes good feature.On the other hand, in spray transfer welding, electric arc length is longer than short circuiting arc welding, and because electric arc becomes wide shape, therefore fusion penetration shoals.This point becomes problem because of workpiece sometimes in welding quality.Below, the spray transfer welding of prior art is described with reference to accompanying drawing.
Fig. 5 is the voltage and current waveform in general spray transfer welding.This figure (A) represents the time variations be used for the output voltage setting signal Er that the output valve of the constant-voltage characteristic of the source of welding current sets, this figure (B) represents the time variations of the weldingvoltage Vw be applied between welding wire and mother metal, and this figure (C) represents the time variations of the welding current Iw of energising electric arc.Below, illustrate with reference to this figure.
As shown in this figure (A), output voltage setting signal Er is set to fixed value.As shown in this figure (B), weldingvoltage Vw in slightly changing up and down, but roughly becomes fixed value.As shown in this figure (C), welding current Iw also in slightly changing up and down, but roughly becomes fixed value.The instantaneous value of weldingvoltage Vw sets according to output voltage setting signal Er.The mean value of welding current Iw sets according to the feed speed of welding wire.
In the invention of patent document 1, in spray transfer welding and droplet transfer welding, by making the output voltage of the source of welding current with more than 100Hz and the frequency of below 600Hz periodically changes, thus make welding current at more than 20A and in the current amplitude of below 100A, change is welded.
At first technical literature
Patent document
Patent document 1: Japanese Unexamined Patent Publication 2007-229775 publication
Summary of the invention
For this reason, in the present invention, its object is to, provide and can deepen fusion penetration to seek the arc-welding method of high quality in spray transfer welding.
In order to solve above-mentioned problem, the invention of technical scheme 1 is a kind of arc-welding method, feeding welding wire, output voltage is exported from the source of welding current, energising welding current, welded by spray transfer form, it is characterized in that, the 1st output voltage E1 is exported and the 1st welding current Iw1 that is energized in during the 1st, the 2nd output voltage E2 is exported and the 2nd welding current Iw2 that is energized in during the 2nd, the 3rd output voltage E3 is exported and the 3rd welding current Iw3 that is energized in during the 3rd, 0 < E2 < E3 < E1, 0 < Iw2 < Iw3 < Iw1, during repeating the above-mentioned 1st ~ the above-mentioned 3rd during, detect to switch during the above-mentioned 1st ~ the above-mentioned 3rd during each period time the rate of change of above-mentioned welding current, when this rate of change is less than prespecified reference change rate, carry out the increase of above-mentioned 1st output voltage E1 and/or the minimizing of above-mentioned 2nd output voltage E2.
The invention of technical scheme 2 is for the arc-welding method given the alarm when above-mentioned rate of change is less than said reference rate of change described in the technical scheme 1 of feature.
The invention of technical scheme 3 is for the arc-welding method extended when above-mentioned rate of change is less than said reference rate of change during the above-mentioned 1st and/or during the above-mentioned 2nd described in the technical scheme 1 or 2 of feature.
Invention effect
According to the present invention, in during the 1st, larger arc pressure acts on molten bath, and molten bath becomes the concave shape caved in immediately below welding wire, and the deposite metal immediately below welding wire becomes thinner state.During the follow-up the 2nd, the shape that arc shape has become flat, the state that the part that the electric arc deposite metal become immediately below welding wire becomes thinner state is concentrated.During the follow-up the 3rd, in first half, the part of gouged weld pool is intensively heated by electric arc, fixes at latter half of middle arc pressure, and therefore the part of gouged weld pool becomes nothing, becomes mild state.In the present invention, by repeat these during the 1st ~ the 3rd during, thus fusion penetration can be deepened to seek high quality in spray transfer welding.And then, in the present invention, because the inductance value of welding cable is large, therefore the rate of change of welding current diminishes, become be less than reference change rate time, by the minimizing of the increase and/or the 2nd output voltage E2 of carrying out the 1st output voltage values E1, thus can the rate of change of increase of weld current.Thus, the impact of the inductance value of welding cable can not be subject to, above-mentioned effect can be played.
Accompanying drawing explanation
Fig. 1 is the block diagram of the source of welding current for implementing the arc-welding method involved by embodiments of the present invention 1.
Fig. 2 is the sequential chart of each signal in the source of welding current of the Fig. 1 of the arc-welding method represented involved by embodiments of the present invention 1.
Fig. 3 is the block diagram of the source of welding current for implementing the arc-welding method involved by embodiments of the present invention 2.
Fig. 4 is the sequential chart of each signal in the source of welding current of the Fig. 3 of the arc-welding method represented involved by embodiments of the present invention 2.
Fig. 5 is the voltage and current waveform in spray transfer welding general in prior art.
Symbol description
1 welding wire
2 mother metals
3 electric arcs
4 welding torches
5 feed rolls
6,7 welding cables
AR circuit for alarming
E output voltage
E1 the 1st output voltage
E2 the 2nd output voltage
E3 the 3rd output voltage
ECR output voltage control initialization circuit
Ecr output voltage control setting signal
ECR2 the 2nd output voltage control initialization circuit
ED output voltage detecting circuit
Ed voltage sense signal
EDR voltage reduction value initialization circuit
Edr voltage reduction value setting signal
ER output voltage initialization circuit
Er output voltage setting signal
EUR voltage value added initialization circuit
Eur voltage value added setting signal
EV voltage error amplifying circuit
Ev voltage error amplifying signal
ID current detection circuit
Id current detection signal
Iw welding current
Iw1 the 1st welding current
Iw2 the 2nd welding current
Iw3 the 3rd welding current
The inductance value of Lc welding cable
PM electric power main circuit
SD rate of change judging circuit
Sd rate of change judgment signal
Signal during Sp
During T1 the 1st
Initialization circuit during T1R the 1st
Setting signal during T1r the 1st
During T2 the 2nd
Initialization circuit during T2R the 2nd
Setting signal during T2r the 2nd
During T3 the 3rd
Initialization circuit during T3R the 3rd
Setting signal during T3r the 3rd
Vw weldingvoltage
Vw1 the 1st welding voltage value
Vw2 the 2nd welding voltage value
Vw3 the 3rd welding voltage value
WL reactor
Δ d, Δ t, Δ u correction
Detailed description of the invention
Below, with reference to accompanying drawing, embodiments of the present invention are described.
[embodiment 1]
Fig. 1 is the block diagram of the source of welding current for implementing the arc-welding method involved by embodiments of the present invention 1.Below, each piece is illustrated with reference to this figure.
The source power supplies such as 3 phase 200V (omitting diagram) as input, are carried out output by the inverter control based on voltage error amplifying signal Ev described later and control, export output voltage E by electric power main circuit PM.Although this electric power main circuit PM omits diagram, possess: to source power supply carry out rectification No. 1 rectification circuit, to the smoothing capacitor of the direct current after being rectified, by by the DC converting after level and smooth be high-frequency ac inverter circuit, by high-frequency ac step-down be the magnitude of voltage of applicable arc welding high frequency transformer, to being carried out No. 2 rectification circuits of rectification by the high-frequency ac after step-down and above-mentioned voltage error amplifying signal Ev being carried out the modulation controls such as PWM control to drive the drive circuit of above-mentioned inverter circuit as input.This electric power main circuit PM becomes constant pressure source, with output voltage control setting signal Ecr described later for desired value carries out Isobarically Control, exports output voltage E.Reactor WL is smoothing to this output voltage E.Therefore, output voltage E be level and smooth by reactor WL before voltage.
Welding wire 1 by the rotation of feed rolls 5 that combines with feeding motor (omit and illustrate) and feeding in welding torch 4, and produces electric arc 3 between mother metal 2, weld.Apply weldingvoltage Vw between power supply chip (omitting diagram) in welding torch 4 and mother metal 2, be energized welding current Iw in electric arc 3.A lead-out terminal (omitting diagram) of the source of welding current and welding torch 4 are connected by welding cable 6, and another lead-out terminal (omitting diagram) of the source of welding current and mother metal 2 are connected by welding cable 7.The inductance value that welding cable 6,7 adds up to is Lc (μ H).Welding wire 1 welds with Electrode Negative (EN) or electrode straight polarity (EP) according to its kind.
Output voltage initialization circuit ER exports prespecified output voltage setting signal Er.Voltage value added initialization circuit EUR exports prespecified voltage value added setting signal Eur.Voltage reduction value initialization circuit EDR exports prespecified voltage reduction value setting signal Edr.
Setting signal T1r during initialization circuit T1R exports the prespecified 1st during 1st.Setting signal T2r during initialization circuit T2R exports the prespecified 2nd during 2nd.Setting signal T3r during initialization circuit T3R exports the prespecified 3rd during 3rd.
Output voltage control initialization circuit ECR using setting signal T3r and rate of change judgment signal Sd described later during setting signal T2r, the above-mentioned 3rd during setting signal T1r, the above-mentioned 2nd during above-mentioned output voltage setting signal Er, above-mentioned voltage value added setting signal Eur, above-mentioned voltage reduction value setting signal Edr, the above-mentioned 1st as input, carry out following process, export output voltage control setting signal Ecr and period signal Sp.
1) in the 1st period T1 specified to setting signal T1r during by the 1st in the sart point in time in cycle of the 1st time, export Ecr=Er+Eur, output voltage control setting value Ecr (1,1) as the 1st period T1 in the cycle of the 1st time stores.In addition, in this period, Sp=1 is exported.
2) following, in the 2nd period T2 that setting signal T2r specifies during by the 2nd, export Ecr=Er-Edr, the output voltage control setting value Ecr (1,2) as the 2nd period T2 in the cycle of the 1st time stores.In addition, in this period, Sp=2 is exported.
3) following, in the 3rd period T3 that setting signal T3r specifies during by the 3rd, export Ecr=Er.In addition, in this period, Sp=3 is exported.
4) in the 1st period T1 specified to setting signal T1r during by the 1st in the sart point in time in cycle of n-th time, Ecr=Ecr (n-1 is exported when the rate of change judgment signal Sd of the 1st period T1 sart point in time of n-th time is low (Low) level, 1), Ecr=Ecr (n-1,1)+Δ u is exported when high (High) level.Further, the output voltage control setting value Ecr (n, 1) as the 1st period T1 in the cycle of n-th time stores.Δ u is correction, be prespecified on the occasion of.In addition, in this period, Sp=1 is exported.
5) following, in the 2nd period T2 that setting signal T2r specifies during by the 2nd, Ecr=Ecr (n-1 is exported when the rate of change judgment signal Sd of the 1st period T1 sart point in time of n-th time is low level, 2), Ecr=Ecr (n-1,2)-Δ d is exported when high level.Further, the output voltage control setting value Ecr (n, 2) as the 2nd period T2 in the cycle of n-th time stores.Δ d is correction, be prespecified on the occasion of.In addition, in this period, Sp=2 is exported.
6) following, in the 3rd period T3 that setting signal T3r specifies during by the 3rd, independently export Ecr=Er with rate of change judgment signal Sd.In addition, in this period, Sp=3 is exported.
7) repeat above-mentioned 4) ~ 6) process.
In above-mentioned output voltage control initialization circuit ECR, output voltage control setting signal Ecr when rate of change judgment signal Sd is high level, value than the front cycle in the 1st period T1 only increases Δ U, value than the front cycle in the 2nd period T2 only reduces Δ D, and the value maintaining output voltage setting signal Er in the 3rd period T3 is constant.
Output voltage detecting circuit ED detects above-mentioned output voltage E, smoothing to the pulsation caused by inverter frequency, exports voltage sense signal Ed.Error between above-mentioned output voltage control setting signal Ecr (+) and this voltage sense signal Ed (-) is amplified by voltage error amplifying circuit EV, and output voltage error amplifying signal Ev.By this voltage error amplifying circuit EV, the source of welding current is carried out Isobarically Control.
Current detection circuit ID detects above-mentioned welding current Iw, and output electric current measure signal Id.Rate of change judging circuit SD using this current detection signal Id and above-mentioned period signal Sp as input, detect the rate of change of the current detection signal id lighted to the time that Sp=1 changes since Sp=3, make to become high level when this rate of change is less than prespecified reference change rate and more than the reference change rate that this rate of change is prespecified time become low level rate of change judgment signal Sd, becoming Sp=2 time point export.In the circuit, also can detect the rate of change of the current detection signal Id that the time point since Sp=1 changes to Sp=2 or time from Sp=2 to Sp=3 that change from light, and compare with reference change rate corresponding separately.If the length of welding cable 6,7 or as describing circle by roundabout and make the inductance value Lc of welding cable become large, then to switch during the 1st ~ the above-mentioned 3rd during each period time the rate of change of welding current Iw become mild.During differentiating switching the 1st according to this circuit ~ the above-mentioned 3rd during each period time the rate of change of welding current Iw become milder situation than prespecified reference change rate.
Above-mentioned rate of change judgment signal Sd as input, gives the alarm when rate of change judgment signal Sd=high level by circuit for alarming AR.Alarm by lighting display lamp, the alarm tone that pipes, externally export alarm signal etc. and carry out.
Fig. 2 is the sequential chart of each signal in the source of welding current of the Fig. 1 of the arc-welding method represented involved by embodiments of the present invention 1.This figure (A) represents the time variations of output voltage control setting signal Ecr, this figure (B) represents the time variations of weldingvoltage Vw, this figure (C) represents the time variations of welding current Iw, and this figure (D) represents the time variations of rate of change judgment signal Sd.Below, be described with reference to this figure.
In the figure, from welding to moment t4 during in, because the inductance value Lc of welding cable is little, therefore the rate of change of welding current Iw becomes more than reference change rate, as shown in this figure (D), rate of change judgment signal Sd maintains low level.On the other hand, moment t4 later during be roundabout the changing of welding cable and inductance value Lc becomes large situation.Because the inductance value Lc of welding cable is decided by the environment that arranges of welder, therefore change in welding comparatively rare.In the figure, for ease of understanding the action of present embodiment, the situation that inductance value Lc in welding changes is set to.
As shown in this figure (A), output voltage control setting signal Ecr becomes the waveform of periodic swinging by the output voltage control initialization circuit ECR of Fig. 1.As shown in this figure (D), rate of change judgment signal Sd was low level before moment t1, and the sart point in time t1 of the 1st period T1 is also low level.Thus, as shown in this figure (A), output voltage control setting signal Ecr becomes the value of output voltage setting signal Er phase making alive value added setting signal Eur gained in the 1st prespecified period T1 of moment t1 ~ t2, in the 2nd prespecified period T2 of moment t2 ~ t3, become the value that output voltage setting signal Er deducts voltage reduction value setting signal Edr gained, in the 3rd prespecified period T3 of moment t3 ~ t4, become the value of output voltage setting signal Er.At this, Er > 0, Eur > 0, Edr > 0, Ecr > 0.
Output voltage E sets according to output voltage control setting signal Ecr, becomes roughly the same square waveform.Below, the output voltage E of the 1st period T1 is recited as the 1st output voltage E1, the output voltage E of the 2nd period T2 is recited as the 2nd output voltage E2, the output voltage E of the 3rd period T3 is recited as the 3rd output voltage E3.
As shown in this figure (B), because output voltage E is waveform, therefore weldingvoltage Vw becomes waveform, in the 1st period T1 of moment t1 ~ t2, from the 3rd welding voltage value Vw3, there is the 1st welding voltage value Vw1 increasing obliquely and become roughly fixed value, in the 2nd period T2 of moment t2 ~ t3, from the 1st welding voltage value Vw1, there is the 2nd welding voltage value Vw2 reducing obliquely and become roughly fixed value, in the 3rd period T3 of moment t3 ~ t4, from the 2nd welding voltage value Vw2, there is the 3rd welding voltage value Vw3 increasing obliquely and become roughly fixed value.1st welding voltage value Vw1 is set by Er+Eur, and the 2nd welding voltage value Vw2 is set by Er-Edr, and the 3rd welding voltage value Vw3 is set by Er.
As shown in this figure (C), welding current Iw is decided by weldingvoltage Vw and electric arc load, because weldingvoltage Vw vibrates, therefore welding current Iw becomes waveform, in the 1st period T1 of moment t1 ~ t2, from the 3rd welding current value Iw3, there is the 1st welding current value Iw1 increasing obliquely and become roughly fixed value, in the 2nd period T2 of moment t2 ~ t3, from the 1st welding current value Iw1, there is the 2nd welding current value Iw2 reducing obliquely and become roughly fixed value, in the 3rd period T3 of moment t3 ~ t4, from the 2nd welding current value Iw2, there is the 3rd welding current value Iw3 increasing obliquely and become roughly fixed value.At this, 0 < Iw2 < Iw3 < Iw1.Rate of change due to the welding current Iw in the 1st period T1 is more than reference change rate, and therefore as shown in this figure (D), it is constant that rate of change judgment signal Sd maintains low level.
As shown in this figure (D), the rate of change judgment signal Sd at the sart point in time t4 place of the 1st period T1 is low level.Thus, as shown in this figure (A), output voltage control setting signal Ecr becomes the value identical with the front cycle, in the 1st period T1 of moment t4 ~ t5, become Er+Eur, in the 2nd period T2 of moment t5 ~ t6, become Er-Edr, in the 3rd period T3 of moment t6 ~ t7, become Er.
Because from moment t4, the inductance value Lc of welding cable becomes large, therefore as shown in this figure (B), the inclination (rate of change) of weldingvoltage Vw becomes mild.Thus, weldingvoltage Vw gently increases in the 1st period T1 of moment t4 ~ t5, terminates, gently reduce in the 2nd period T2 of moment t5 ~ t6 during the midway increased, and terminates during the midway of reducing.Gently increase in the 3rd period T3, become the 3rd welding voltage value Vw3 of roughly fixed value.
Similarly, as shown in this figure (C), the inclination (rate of change) of welding current Iw also becomes mild.Thus, welding current Iw gently increases in the 1st period T1 of moment t4 ~ t5, terminates, gently reduce in the 2nd period T2 of moment t5 ~ t6 during the midway increased, and terminates during the midway of reducing.Gently increase in the 3rd period T3, become the 3rd welding current value Iw3 of roughly fixed value.That is, the amplitude of the welding current Iw of the 1st period T1 and the 2nd period t2 diminishes.At this, because the rate of change of the welding current Iw in the 1st period T1 is less than reference change rate, therefore as shown in this figure (D), at moment t5, rate of change judgment signal Sd becomes high level.
As shown in this figure (D), the rate of change judgment signal Sd at the sart point in time t7 place of the 1st period T1 is high level.Thus, as shown in this figure (A), output voltage control setting signal Ecr becomes the revised value of value in cycle in the past, before becoming in the 1st period T1 of moment t7 ~ t8, the value in cycle is added value and the Er+Eur+ Δ u of Δ u gained, before becoming in the 2nd period T2 of moment t8 ~ t9, the value in cycle deducts value and the Er-Edr-Δ d of Δ d gained, the value in cycle and Er before maintaining in the 3rd period T3 of moment t9 ~ t10.
Although the inductance value Lc of welding cable becomes large from moment t4, but the value of the output voltage control setting signal Ecr in the 1st period T1 becomes large, 1st output voltage E1 becomes large, the value of the output voltage control setting signal Ecr in the 2nd period T2 diminishes, 2nd output voltage E2 diminishes, therefore, as shown in this figure (B), although the inclination (rate of change) of weldingvoltage Vw is more precipitous than the cycle of moment t4 ~ t7 gently in the past than moment t4.Thus, weldingvoltage Vw, in the 1st period T1 of moment t7 ~ t8, till having near value i.e. the 1st welding voltage value Vw1 that is increased to obliquely before moment t4 from the 3rd welding voltage value Vw3, in the 2nd period T2 of moment t8 ~ t9, till having near value i.e. the 2nd welding voltage value Vw2 that is reduced to obliquely before moment t4 near the 1st welding voltage value Vw1, in the 3rd period T3 of moment t9 ~ t10, near the 2nd welding voltage value Vw2, there is the 3rd welding voltage value Vw3 increasing obliquely and become roughly fixed value.
Similarly, as shown in this figure (C), although the inclination (rate of change) of welding current Iw is more precipitous than the cycle of moment t4 ~ t7 gently in the past than moment t4.Thus, welding current Iw, in the 1st period T1 of moment t7 ~ t8, till having near value i.e. the 1st welding current value Iw1 that is increased to obliquely before moment t4 from the 3rd welding current value Iw3, in the 2nd period T2 of moment t8 ~ t9, till having near value i.e. the 2nd welding current value Iw2 that is reduced to obliquely before moment t4 near the 1st welding current value Iw1, in the 3rd period T3 of moment t9 ~ t10, near the 2nd welding current value Iw2, there is the 3rd welding current value Iw3 increasing obliquely and become roughly fixed value.That is, the amplitude of the welding current Iw of the 1st period T1 and the 2nd period t2 becomes the value roughly the same with before moment t4.At this, the rate of change due to the welding current Iw in the 1st period T1 is more than reference change rate, and therefore as shown in this figure (D), at moment t8, rate of change judgment signal Sd becomes low level.
As shown in this figure (D), the rate of change judgment signal Sd at the sart point in time t10 place of the 1st period T1 is low level.Thus, as shown in this figure (A), output voltage control setting signal Ecr becomes the value identical with the value in front cycle, Er+Eur+ Δ u is become in the 1st period T1 of moment t10 ~ t11, in the 2nd period T2 of moment t11 ~ t12, become Er-Edr-Δ d, in the 3rd period T3 of moment t12 ~ t13, become Er.
Although the inductance value Lc of welding cable becomes large from moment t4, but the value of the output voltage control setting signal Ecr in the 1st period T1 becomes large, 1st output voltage E1 becomes large, the value of the output voltage control setting signal Ecr in the 2nd period T2 becomes large, 2nd output voltage E2 diminishes, therefore, as shown in this figure (B), the inclination (rate of change) of weldingvoltage Vw is identical with the front cycle.Thus, weldingvoltage Vw becomes the waveform roughly the same with the front cycle.
Similarly, as shown in this figure (C), the inclination (rate of change) of welding current Iw is also identical with the front cycle.Thus, welding current Iw becomes the waveform roughly the same with the front cycle.That is, the amplitude of the welding current Iw of the 1st period T1 and the 2nd period t2 becomes the value roughly the same with before moment t4.At this, the rate of change due to the welding current Iw in the 1st period T1 is more than reference change rate, and therefore as shown in this figure (D), rate of change judgment signal Sd maintains low level.
Henceforth, the action in the cycle of moment t10 ~ t13 is repeated.In the figure, although only have the situation in 1 cycle of moment t7 ~ t10 exemplified with the correction of output voltage control setting signal Ecr, also there is the situation of continuous multiple cycle till the rate of change of welding current Iw becomes more than reference change rate.Above-mentioned correction amount u and Δ d is set to 1 ~ 3V degree.If this value is excessive, welded condition becomes unstable, if this value is too small, revises and need the time, the welding quality between validation period is deteriorated.Also higher limit can be set for the value of the output voltage control setting signal Ecr in the 1st period T1 after being corrected.Also lower limit can be set for the value of the output voltage control setting signal Ecr in the 2nd period T2 after being corrected.
Above-mentioned reference change rate is set to 50 ~ 70A/ms degree.If this value is too small, then the fusion penetration depth shallower when inductance value Lc is large, does not reach required value.If this value is excessive, then till being corrected when correction without the need to output voltage control setting signal Ecr, therefore produce the situation that welded condition becomes unstable.
Next, numerical example is enumerated.For using self-shield filling flux welding wire (material: iron and steel, diameter: 1.6mm) for welding wire, average welding current is 250A, average weldingvoltage is the numerical example that 21V carries out the situation of welding.Er=21V, Eur=10V, Edr=10V, Δ u=2V, Δ d=2V, T1r=2ms, T2r=4ms, T3r=6ms, reference change rate=65A/ms.Its result, 1 cycle became 12ms, Vw1=31V, Vw2=11V, Vw3=21V, Iw1=400A, Iw2=60A, Iw3=250A.
The rate of change of the welding current Iw in the cycle before moment t4, becomes 100A/ms, in the 2nd period T2, becomes 113A/ms, in the 3rd period T3, become 126A/ms in the 1st period T1.The rate of change of the welding current Iw in the cycle that moment t7 is later, becomes 75A/ms in the 1st period T1, in the 2nd period T2, become 85A/ms, in the 3rd period T3, become 95A/ms.
Next, the action effect of present embodiment is described.First, the action effect of inductance value Lc hour of the welding cable before moment t4 is described.In the 1st period T1 of moment t1 ~ t2, because welding current Iw becomes maximum value i.e. the 1st welding current value Iw1, therefore larger arc pressure acts on molten bath, and molten bath becomes the concave shape caved in immediately below welding wire, and the deposite metal immediately below welding wire becomes thinner state.In the 2nd period T2 of moment t2 ~ t3, because welding current Iw becomes minimum value i.e. the 2nd welding current value Iw2, therefore the arc shape shape that become flat, the state that the part that the electric arc deposite metal become immediately below welding wire becomes thinner state is concentrated.In the 3rd period T3 of moment t3 ~ t4, welding current Iw becomes value i.e. the 3rd welding current value Iw3 of the close centre of the welding current value that specifies with the feed speed by welding wire.By the 3rd welding current value Iw3 is maintained roughly fixed value, thus the part of gouged weld pool is intensively heated by electric arc in the first half of the 3rd period T3, fix at latter half of middle arc pressure, therefore the part of gouged weld pool becomes nothing, becomes mild state.Transitting to the time point of the 1st period T1, if molten bath does not become mild state, then in the 1st period T1, do not becoming the shape of depression immediately below welding wire, become the shape of deformation, the action effect deepening fusion penetration is lost.Therefore, at the end time point of the 3rd period T3, for making molten bath reliably become mild state, expect that the 3rd period T3 is set to than during the 1st period T1 and the 2nd period T2 length.According to these action effects, darker fusion penetration shape stably can be formed.
The 1st welding voltage value Vw1 (voltage value added setting signal Eur) and the 1st period T1 (during the 1st setting signal T1r) is set, molten bath can be made to be deformed into the concave shape of depression according to the 1st welding current value Iw1.In addition, set the 2nd welding voltage value Vw2 (voltage reduction value setting signal Edr) and the 2nd period T2 (during the 2nd setting signal T2r) according to the 2nd welding current value Iw2, so as the shape making electric arc become flat and immediately below welding wire concentrate.And then, the 3rd welding voltage value Vw3 (voltage setting signal Er) and the 3rd period T3 (during the 3rd setting signal T3r) is set, so that molten bath becomes mild state after heating in the segment set of depression according to the 3rd welding current value Iw3.Do not carry out current constant control and the reason that makes welding current Iw become the 1st welding current value Iw1 ~ the 3rd welding current value Iw3 is, in order to maintain appropriate value by long for electric arc and need to carry out Isobarically Control.Therefore, welding current Iw is indirectly set.Thus, according to electric arc load condition, the 1st welding current value Iw1 ~ the 3rd welding current value Iw3 slightly changes.
Because from moment t4, the inductance value Lc of welding cable becomes large, the rate of change of the welding current Iw in the 1st period T1 of therefore moment t4 ~ t5 and in the 2nd period T2 of moment t5 ~ t6 becomes mild, and amplitude diminishes.Its result, the maximum of the welding current Iw in the 1st period T1 diminishes, and the minimum of a value of the welding current Iw in the 2nd period T2 becomes large.Thus, the 1st above-mentioned period T1 and the action effect of the 2nd period T2 become insufficient.Be less than reference change rate by the rate of change of welding current Iw and differentiate this state.
If the rate of change determining welding current Iw is less than reference change rate, then make the value of the output voltage control setting signal Ecr in the 1st period T1 of moment t7 ~ t8 only increase Δ u, make the value of the output voltage control setting signal Ecr in the 2nd period T2 of moment t8 ~ t9 only reduce Δ d.Its result, the rate of change of welding current Iw becomes large, becomes the waveform roughly the same with the current waveform before moment t4.Thus, the action effect before above-mentioned moment t4 is played.
In the present embodiment, when the rate of change of welding current Iw is less than reference change rate, carry out the minimizing (minimizing of the 2nd output voltage E2) of the output voltage control setting signal Ecr in the increase (increase of the 1st output voltage E1) of the output voltage control setting signal Ecr in the 1st period T1 and the 2nd period T2.Now, also a wherein side can only be carried out.
According to above-mentioned embodiment 1, the 1st output voltage E1 is exported and the 1st welding current Iw1 that is energized in during the 1st, the 2nd output voltage E2 is exported and the 2nd welding current Iw2 that is energized in during the 2nd, the 3rd output voltage E3 is exported and the 3rd welding current Iw3 that is energized in during the 3rd, 0 < E2 < E3 < E1, 0 < Iw2 < Iw3 < Iw1, during repeating the 1st ~ the 3rd during, to detect during switching the 1st ~ the 3rd during each period time the rate of change of welding current, when this rate of change is less than prespecified reference change rate, carry out the increase of the 1st output voltage E1 and/or the minimizing of the 2nd output voltage E2.During the 1st, larger arc pressure acts on molten bath, and molten bath becomes the concave shape caved in immediately below welding wire, and the deposite metal immediately below welding wire becomes thinner state.During the follow-up the 2nd, the shape that arc shape has become flat, the state that the part that the electric arc deposite metal become immediately below welding wire becomes thinner state is concentrated.During the follow-up the 3rd, in first half, the part of gouged weld pool is intensively heated by electric arc, fixes at latter half of middle arc pressure, and therefore the part of gouged weld pool becomes nothing, becomes mild state.In the present embodiment, by repeat these during the 1st ~ the 3rd during, thus fusion penetration can be deepened to seek high quality in spray transfer welding.Now, in the present embodiment, because the inductance value of welding cable is large, therefore the rate of change of welding current diminishes, become be less than reference change rate time, by the minimizing of the increase and/or the 2nd output voltage E2 of carrying out the 1st output voltage values E1, thus can the rate of change of increase of weld current.Thus, the impact of the inductance value of welding cable can not be subject to, above-mentioned effect can be played.
And then, according to the present embodiment, during switching the 1st ~ the 3rd during each period time the rate of change of welding current when being less than reference change rate, give the alarm.When continuing this alarm not removing, even if expression revises output voltage the rate of change of welding current also can not be made to be less than the state of reference change rate.Weld job person can recognize when this state and can produce the situation that the fusion penetration degree of depth does not reach required value.For this reason, weld job person can implement the measure arranging environment improving welder, and the inductance value of welding cable is diminished.
[embodiment 2]
In the invention of embodiment 2, when the rate of change of welding current is less than reference change rate, during extending the 1st and/or during the 2nd.
Fig. 3 is the block diagram of the source of welding current for implementing the arc-welding method involved by embodiments of the present invention 2.This figure is corresponding with above-mentioned Fig. 1, gives identical symbol for identical block, does not repeat the explanation of these contents.The output voltage control initialization circuit ECR of Fig. 1 is replaced as the 2nd output voltage control initialization circuit ECR2 by this figure.Below, with reference to this figure, this block is described.
2nd output voltage control initialization circuit ECR2 using setting signal T3r and rate of change judgment signal Sd during setting signal T2r, the 3rd during setting signal T1r, the 2nd during output voltage setting signal Er, voltage value added setting signal Eur, voltage reduction value setting signal Edr, the 1st as input, carry out following process, output be output voltage control setting signal Ecr and period signal Sp.
1) in the 1st period T1 specified to setting signal T1r during by the 1st from the sart point in time in cycle of the 1st time, export Ecr=Er+Eur, as the 1st period T1 in the cycle of the 1st time output voltage control setting value Ecr (1,1) and the 1st during setting value T1r (1) store.In addition, in this period, Sp=1 is exported.
2) following, in the 2nd period T2 that setting signal T2r specifies during by the 2nd, export Ecr=Er-Edr, as the 2nd period T2 in the cycle of the 1st time output voltage control setting value Ecr (1,2) and the 2nd during setting value T2r (1) store.In addition, in this period, Sp=2 is exported.
3) following, in the 3rd period T3 that setting signal T3r specifies during by the 3rd, export Ecr=Er.In addition, in this period, Sp=3 is exported.
4) in the cycle of the sart point in time to the (n-1)th time in cycle of n-th time by the 1st during in the 1st period T1 that specifies of setting value T1r (n-1), when the rate of change judgment signal Sd of the 1st period T1 sart point in time of n-th time is low level, export Ecr=Ecr (n-1,1) and establish T1r (n)=T1r (n-1), export Ecr=Ecr (n-1,1)+Δ u when high level and establish T1r (n)=T1r (n-1)+Δ t.Further, setting value T1r (n) during the output voltage control setting value Ecr (n, 1) and the 1st of the 1st period T1 in the cycle storing n-th time.Δ u and Δ t is correction, be prespecified on the occasion of.In addition, in this period, Sp=1 is exported.
5) following, in the 2nd period T2 specified by setting value T2r (n-1) during the 2nd in the cycle of (n-1)th time, when the rate of change judgment signal Sd of the 1st period T1 sart point in time of n-th time is low level, export Ecr=Ecr (n-1,2) and establish T2r (n)=T2r (n-1), export Ecr=Ecr (n-1,2)-Δ d when high level and establish T2r (n)=T2r (n-1)+Δ t.Further, the output voltage control setting value Ecr (n, 2) of the 2nd period T2 in the cycle storing n-th time and T2r (n).Δ d is correction, be prespecified on the occasion of.In addition, in this period, Sp=2 is exported.
6) following, in the 3rd period T3 that setting signal T3r specifies during by the 3rd, independently export Ecr=Er with rate of change judgment signal Sd.In addition, in this period, Sp=3 is exported.
7) repeat above-mentioned 4) ~ 6) process.
In above-mentioned 2nd output voltage control initialization circuit ECR2, the action of output voltage control setting signal Ecr is identical with the output voltage control initialization circuit ECR of Fig. 1.On the other hand, in the 2nd output voltage control initialization circuit ECR2, the 1st period T1 when rate of change judgment signal Sd is high level is than the value only elongated Δ t in front cycle, and the 2nd period T2 is than the value only elongated Δ t in front cycle, and the 3rd period T3 does not change.This action is different from the output voltage control initialization circuit ECR of Fig. 1.
Fig. 4 is the sequential chart of each signal in the source of welding current of the Fig. 3 of the arc-welding method represented involved by embodiments of the present invention 2.This figure (A) represents the time variations of output voltage control setting signal Ecr, this figure (B) represents the time variations of weldingvoltage Vw, this figure (C) represents the time variations of welding current Iw, and this figure (D) represents the time variations of rate of change judgment signal Sd.In the explanation of this figure, the point different from the action of above-mentioned Fig. 2 is described, the explanation for same action will not repeat.Below, be described with reference to this figure.
In the figure, because the action during till moment t7 is identical with Fig. 2, therefore not repeat specification.
As shown in this figure (D), the rate of change judgment signal Sd at the sart point in time t7 place of the 1st period T1 is high level.Thus, as shown in this figure (A), output voltage control setting signal Ecr becomes the revised value of value in cycle in the past, before becoming in the 1st period T1 of moment t7 ~ t8, the value in cycle is added value and the Er+Eur+ Δ u of Δ u gained, before becoming in the 2nd period T2 of moment t8 ~ t9, the value in cycle deducts value and the Er-Edr-Δ d of Δ d gained, the value in cycle and Er before maintaining in the 3rd period T3 of moment t9 ~ t10.Similarly, as shown in the drawing, 1st period T1 becomes the revised value of value in cycle in the past, before becoming in the 1st period T1 of moment t7 ~ t8, the value in cycle is added value and the T1=T1r+ Δ t of Δ t gained, before becoming in the 2nd period T2 of moment t8 ~ t9, the value in cycle is added value and the T2=T2r+ Δ t of Δ t gained, the value in cycle and T3r before maintaining in the 3rd period T3 of moment t9 ~ t10.
As shown in this figure (B), the weldingvoltage Vw in the 1st period T1 of moment t7 ~ t8 increases with the inclination identical with Fig. 2 from the 3rd welding voltage value Vw3, because the 1st period T1 is elongated, therefore becomes the 1st welding voltage value Vw1 of roughly fixed value.Weldingvoltage Vw in the 2nd period T2 of moment t8 ~ t9 reduces with the inclination identical with Fig. 2 from the 1st welding voltage value Vw1, because the 2nd period T2 is elongated, therefore becomes the 2nd welding voltage value Vw2 of roughly fixed value.Weldingvoltage Vw in the 3rd period T3 of moment t9 ~ t10 increases with the inclination identical with Fig. 2 from the 2nd welding voltage value Vw2, becomes the 3rd welding voltage value Vw3 of roughly fixed value.
Similarly, as shown in this figure (C), welding current Iw in the 1st period T1 of moment t7 ~ t8 increases with the inclination identical with Fig. 2 from the 3rd welding current value Iw3, because the 1st period T1 is elongated, therefore becomes the 1st welding current value Iw1 of roughly fixed value.Welding current Iw in the 2nd period T2 of moment t8 ~ t9 reduces with the inclination identical with Fig. 2 from the 1st welding current value Iw1, because the 2nd period T2 is elongated, therefore becomes the 2nd welding current value Iw2 of roughly fixed value.Welding current Iw in the 3rd period T3 of moment t9 ~ t10 increases with the inclination identical with Fig. 2 and becomes the 3rd welding current value Iw3 of roughly fixed value from the 2nd welding current value Iw2.Therefore, the amplitude of the welding current Iw of the 1st period T1 and the 2nd period t2 becomes the value roughly the same with before moment t4.And then the welding current Iw of the 1st period T1 and the 2nd period T2 is different from during Fig. 2, has the part of fixed value after change, even if therefore the inductance value Lc of welding cable becomes large further, the amplitude before moment t4 also can be guaranteed.
As shown in this figure (D), the rate of change judgment signal Sd at the sart point in time t10 place of the 1st period T1 is low level.Thus, as shown in the drawing, the 1st period T1 becomes the value identical with the value in front cycle, the 2nd period T2=T2r+ Δ t of the 1st period T1=T1r+ Δ t of moment t10 ~ t11, moment t11 ~ t12, the 3rd period T3=T3r of moment t12 ~ t13.Thus, the waveform of weldingvoltage Vw and welding current Iw becomes identical with the front cycle.
Henceforth, the action in the cycle of moment t10 ~ t13 is repeated.Above-mentioned correction amount t is set to 0.1 ~ 1.0ms degree.If this value is excessive, welded condition becomes unstable, if this value is too small, revises and need the time, the welding quality between validation period is deteriorated.Also higher limit can be set for the 1st period T1 after being corrected and the 2nd period T2.
In present embodiment, when the rate of change of welding current Iw is less than reference change rate, extend the 1st period T1 and the 2nd period T2.Now, also a wherein side can only be extended.
According to above-mentioned embodiment 2, during switching the 1st ~ the 3rd during each period time the rate of change of welding current when being less than reference change rate, during extending the 1st and/or during the 2nd.Thus, in the present embodiment, except the effect of embodiment 1, even if the inductance value of welding cable becomes large further, also the amplitude of the welding current in during the 1st and during the 2nd can be maintained desired value, therefore, it is possible to guarantee darker fusion penetration.
Claims (3)
1. an arc-welding method, feeding welding wire, makes output voltage export from the source of welding current, energising welding current, and welded by spray transfer form, the feature of this arc-welding method is,
The 1st output voltage E1 is exported and the 1st welding current Iw1 that is energized in during the 1st, the 2nd output voltage E2 is exported and the 2nd welding current Iw2 that is energized in during the 2nd, the 3rd output voltage E3 is exported and the 3rd welding current Iw3 that is energized in during the 3rd, 0 < E2 < E3 < E1,0 < Iw2 < Iw3 < Iw1, during repeating the above-mentioned 1st ~ the above-mentioned 3rd during
Detect to switch during the above-mentioned 1st ~ the above-mentioned 3rd during each period time the rate of change of above-mentioned welding current, when this rate of change is less than prespecified reference change rate, carry out the increase of above-mentioned 1st output voltage E1 and/or the minimizing of above-mentioned 2nd output voltage E2.
2. arc-welding method according to claim 1, is characterized in that,
When above-mentioned rate of change is less than said reference rate of change, give the alarm.
3. arc-welding method according to claim 1 and 2, is characterized in that,
When above-mentioned rate of change is less than said reference rate of change, during extending the above-mentioned 1st and/or during the above-mentioned 2nd.
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