CN109530878B - Unified regulation method, system and storage medium for Gaussian pulse MIG welding - Google Patents

Unified regulation method, system and storage medium for Gaussian pulse MIG welding Download PDF

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CN109530878B
CN109530878B CN201811213593.4A CN201811213593A CN109530878B CN 109530878 B CN109530878 B CN 109530878B CN 201811213593 A CN201811213593 A CN 201811213593A CN 109530878 B CN109530878 B CN 109530878B
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welding
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CN109530878A (en
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朱强
吴立华
李�权
康国坡
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Guangdong Polytechnic Institute
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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
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • 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
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters

Abstract

The invention discloses a unified adjusting method, a unified adjusting system and a storage medium for Gaussian pulse MIG welding, wherein the method comprises the following steps: setting the current of Gaussian pulse welding and arc striking; acquiring a parameter set value according to the current magnitude of Gaussian pulse welding; calculating weak pulse group base value current according to the current magnitude of Gaussian pulse welding and the value of the parameter group; the unified adjusting welding process of the Gaussian pulse MIG welding is completed by dynamically adjusting the weak pulse group base value current; the system comprises a setting module, an obtaining module, a calculating module and an adjusting module. The invention can complete the unified adjusting welding process of Gaussian pulse MIG welding by setting the current of Gaussian pulse welding and finally dynamically adjusting the weak pulse group basic value current obtained by calculation, the adjusting process is simple and efficient, the professional requirement on welders is lower, and the method can be widely applied to the technical field of intelligent welding machines.

Description

Unified regulation method, system and storage medium for Gaussian pulse MIG welding
Technical Field
The invention relates to the technical field of intelligent welding machines, in particular to a unified adjusting method, a unified adjusting system and a storage medium for Gaussian pulse MIG welding.
Background
MIG welding (metal inert-gas welding) is an inert gas (Ar or He) shielded arc welding method using a solid wire; among them, an arc welding method in which a consumable electrode is used and a gas other than the consumable electrode is used as an arc medium to protect a metal droplet, a weld pool, and high-temperature metal in a weld zone is called gas metal arc welding.
Pulse metal inert-gas welding (PMIG) is a welding method with low input energy, and is widely used in welding. The double-pulse MIG welding is low-frequency modulation of high-frequency pulse current, specifically realizes that a group of strong pulses and a group of weak pulses alternately appear, and is considered to be an aluminum alloy light metal welding method with a better welding effect at present.
Shown in the waveform diagram of the double pulse welding current of FIG. 1, TSMaintaining total time, T, for a burst of intense pulsesWMaintaining total time, I, for weak pulse groupsspIs the peak current magnitude, I, of the intense pulse packetsbFor the magnitude of the current, t, of the background of the intense pulse packetspIs the time length of the peak of the intense burst, tsbThe time length of the strong pulse group basic value,IwpThe peak current of weak pulse group is IwbIs the magnitude of the weak pulse group background current, twpIs the peak time length, t, of the weak pulse groupwbThe weak pulse group base value time length. Let NsIs TSNumber of current pulses in a cycle, NwIs TWNumber of current pulses in a cycle, IavgWhen the average current is input for welding, the calculation formula of the average input current can be known by adjusting Ns、NwOr the parameters in FIG. 1 are used to change the average current of the welding input so that the welding power supply can adapt to welding of parent metal with various thicknesses of materials, wherein the average input current IavgThe calculation formula of (2) is as follows:
Figure BDA0001833007840000011
in summary, for the welding method of the double-pulse MIG welding, the related parameters are various, and in the actual welding process, the parameters can affect each other, when one parameter changes, the other parameters need to be synchronously changed correspondingly to keep a good welding effect, the adjusting process is very inconvenient, and only experienced skilled welders can complete the welding operation.
The graph curve of the Gaussian function is a smooth curve with an obvious peak value, has the mathematical characteristic of infinite connection and guidance, and has better theoretical application value for the aluminum alloy light metal welding with more concentrated heat input requirements. At present, no relevant report of applying the Gaussian function to the MIG welding adjustment process exists.
Disclosure of Invention
To solve the above technical problems, the present invention aims to: a unified regulating method, system and storage medium for conveniently regulating the Gaussian pulse MIG welding are disclosed.
On one hand, the technical scheme adopted by the invention is as follows:
the unified regulation method of Gaussian pulse MIG welding comprises the following steps:
setting the current of Gaussian pulse welding and arc striking;
acquiring a parameter set value according to the current magnitude of Gaussian pulse welding;
calculating weak pulse group base value current according to the current magnitude of Gaussian pulse welding and the value of the parameter group;
the unified regulation welding process of the Gaussian pulse MIG welding is completed by dynamically regulating the weak pulse group base value current.
Further, the step of setting the current of the Gaussian pulse welding and performing welding arcing comprises the following steps:
setting average input current of Gaussian pulse welding according to the thickness of the aluminum alloy material plate;
carrying out welding arcing;
and when the welding arcing is unsuccessful, returning to the step of executing the welding arcing until the welding arcing is successful.
Further, the parameter set includes a time interval of the strong current pulse, a time interval of the weak current pulse, a number of the gaussian pulses, a number of the weak pulses, a gaussian strong pulse group base current, a weak pulse group base current, and a gaussian pulse peak initial current.
Further, the step of obtaining the parameter set value according to the current magnitude of the gaussian pulse welding comprises the following steps:
simplifying the first expression of the Gaussian function to obtain a second expression;
modulating pulse MIG welding through a second expression to obtain a Gaussian pulse welding current oscillogram;
and acquiring the values of the parameter group according to the Gaussian pulse welding current oscillogram.
Further, the step of obtaining the values of the parameter group according to the current magnitude of the gaussian pulse welding further comprises the step of storing the values of the parameter group in a memory of the welding power source.
Further, the step of calculating the weak pulse group base value current according to the current magnitude of the gaussian pulse welding and the parameter group value specifically includes:
calculating weak pulse group base value current according to the Gaussian pulse welding current oscillogram and the current magnitude of Gaussian pulse welding;
the weak pulse group fundamental current is calculated according to the following formula:
Figure BDA0001833007840000021
Iavgrepresenting the current magnitude of Gaussian pulse welding; n issRepresenting the number of gaussian pulses; i isopRepresenting the initial current of the Gaussian pulse peak; t is tsTime intervals representing strong current pulses; t is twTime intervals representing weak current pulses; a represents the peak of the Gaussian curve; i isbsRepresenting a Gaussian intensity pulse group background current; i isbwRepresenting weak pulse group base value current; n iswRepresenting the number of weak pulses.
Further, the method also comprises the step of adopting step current to carry out ball cutting and pit filling.
The technical scheme adopted by the other aspect of the invention is as follows:
a unified regulatory system for Gaussian pulse MIG welding comprising:
the setting module is used for setting the current of the Gaussian pulse welding and performing welding arcing;
the acquisition module is used for acquiring the value of the parameter group according to the current of the Gaussian pulse welding;
the calculation module is used for calculating the weak pulse group base value current according to the current magnitude of the Gaussian pulse welding and the parameter group value;
and the adjusting module is used for completing the unified adjusting welding process of the Gaussian pulse MIG welding by dynamically adjusting the weak pulse group base value current.
The technical scheme adopted by the other aspect of the invention is as follows:
a unified regulatory system for Gaussian pulse MIG welding comprising:
at least one processor;
at least one memory for storing at least one program;
when executed by the at least one processor, cause the at least one processor to implement the unified method of tuning for Gaussian pulse MIG welding.
The technical scheme adopted by the other aspect of the invention is as follows:
a storage medium having stored therein processor-executable instructions which, when executed by a processor, perform the unified method of tuning for MIG welding with gaussian pulses.
The invention has the beneficial effects that: the invention can complete the unified adjusting welding process of the Gaussian pulse MIG welding by setting the current of the Gaussian pulse welding and finally dynamically adjusting the weak pulse group basic value current obtained by calculation, the adjusting process is simple and efficient, the professional requirement on welders is lower, and the application range is wide.
Drawings
FIG. 1 is a waveform diagram of a double pulse welding current;
FIG. 2 is a waveform of Gaussian pulse welding current in accordance with an embodiment of the present invention;
FIG. 3 is a flowchart illustrating steps according to an embodiment of the present invention.
Detailed Description
The invention will be further explained and explained with reference to the drawings and the embodiments in the description. The step numbers in the embodiments of the present invention are set for convenience of illustration only, the order between the steps is not limited at all, and the execution order of each step in the embodiments can be adaptively adjusted according to the understanding of those skilled in the art.
The embodiment of the invention provides a unified adjusting method for Gaussian pulse MIG welding, which comprises the following steps of:
s1, setting the current of Gaussian pulse welding and arc striking;
further as a specific implementation manner of step S1, the step S1 specifically includes the following steps:
s11, setting average input current of Gaussian pulse welding according to the thickness of the aluminum alloy material plate;
s12, performing welding and arc striking;
and S13, when the welding arcing is unsuccessful, returning to the step of performing welding arcing until the welding arcing is successful.
Specifically, taking ER4043 aluminum alloy flat plate material with a thickness of 5mm as an example for welding, in this embodiment, the average input current for gaussian welding is first set to 127A according to the thickness of the aluminum alloy plate material; and then, carrying out welding arcing operation, and repeatedly executing the arcing operation if the welding arcing is unsuccessful until the arcing is successful.
S2, acquiring the value of the parameter group according to the current of the Gaussian pulse welding;
further as a preferred embodiment of step S2, the step S2 includes the steps of:
s21, simplifying the first expression of the Gaussian function to obtain a second expression;
s22, modulating pulse MIG welding through a second expression to obtain a Gaussian pulse welding current waveform diagram;
and S23, acquiring the values of the parameter group according to the Gaussian pulse welding current waveform diagram.
Specifically, the graphic curve of the Gaussian function is a smooth curve with an obvious peak value, has the mathematical characteristic of infinite connection and derivation, has better theoretical application value for aluminum alloy light metal welding with more concentrated heat input requirements, and is general
The mathematical expression (i.e., the first expression) is:
Figure BDA0001833007840000044
wherein a, b and c are real constants, and a>0, the parameter a refers to the peak value of the gaussian curve, b is the corresponding abscissa, and c is the standard deviation (sometimes called the gaussian RMS width). The gaussian function belongs to an elementary function, but it has no elementary indefinite integral, but its generalized integral can still be calculated over the whole real axis.
The present embodiment simplifies the first expression to obtain a second expression:
Figure BDA0001833007840000041
after applying the second expression to MIG welding of modulated pulses, a Gaussian pulse weld as shown in FIG. 2 can be obtainedThe current waveform is applied.
Then, carrying out indefinite integration on the second expression to obtain a third expression:
Figure BDA0001833007840000042
from the third expression, it can be seen that the area contained by the gaussian curve is a value related to the parameter a, and if the value of a is determined, the area of the curve is fixed and the corresponding input current in the weld is determined.
As shown in FIG. 2, IpsRepresenting the peak current of the Gaussian pulse with a magnitude equal to the initial peak current I of the Gaussian pulseopPlus a Gauss value, IbsRepresenting the base current of a Gaussian intensity pulse packet, IpwIndicating the peak current, I, of the weak pulse groupbwRepresenting weak pulse-burst background current, tsTime intervals, t, representing strong current pulseswRepresenting the time interval of the weak current pulse. Peak current of Gaussian pulse IpsThe peak value of (1) changes along with the time change, the change rule is changed according to a Gaussian curve, and the following relation is satisfied:
Figure BDA0001833007840000043
the average input current for the entire welding process is:
Figure BDA0001833007840000051
wherein, IavgRepresenting the current magnitude of Gaussian pulse welding; n issRepresenting the number of gaussian pulses; i isopRepresenting the initial current of the Gaussian pulse peak; t is tsTime intervals representing strong current pulses; t is twTime intervals representing weak current pulses; a represents the peak of the Gaussian curve; i isbsRepresenting a Gaussian intensity pulse group background current; i isbwRepresenting weak pulse group base value current; n iswRepresenting the number of weak pulses. Proved by empirical data of a welding process, nsAnd nwWhen the value is proper, ts、tw、Iop、IbsAnd IbwWithin a relatively wide value range, the welding process is stable, the welding seam forming effect is good, and the characteristics provide a foundation for adjusting the input current by the sectional base value.
S3, calculating weak pulse group base value current according to the current magnitude of Gaussian pulse welding and the value of the parameter group;
specifically, the present embodiment obtains the calculation formula of the weak burst base current according to the calculation formula of the average input current in step S2:
Figure BDA0001833007840000052
wherein, IavgRepresenting the current magnitude of Gaussian pulse welding; n issRepresenting the number of gaussian pulses; i isopRepresenting the initial current of the Gaussian pulse peak; t is tsTime intervals representing strong current pulses; t is twTime intervals representing weak current pulses; a represents the peak of the Gaussian curve; i isbsRepresenting a Gaussian intensity pulse group background current; i isbwRepresenting weak pulse group base value current; n iswRepresenting the number of weak pulses.
S4, completing an integrated regulation welding process of Gaussian pulse MIG welding by dynamically regulating the weak pulse group base value current;
taking the step-type basic value adjustment process with the average input current of 50A-300A as an example, the unified adjustment welding process of the embodiment is as follows:
s41, taking 50A as a section, and respectively taking 5 current values of 50A, 100A, 150A, 200A and 250A;
s42, obtaining the values of the parameter group corresponding to the 5 average input current values through process experiments, wherein the parameter group comprises ns、nw、ts、tw、Iop、IbsAnd IbwThe present embodiment stores the values of the acquired parameter sets in a table, and stores the table in a memory of the welding power supply;
s43, keeping other parameters unchanged, and adding IbwAs a variable, by increasing IbwThe values of (a) to (b) to (d) to obtain values of 51A-99A, 101A-149A, 151A-199A,201A-249A and 251A-299A.
Taking ER4043 aluminum alloy flat plate material with thickness of 5mm as an example, the arc welding power supply of this embodiment can complete the welding process of 127A input current by the values of the parameter set; if the process is found to be less than ideal during the welding process, by changing IbwThe magnitude of one parameter can obtain any input current in the interval from 101A to 149A until the proper welding process effect is achieved.
And S5, performing ball cutting and pit filling by adopting step current. The adoption of step current for ball cutting and pit filling is a terminating process method when the welding process is completed. When the welding process is about to be finished, if the current is directly and instantly switched to 0, the tail part of the welding seam is easy to collapse or crack, and therefore the invention reduces the probability of defects by adopting step current ball cutting and pit filling.
Further as a preferred embodiment of step S5, the step S5 includes the steps of:
and S51, outputting 10 groups of peak value and base value currents, wherein the base value current is a single pulse current, and the maintaining time of the base value current is gradually increased by 20%, so that the welding average input current can be slowly reduced.
S52, the peak value of 10 groups of pulses output by S51 is reduced by 20%.
S53, the peak value of 10 groups of pulses output by S52 is reduced by 20 percent.
And S54, outputting a transient high-current pulse to complete the final droplet transfer process.
The present embodiment completes the final ball chipping and crater filling processes of the soldering process through the above-described steps S51-S54.
In alternative embodiments, the functions/acts noted in the block diagrams may occur out of the order noted in the operational illustrations. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Furthermore, the embodiments presented and described in the flow charts of the present invention are provided by way of example in order to provide a more thorough understanding of the technology. The disclosed methods are not limited to the operations and logic flows presented herein. Alternative embodiments are contemplated in which the order of various operations is changed and in which sub-operations described as part of larger operations are performed independently.
The embodiment of the invention also provides a unified regulating system for Gaussian pulse MIG welding, which comprises the following steps:
the setting module is used for setting the current of the Gaussian pulse welding and performing welding arcing;
the acquisition module is used for acquiring the value of the parameter group according to the current of the Gaussian pulse welding;
the calculation module is used for calculating the weak pulse group base value current according to the current magnitude of the Gaussian pulse welding and the parameter group value;
and the adjusting module is used for completing the unified adjusting welding process of the Gaussian pulse MIG welding by dynamically adjusting the weak pulse group base value current.
The contents in the above method embodiments are all applicable to the present system embodiment, the functions specifically implemented by the present system embodiment are the same as those in the above method embodiment, and the beneficial effects achieved by the present system embodiment are also the same as those achieved by the above method embodiment.
Although the present invention is described in the context of functional modules, it should be understood that, unless otherwise stated to the contrary, one or more of the described functions and/or features may be integrated in a single physical device and/or software module, or one or more functions and/or features may be implemented in a separate physical device or software module. It will also be appreciated that a detailed discussion of the actual implementation of each module is not necessary for an understanding of the present invention. Rather, the actual implementation of the various functional modules in the system disclosed herein will be understood within the ordinary skill of an engineer, given the nature, function, and inter-relationships of the modules. Accordingly, those skilled in the art can, using ordinary skill, practice the invention as set forth in the claims without undue experimentation. It is also to be understood that the specific concepts disclosed are merely illustrative of and not intended to limit the scope of the invention, which is defined by the appended claims and their full scope of equivalents.
The embodiment of the invention also provides a unified regulating system for Gaussian pulse MIG welding, which comprises the following steps:
at least one processor;
at least one memory for storing at least one program;
when executed by the at least one processor, cause the at least one processor to implement the unified method of tuning for Gaussian pulse MIG welding.
The contents in the above method embodiments are all applicable to the present system embodiment, the functions specifically implemented by the present system embodiment are the same as those in the above method embodiment, and the beneficial effects achieved by the present system embodiment are also the same as those achieved by the above method embodiment.
Further, an embodiment of the present invention provides a storage medium having stored therein instructions executable by a processor, wherein: the processor-executable instructions, when executed by a processor, perform a unified tuning method of the gaussian pulse MIG welding.
In summary, the unified adjusting method, system and storage medium for the MIG welding with gaussian pulses of the present invention have the following advantages:
1) the invention provides a method for continuously changing welding input current according to the characteristics of Gaussian pulse MIG welding, and achieves the unified regulation target that the process requirement can be met only by regulating the basic value current of a weak pulse group by recording the optimal parameters of the welding input current in a segmented manner according to the experimental effect.
2) The invention greatly reduces the workload of welding personnel, and different output currents can be obtained by adjusting one input parameter of the welding process no matter the welding personnel is not skilled operators, so that a good process effect is obtained, and the intelligent adjusting process is realized.
While the preferred embodiments of the present invention have been illustrated and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (7)

1. The unified regulation method of Gaussian pulse MIG welding is characterized in that: the method comprises the following steps:
setting the current of Gaussian pulse welding and arc striking;
acquiring a parameter set value according to the current magnitude of Gaussian pulse welding; the parameter group comprises time intervals of strong current pulses, time intervals of weak current pulses, the number of Gaussian pulses, the number of weak pulses, group base value current of Gaussian strong pulses, group base value current of weak pulses and initial current of Gaussian pulse peak values;
the step of obtaining the parameter set value according to the current magnitude of the Gaussian pulse welding comprises the following steps:
simplifying the first expression of the Gaussian function to obtain a second expression; modulating pulse MIG welding through a second expression to obtain a Gaussian pulse welding current oscillogram; acquiring values of a parameter group according to a Gaussian pulse welding current oscillogram;
the first expression is:
Figure FDA0002918789370000011
wherein, a is the peak value of the Gaussian curve, b is the corresponding abscissa, and c is the standard deviation;
the second expression is:
Figure FDA0002918789370000012
calculating weak pulse group base value current according to the current magnitude of Gaussian pulse welding and the value of the parameter group; the calculation formula of the weak pulse group base value current is as follows:
Figure FDA0002918789370000013
wherein, IavgRepresenting the current magnitude of Gaussian pulse welding; n issRepresenting the number of gaussian pulses; i isopRepresenting the initial current of the Gaussian pulse peak; t is tsTime intervals representing strong current pulses; t is twTime intervals representing weak current pulses; i isbsRepresenting a Gaussian intensity pulse group background current; i isbwRepresenting weak pulse group base value current; n iswRepresents the number of weak pulses;
the unified regulation welding process of the Gaussian pulse MIG welding is completed by dynamically regulating the weak pulse group base value current.
2. A unified method of regulation of MIG welding with gaussian pulses according to claim 1 characterized by: the step of setting the current of the Gaussian pulse welding and arc striking of the welding comprises the following steps:
setting average input current of Gaussian pulse welding according to the thickness of the aluminum alloy material plate;
carrying out welding arcing;
and when the welding arcing is unsuccessful, returning to the step of executing the welding arcing until the welding arcing is successful.
3. A unified method of regulation of MIG welding with gaussian pulses according to claim 1 characterized by: the step of obtaining a value of the parameter set based on the magnitude of the current of the gaussian pulse weld further comprises the step of storing the value of the parameter set in a memory of the welding power source.
4. A unified method of regulation of MIG welding with gaussian pulses according to claim 1 characterized by: and the method also comprises the steps of adopting step current to carry out ball cutting and pit filling.
5. Unified governing system of gaussian pulse MIG welding which characterized in that: the method comprises the following steps:
the setting module is used for setting the current of the Gaussian pulse welding and performing welding arcing;
the acquisition module is used for acquiring the value of the parameter group according to the current of the Gaussian pulse welding; the parameter group comprises time intervals of strong current pulses, time intervals of weak current pulses, the number of Gaussian pulses, the number of weak pulses, group base value current of Gaussian strong pulses, group base value current of weak pulses and initial current of Gaussian pulse peak values;
the obtaining of the parameter set value according to the current magnitude of the gaussian pulse welding comprises:
simplifying the first expression of the Gaussian function to obtain a second expression; modulating pulse MIG welding through a second expression to obtain a Gaussian pulse welding current oscillogram; acquiring values of a parameter group according to a Gaussian pulse welding current oscillogram;
the first expression is:
Figure FDA0002918789370000021
wherein, a is the peak value of the Gaussian curve, b is the corresponding abscissa, and c is the standard deviation;
the second expression is:
Figure FDA0002918789370000022
the calculation module is used for calculating the weak pulse group base value current according to the current magnitude of the Gaussian pulse welding and the parameter group value; the calculation formula of the weak pulse group base value current is as follows:
Figure FDA0002918789370000023
wherein, IavgRepresenting the current magnitude of Gaussian pulse welding; n issRepresenting the number of gaussian pulses; i isopRepresenting the peak initial current of a Gaussian pulse；tsTime intervals representing strong current pulses; t is twTime intervals representing weak current pulses; i isbsRepresenting a Gaussian intensity pulse group background current; i isbwRepresenting weak pulse group base value current; n iswRepresents the number of weak pulses;
and the adjusting module is used for completing the unified adjusting welding process of the Gaussian pulse MIG welding by dynamically adjusting the weak pulse group base value current.
6. Unified governing system of gaussian pulse MIG welding which characterized in that: the method comprises the following steps:
at least one processor;
at least one memory for storing at least one program;
when executed by the at least one processor, cause the at least one processor to implement a unified tuning method for gaussian pulse MIG welding as recited in any of claims 1-4.
7. A storage medium having stored therein instructions executable by a processor, the storage medium comprising: the processor-executable instructions, when executed by a processor, are for performing a unified method of conditioning of gaussian pulse MIG welding as recited in any of claims 1-4.
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