CN110125518B - Parallel three-wire welding system and method - Google Patents
Parallel three-wire welding system and method Download PDFInfo
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- CN110125518B CN110125518B CN201910472861.2A CN201910472861A CN110125518B CN 110125518 B CN110125518 B CN 110125518B CN 201910472861 A CN201910472861 A CN 201910472861A CN 110125518 B CN110125518 B CN 110125518B
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- 238000003466 welding Methods 0.000 title claims abstract description 330
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- 238000002844 melting Methods 0.000 claims description 14
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- 239000011324 bead Substances 0.000 description 4
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- 238000005493 welding type Methods 0.000 description 4
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
- B23K9/1336—Driving means
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Abstract
The invention discloses a parallel three-wire welding system and method, comprising a wide standard welding power supply, a wire feeding mechanism with three-groove wire feeding wheels and a welding gun with three-hole conductive nozzles. Three welding wires are simultaneously delivered to a welding gun through a wire feeding mechanism, respectively pass through three independent holes with certain intervals on the contact tip, and a welding waveform output by a welding power supply is provided for the welding wires through the contact tip so as to simultaneously weld by using the three wires. After the three wire ends are melted, the molten drops are attracted to each other under the action of electromagnetic force to form molten drops, and then the molten drops are smoothly transited into a molten pool. The single power supply parallel three-wire system improves the welding efficiency, improves the arc shape, the welding seam penetration size and the outline, reduces the welding defects and improves the mechanical strength. Meanwhile, the three welding wires adopt one wire feeding mechanism, the wire feeding is stable, and the conventional welding gun is convenient to operate, has good accessibility, and can meet the requirements of manual, semi-automatic and robot welding operation.
Description
Technical Field
The invention relates to the technical field of welding engineering, in particular to a parallel three-wire welding system and method.
Background
The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art.
In recent years, with the continuous development of industrial technology, large-scale structural members are increasingly widely used in the fields of ship manufacturing, building bridges, heavy equipment, pressure vessels, rail transit, oil and gas pipelines and the like. With the diversity of large-scale structural member products, materials and use conditions, medium plates with higher strength grade and larger thickness are increasingly used, and the requirements on welding quality are also higher. Therefore, on the premise of ensuring the welding quality, the improvement of the welding efficiency to meet the development requirement of the modern manufacturing industry is one of the development trends in the future.
The current common method for improving the welding production efficiency of the medium plate, namely improving the welding wire deposition rate, is to increase the current of a single wire welding system to melt more welding wires or adopt a double wire or multi-wire welding system.
For a single wire welding system, when the welding current exceeds the critical value of the rotary jet transition, the welding current enters an unstable rotary jet transition zone, and molten drops transversely fly out of a molten pool, so that the welding process is very unstable. Moreover, the welding current is increased, the undesirable welding line profile and section are generated, and welding defects such as air holes are easy to generate.
Compared with single wire welding, the multi-wire high-efficiency consumable electrode gas shielded welding has obvious advantages in the aspects of welding efficiency, welding heat input, molten pool heat distribution, gas hole tendency and the like.
The inventor searches and discovers that the double-wire high-speed welding system disclosed in the prior art has obvious advantages in the aspects of welding efficiency, welding heat input, molten pool heat distribution, air hole tendency and the like. However, the welding system adopts two power supplies, each welding wire is independently powered by the power supply, the system integration is complex, the electric arc needs to be accurately controlled, and otherwise, the electric arc interference is serious. In addition, the welding gun is large in size, complex in structure and poor in flexibility. Meanwhile, the investment cost of the collaborative double-wire system is too high, so that the popularization of the process is partially limited.
In the single-power double-wire welding system disclosed by the prior art, two welding wires share one power supply, so that the problem of large arc interference can be solved, but in the welding process, the welding line width and the penetration are inconsistent due to the change of the arrangement mode between the double wires, so that the welding operation process parameters are complicated to adjust, and the welding defect occurs when serious. Therefore, during the welding process and when the accessories are replaced, the welding process of the double-wire system is unstable because the arrangement position of the welding wires is easy to change.
The single-power three-wire submerged arc welding gun disclosed in the prior art adopts 3 sets of wire feeding mechanisms and conductive nozzles, wherein two wires are connected with the positive electrode of a power supply, and one wire is connected with the negative electrode of the power supply, so that the welding penetration is small, and the welding gun is only suitable for surfacing welding on the surface of a base material; in addition, the molten drop transition mode is that three wires are respectively in transition, three wires and three arcs are in transition, mutual interference is easy to occur between the arcs, and the control process is complex.
In the three-wire open arc welding method disclosed in the prior art, three electric arcs are in direct current and eutectic pool forms in the welding process so as to improve the welding efficiency and the welding speed. However, three independent power supplies are used for controlling three welding wires during welding, so that the three welding wires are simply overlapped by three consumable electrode electric arcs, communication between the electric arcs cannot be realized, the controllability of the electric arcs is poor, and the melting and molten drop transition of the three welding wires are difficult to control accurately.
The prior art discloses a three-wire welding method of double open arcs and single filler wires, wherein the trace distance is reserved between the position of the filler wires and the connecting line between the two arcs, and the action of controlling the flow behavior of a molten pool can be realized by fine adjustment of the distance, so that the welding quality is ensured. However, the filler wire is actually filled as a cold wire, and is melted by the energy of double bright arcs and the heat of a molten pool, so that when welding parameters are small, insufficient energy is likely to occur, the filler wire is insufficiently melted, and further, the problem of welding defects is caused.
Disclosure of Invention
In order to solve the problems, the invention provides a parallel three-wire welding system and a parallel three-wire welding method, wherein three wires are powered by a single power supply, so that the problem of arc interference is solved, and a control system is not complex; the three wires are distributed at equal intervals, so that the welding width can be ensured to be consistent; the stability of high-current welding is improved, and meanwhile, the welding deposition efficiency is greatly increased.
In some embodiments, the following technical scheme is adopted:
A side-by-side three wire welding system comprising: a welding power supply, a wire feeding mechanism and a conductive nozzle; the contact tip includes a first outlet aperture, a second outlet aperture, and a third outlet aperture; the first exit hole is configured to deliver a first welding wire, the second exit hole is configured to deliver a second welding wire, and the third exit hole is configured to deliver a third welding wire; wherein the first outlet hole, the second outlet hole and the third outlet hole are separated from each other, and the projection points of the centers of the first outlet hole, the second outlet hole and the third outlet hole on the surface of the workpiece are three vertexes of an equilateral triangle, so that the interval between every two three welding wires is L;
The welding power source is configured to provide an output current waveform to a contact tip configured to deliver the current waveform to a first wire, a second wire, and a third wire, respectively;
the spacing L is configured to facilitate a post-droplet transition of the ends of the first, second, and third welding wires by the current waveform melting together.
In another embodiment, the following technical scheme is adopted:
a method of parallel three wire welding comprising:
Providing an output current waveform to the contact tip; the contact tip includes a first outlet aperture, a second outlet aperture, and a third outlet aperture;
providing a first welding wire to the contact tip, the first welding wire being delivered through a first exit aperture;
Providing a second welding wire to the contact tip, the second welding wire being delivered through a second exit aperture;
Providing a third welding wire to the contact tip, the third welding wire being delivered through a third exit aperture;
Wherein the first outlet hole, the second outlet hole and the third outlet hole are separated from each other, and the projection points of the centers of the first outlet hole, the second outlet hole and the third outlet hole on the surface of the workpiece are three vertexes of an equilateral triangle, so that the interval between every two three welding wires is L;
The contact tip delivers the current waveforms to the first, second, and third wires, respectively, such that ends of the first, second, and third wires melt and merge into a droplet, which transitions.
Compared with the prior art, the invention has the beneficial effects that:
The invention adopts a single-power three-wire common-arc mode, has simple equipment, has no arc interference problem and saves input cost; the three-wire welding gun has the same volume as the common welding gun, flexible operation and lower cost.
The three welding wires are connected with the positive electrode and the base metal is connected with the negative electrode, and at the moment, welding current flows through the base metal, so that the welding penetration is larger, and the welding method is suitable for the angle joint and the splicing of the medium plate.
The three wires are distributed in an equilateral triangle, the spacing between any two welding wires is the same, and when the angle and the welding direction of a welding gun are changed in the welding process, the arrangement mode of the equilateral triangle can ensure that the distribution change of the welding wires and the electric arcs in the welding direction is the minimum, and the consistency of the welding width and the penetration can be ensured.
The invention adjusts the output current waveform by detecting the arc length, ensures that the melting speed of the welding wire is consistent with the wire feeding speed, and ensures that the welding process is more stable.
In the welding process, the molten drops of the three welding wires are converged into one molten drop, and then the molten drop is transited to a molten pool. The transition state of the rotary jet flow when the single wire is welded with large current is overcome, the transition after converging into a molten drop is more uniform and stable than the transition of three wires respectively, and the welding seam is formed well.
The parallel three-wire system improves the welding efficiency, improves the arc shape, the welding seam penetration size and the contour, reduces the welding defects and improves the mechanical strength. Meanwhile, the three welding wires adopt one wire feeding mechanism, the wire feeding is stable, and the conventional welding gun is convenient to operate, has good accessibility, and can meet the requirements of manual, semi-automatic and robot welding operation.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention.
FIG. 1 is a schematic diagram of a parallel three wire welding system according to a first embodiment of the present invention;
FIG. 2 (a) is a schematic view of a three-hole contact tip according to a first embodiment of the present invention;
FIG. 2 (b) is a schematic diagram showing the pitch of three-hole contact tips according to the first embodiment of the present invention;
FIG. 3 (a) is a schematic diagram showing the direction of the current and magnetic field in the first embodiment of the present invention;
FIG. 3 (b) is a schematic diagram illustrating electromagnetic force action in accordance with the first embodiment of the present invention;
FIG. 3 (c) is a schematic view showing droplet formation in accordance with the first embodiment of the present invention;
FIG. 4 (a) is a schematic diagram showing droplet transitions in accordance with the first embodiment of the present invention;
FIG. 4 (b) is a schematic diagram showing another droplet transition according to the first embodiment of the present invention;
FIG. 5 (a) is an exemplary output current waveform for a pulse jet welding type operation in accordance with one embodiment of the present invention; FIG. 5 (b) is a schematic diagram of another exemplary welding current waveform according to one embodiment of the present invention;
FIG. 6 (a) is a schematic view of a weld and a welding process using a single welding wire, and FIG. 6 (b) is a schematic view of a weld and a welding process using the welding system of the first embodiment;
The welding machine comprises a welding power supply, a control system, a wire feeding mechanism, a wire feeding wheel, a welding gun, a three-hole contact tip assembly, a welding base material, a first welding wire source, a second welding wire source, a third welding wire source, a first outlet hole, a second outlet hole and a third outlet hole.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
Example 1
In one or more embodiments, a parallel three wire welding system is disclosed, referring to fig. 1, consisting essentially of: a wide specification welding power supply 10 and control system 11 for controlling the output of the welding power supply, a wire feeder 12 having a three-slot wire feed wheel 13, a conventional welding gun 14 having a three-hole contact tip assembly 15, and a welding base metal 16. The welding power supply 10 is connected to a wire feeding mechanism by a wire feeding pipe through a wire feeder control cable 111, the wire feeding mechanism is connected to the welding gun by a wire feeding pipe, the welding gun is connected to one pole of the output electrodes of the wide specification welding power supply through a welding cable 110 with a protective gas hose attached, and the other pole of the output electrodes of the wide specification welding power supply is connected to a welded parent metal 16 through a parent metal connecting cable 113.
It should be noted that the output current of the wide specification welding power supply 10 may range from 50A to 1000A, and the wide specification welding power supply 10 may be any known type of welding power supply capable of outputting the current waveforms described herein, such as a pulse jet or constant voltage arc type of welding waveform. The welding power supply 10 may also include a panel controller 11 that allows a user to input welding parameters for a welding operation. The controller 11 may have a processor, CPU, memory, etc. to be used to control the operation of the welding process described herein. Since the construction, design and operation of such power supplies are well known, they are not described in detail herein.
The method comprises the steps of adjusting a current waveform output by a welding power supply by detecting a change of a voltage value and comparing the voltage value with a given voltage value; the melting speed of the welding wire is controlled through the current waveform, and the melting speed of the welding wire and the wire feeding speed of the wire feeding mechanism can be kept consistent through adjusting the current waveform output by the welding power supply, so that the stability of the arc length is realized.
The welding gun 14 may be similarly configured as known manual, semi-automatic, or robotic welding guns, may be of the straight line or gooseneck type as described above, and may be connected to any universal welding torch.
Wire feeder 12 pulls first, second, and third welding wires A1, A2, and A3 from first, second, and third welding wire sources 17, 18, and 19, respectively, which may be of any known type, such as reels, drums, or the like. The wire feeding mechanism 12 has a general configuration, and pulls the first, second, and third welding wires A1, A2, and A3 at a certain speed using a wire feeding wheel 13, and feeds the welding wires to a welding gun 14. In the exemplary embodiment of the present invention, the wire feeding wheel 13 provides 3 separate wire feeding grooves for feeding the first welding wire A1, the second welding wire A2, and the third welding wire A3, respectively. The wire feed slot may be sized to simultaneously deliver 2 or 3 different wire diameters, with wire feed diameters ranging from 0.8mm to 2.0mm. In other embodiments, two or three separate wire feeders may also be used.
Under the action of the wire feeding wheel 13, the first welding wire A1, the second welding wire A2, and the third welding wire A3 are delivered to the welding gun 14 through the wire feeding tube 110. The wire feeder 110 must be sized to allow at least the first wire A1, the second wire A2, and the third wire A3 to pass simultaneously.
The welding wires according to this embodiment may have the same diameter or different diameters. The embodiment can use a first welding wire with a larger diameter, a second welding wire with a smaller diameter and a third welding wire. Such an embodiment may weld workpieces of different thicknesses with higher quality, and may combine different wire diameters depending on the base material thickness, e.g., a larger diameter wire may be oriented to a thicker base material and a smaller diameter wire may be oriented to a smaller thickness base material.
In addition, the present embodiment of the welding wire may use solid wire, flux cored wire, or a combination of different types of consumables without departing from the spirit or scope of the present invention. In fact, the present embodiment may provide a more stable welding operation when using flux-cored wires. Specifically, the use of a droplet transition after three wires meet may help stabilize the flux-cored wire droplet, which may tend to be unstable in a single wire welding operation.
Furthermore, the three welding wires may be of different types or compositions at the same time, which may optimize a given welding operation. That is, two or three different types or compositions of consumables but compatible may be used in combination to produce the desired weld joint. For example, this embodiment is advantageous when a single wire composition does not achieve the desired weld performance. For example, the present embodiment allows for the use of two or three different composition welding wires, by combining the same droplet post-transition, to produce the desired weld chemistry. As another example, some welding wires for dedicated welding provide the desired weld chemistry and weld strength, but the welding wire is very poorly weldable and unusable. However, this embodiment allows the use of two consumables that are easier to weld, by combining to produce the desired weld chemistry. In addition, when the manufacturing process of the welding wire with a certain specific component is complex and the cost is high, the embodiment of the invention can obtain the expected welding seam component through the welding wires with three different components, thereby saving the cost and the manufacturing process.
It should be noted that the welding system of the present embodiment may be used for manual, semi-automatic and robotic welding operations. Thus, the present embodiment can be used for a wide range of welding operations.
Fig. 2 (a) is a schematic view of an exemplary three-hole contact tip in this embodiment, the contact tip having three separate outlet holes, a first outlet hole 21, a second outlet hole 22, and a third outlet hole 23; the projections of the centers of the three outlet holes on the base material are three vertexes of an equilateral triangle, and the distance between the centers of the two holes is L, as shown in fig. 2 (b).
When the welding wires leave the outlet hole, angles among the first welding wire, the second welding wire and the third welding wire and the central line of the contact tip all meet the range of +/-10 degrees.
Compared with the welding mode of arranging the double wires in tandem and arranging the double wires in parallel, the welding seam width is inconsistent easily, the three outlet holes of the embodiment form an equilateral triangle layout, the minimum change of welding wires and electric arc arrangement in the welding direction can be ensured in the welding process, the consistency of the welding seam width and the penetration can be ensured all the time, the three-wire cladding efficiency is higher, and the welding efficiency is higher.
The distance L is selected to ensure that the wire ends, after melting, merge into one droplet and transition, and that the three wire ends are not connected together. In this embodiment, the distance L is in the range of 1.2 to 3.5 times the larger diameter of the three welding wires A1/A2/A3. For example, if each of the welding wires has a diameter of 1mm, the distance L may be in the range of 1.2-3.5 mm. Further, in manual or semi-automatic welding operations, the distance L may be in the range of 1.2 to 2.5 times the maximum wire diameter, whereas in robotic welding operations, the distance L may be in the range of 2.4 to 3.5 times the maximum wire diameter. In an exemplary embodiment, the distance L is in the range of 1.2mm to 2.5 mm. Experiments prove that when the distance L is in the range of 1.2-1.5mm, the welding effect is very good, and as the distance L is smaller, the penetration is increased, and the smaller the welding line width is, the penetration and the welding line width adjusting range can be increased; in the embodiment of the invention, when the distance L is 1.2mm, the penetration of the welding seam can reach 1.2 times of the penetration when the L is 2.5mm, the width of the welding seam is reduced by 15%, and meanwhile, the welding arc size is reduced, so that the occurrence of undercut defects is reduced.
Fig. 3 (a) depicts the current flow direction and resulting electromagnetic distribution of the welding wires A1, A2, and A3 in the present embodiment. The welding current is split through each respective wire after passing through the contact tip, and when the same diameter and type of wire is used, the welding current will be split evenly through the wires. When welding wires of different diameters and types are used, the welding wire resistance values are different, and corresponding currents are distributed due to the relation of v=i×r. Due to the flow of the current, a magnetic field R is generated around the welding wire. Fig. 3 (b) shows the electromagnetic force distribution of the welding wire according to this embodiment, in which the two welding wires are drawn to each other by a tightening force, and the resultant forces applied to the welding wires A1, A2 and A3 are directed to the center point of the equilateral triangle formed by the three welding wires. This magnetic force tends to create a droplet between the three welding wires. FIG. 3 (c) is a schematic view of a droplet in this embodiment, wherein the distance between the centers of the two welding wires at the ends of the welding wires is less than L, but not touching each other, under the electromagnetic tightening force. As the current through each of the welding wires melts the ends of the welding wires, electromagnetic forces tend to pull the melted droplets toward each other until they join each other, merging into one droplet back transition.
Fig. 4 (a) is a schematic diagram of a droplet transition process in which droplet bridging occurs and grows up, eventually transitioning to a puddle under the force of gravity, surface tension, and electromagnetic force, where electromagnetic force acts on the droplet bridging to pinch off the droplet.
FIG. 4 (b) is a schematic view of another embodiment of a droplet transition where L is small enough to select 1.2-1.5 times the maximum diameter of the welding wire; when the welding wire ends form molten drops, the welding wires are not contacted with each other, but the liquid molten drops are extruded between the three welding wires under the action of electromagnetic force, and at the moment, the stable transition process can be completed. Therefore, compare in the twin wire welding mode, adopt the three silk welding system of this embodiment equilateral triangle overall arrangement, along with welding wire interval L's reduction, will lead to the welding seam penetration to increase, the welding seam width reduces, this patent can further reduce welding wire's interval L, has increased the adjustment range of welding seam width and penetration.
Fig. 5 depicts two different exemplary waveforms that may be used in the present embodiment. Typically, the current is increased to produce droplets, which grow gradually and then transition to the puddle under the force of gravity, electromagnetic forces, etc. In this example, the average diameter of the transitional droplets is approximately 1.2 to 1.5 times the pitch L.
Fig. 5 (a) is an exemplary output current waveform schematic of the pulsed spray welding-type operation of the present embodiment, having a base current 51 which then transitions to a peak current level 52. During this time, the droplet forms and grows gradually, and under the influence of the peak duration, the droplet transitions to the puddle. After the transition, when this process is repeated, the current then drops again to the base level. For example, some embodiments may maintain peak currents in the range of 550A-650A, base currents in the range of 300A-400A, and peak times in the range of 6ms-10 ms. In such embodiments, the welding deposition efficiency may be significantly improved, for example, such embodiments may reach 10Kg/h to 16Kg/h, whereas the deposition rate of a single wire process may be in the range of 4.5Kg/h to 7.5Kg/h, and the deposition rate of a twin wire welding process may be in the range of 8.6Kg/h to 11.79Kg/h.
Fig. 5 (b) is a schematic diagram of another exemplary welding current waveform in this embodiment, where the control mode is constant voltage control, and the welding current is large, so that the droplet and the molten pool have no short circuit in the welding process, and the current has no fluctuation. Under the action of the jet transition current, the molten drops are firstly converged into one molten drop, and then transition into a molten pool. Under the control of the current waveform, the molten drop transition is uniform. For example, some embodiments maintain a current in the range of 500A to 700A and a voltage in the range of 40V to 42V, with droplet transition frequencies of 80 to 150Hz.
Fig. 6 (a) is a schematic diagram of an exemplary medium plate weld joint and a welding process using a conventional single welding wire, and the welding efficiency is low due to the fact that the single-pass welding bead cannot meet the requirement due to the limited deposition rate of a single wire process, and the single-pass welding bead needs to be solved through multiple layers and multiple passes. And finger penetration (the size and the width of the part B are too small) is easy to occur in a monofilament process under the condition of large deposition rate, so that air hole welding defects (gas is not enough to overflow a molten pool to form in the welding process) are easy to occur, and the strength of a welding line is reduced.
The embodiment can alleviate the problem of welding the medium plate, and can improve the welding efficiency while improving the welding quality. Fig. 6 (b) is a schematic view of the weld joint and the welding process of the medium plate of the present embodiment. The embodiment can realize similar or improved weld bead size, enable a wider weld bead to be arranged in the depth of a weld joint, improve the penetration shape, reduce finger penetration and reduce weld joint air hole defects. And the cladding efficiency is improved, and multi-layer and multi-channel welding is not needed.
Example two
In one or more embodiments, a parallel three wire welding method is provided, comprising:
Providing an output current waveform to the contact tip via a wide range welding power source; wherein the contact tip includes a first outlet aperture, a second outlet aperture, and a third outlet aperture; the first outlet hole, the second outlet hole and the third outlet hole are separated from each other, and projection points of circle centers of the first outlet hole, the second outlet hole and the third outlet hole on the surface of the workpiece are three vertexes of an equilateral triangle, so that every two spaces among the three welding wires are L;
A wire feed mechanism provides a first welding wire to the contact tip, the first welding wire being delivered through the first exit orifice;
the wire feeding mechanism provides a second welding wire to the contact tip, and the second welding wire is delivered out through the second outlet hole;
the wire feeding mechanism provides a third welding wire to the contact tip, and the third welding wire is delivered out through a third outlet hole;
Wherein the first outlet hole, the second outlet hole and the third outlet hole are separated from each other, and the projection points of the centers of the circles of the first outlet hole, the second outlet hole and the third outlet hole on the surface of the workpiece are three vertexes of an equilateral triangle, so that the interval between every two three welding wires is L;
The contact tip delivers the current waveforms to the first, second, and third wires, respectively, such that ends of the first, second, and third wires melt, merge into one droplet, and then transition.
The structure of the contact tip, the wire feeding mechanism, the welding wire, the welding power source and the droplet forming process related to the above method are described in the first embodiment, and are not repeated here.
While the foregoing description of the embodiments of the present invention has been presented in conjunction with the drawings, it should be understood that it is not intended to limit the scope of the invention, but rather, it is intended to cover all modifications or variations within the scope of the invention as defined by the claims of the present invention.
Claims (8)
1. A side-by-side three wire welding system comprising: a welding power supply, a wire feeding mechanism and a conductive nozzle; wherein the contact tip comprises a first outlet aperture, a second outlet aperture, and a third outlet aperture; the first exit hole is configured to deliver a first welding wire, the second exit hole is configured to deliver a second welding wire, and the third exit hole is configured to deliver a third welding wire; wherein the first outlet hole, the second outlet hole and the third outlet hole are separated from each other, and the projection points of the centers of the first outlet hole, the second outlet hole and the third outlet hole on the surface of the workpiece are three vertexes of an equilateral triangle, so that the interval between every two three welding wires is L;
The welding power source is configured to provide an output current waveform to a contact tip configured to deliver the current waveform to a first wire, a second wire, and a third wire, respectively; controlling the melting speed of the welding wire through a current waveform, and ensuring that the melting speed of the welding wire is consistent with the wire feeding speed of a wire feeding mechanism through adjusting the current waveform output by a welding power supply;
The spacing L is configured to facilitate a post-droplet transition by the current waveform such that ends of the first, second, and third welding wires melt and merge into a droplet; specifically, the spacing L is configured to ensure that the three wire ends, after melting, can merge into one droplet and transition, and that the three wire ends are not connected together;
The distance L is in the range of 1.2-3.5 times of the maximum diameter of any one of the three welding wires, and the distance L is measured according to the minimum distance between the edges of any two of the first welding wire, the second welding wire and the third welding wire; or the distance L is in the range of 1.2 mm-3 mm; the spacing L is measured as the minimum distance between the edges of any two of the first, second and third wires.
2. A parallel three wire welding system as set forth in claim 1 wherein the current waveform output by the welding power supply is adjusted by detecting the arc length and comparing it to a given voltage value; so that the melting speed of the welding wire under the control of the current waveform is consistent with the wire feeding speed of the wire feeding mechanism.
3. A parallel three wire welding system as set forth in claim 1 wherein said welding power source has an output current in the range of 50A-1000A.
4. The juxtaposed three wire welding system of claim 1, wherein the angles between said first, second and third wires and the centerline of the contact tip are within + -10 degrees when three wires leave three exit holes;
Or the first welding wire has a first diameter, and the second or third welding wire has a second diameter different from the first diameter;
or at least one of the three welding wires is a flux-cored wire;
or the first welding wire has a first composition, and the second welding wire or the third welding wire has a second composition different from the first composition;
Or the first welding wire has a first composition, the second welding wire has a second composition different from the first welding wire, and the third welding wire has a third composition different from both the first welding wire and the second welding wire.
5. A method of parallel three wire welding comprising:
Providing an output current waveform to the contact tip; the contact tip includes a first outlet aperture, a second outlet aperture, and a third outlet aperture;
providing a first welding wire to the contact tip, the first welding wire being delivered through a first exit aperture;
Providing a second welding wire to the contact tip, the second welding wire being delivered through a second exit aperture;
Providing a third welding wire to the contact tip, the third welding wire being delivered through a third exit aperture;
Wherein the first outlet hole, the second outlet hole and the third outlet hole are separated from each other, and the projection points of the centers of the first outlet hole, the second outlet hole and the third outlet hole on the surface of the workpiece are three vertexes of an equilateral triangle, so that the interval between every two three welding wires is L; specifically, the spacing L is configured to ensure that the three wire ends, after melting, can merge into one droplet and transition, and that the three wire ends are not connected together;
The distance L is in the range of 1.2-3.5 times of the maximum diameter of any one of the three welding wires, and the distance L is measured according to the minimum distance between the edges of any two of the first welding wire, the second welding wire and the third welding wire; or the distance L is in the range of 1.2 mm-3 mm; the distance L is measured according to the minimum distance between the edges of any two of the first welding wire, the second welding wire and the third welding wire;
The current waveform is respectively delivered to the first welding wire, the second welding wire and the third welding wire by the conducting nozzle, so that the ends of the first welding wire, the second welding wire and the third welding wire are melted and are converged into molten drops for transition; the melting speed of the welding wire is controlled through the current waveform, and the melting speed of the welding wire is ensured to be consistent with the wire feeding speed of the wire feeding mechanism through adjusting the current waveform output by the welding power supply.
6. A parallel three wire welding method as defined in claim 5 wherein the current waveform output by the welding power supply is adjusted by detecting the arc length and comparing it to a given voltage value; so that the melting speed of the welding wire under the control of the current waveform is consistent with the wire feeding speed of the wire feeding mechanism.
7. The method of claim 5, wherein the waveform of the output current provided to the conductive tip is in the range of 50 to 1000A.
8. The method of claim 5, wherein the angles between the first, second and third wires and the centerline of the contact tip are within + -10 DEG when the three wires leave the three outlet holes;
Or the first welding wire has a first diameter, and the second or third welding wire has a second diameter different from the first diameter;
or at least one of the three welding wires is a flux-cored wire;
or the first welding wire has a first composition, and the second welding wire or the third welding wire has a second composition different from the first composition;
Or the first welding wire has a first composition, the second welding wire has a second composition different from the first welding wire, and the third welding wire has a third composition different from both the first welding wire and the second welding wire.
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| US11498146B2 (en) * | 2019-09-27 | 2022-11-15 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| AU2021200311A1 (en) * | 2020-01-27 | 2021-08-12 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| CN112171009A (en) * | 2020-09-27 | 2021-01-05 | 北京博清科技有限公司 | Welding method and welding device |
| CN112427778B (en) * | 2020-11-12 | 2022-03-11 | 唐山松下产业机器有限公司 | Multi-power-supply parallel welding system |
| FR3126912B1 (en) * | 2021-09-16 | 2024-01-12 | Airbus Operations Sas | Deposit head of a three-dimensional printing machine configured to deposit several wires simultaneously and three-dimensional printing machine comprising said deposit head |
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