CN111299758A - Droplet shape control device and method for carbon dioxide gas shielded welding - Google Patents
Droplet shape control device and method for carbon dioxide gas shielded welding Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 136
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 title claims abstract description 68
- 238000000034 method Methods 0.000 title claims abstract description 39
- 229910002092 carbon dioxide Inorganic materials 0.000 title claims abstract description 34
- 239000001569 carbon dioxide Substances 0.000 title claims abstract description 23
- 230000005284 excitation Effects 0.000 claims abstract description 92
- 230000006698 induction Effects 0.000 claims abstract description 59
- 230000000630 rising effect Effects 0.000 claims abstract description 9
- 230000001681 protective effect Effects 0.000 claims description 15
- 230000008859 change Effects 0.000 claims description 12
- 230000008602 contraction Effects 0.000 claims description 5
- 230000008569 process Effects 0.000 abstract description 12
- 230000015572 biosynthetic process Effects 0.000 abstract description 5
- 230000009471 action Effects 0.000 abstract description 2
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- 238000012546 transfer Methods 0.000 description 7
- 238000002474 experimental method Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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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
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- 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
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- 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
本发明公开了一种二氧化碳气体保护焊的熔滴形态控制装置及方法，所述装置及方法采用励磁电源产生励磁脉冲电流，通过导线供给安装在CO2气体保护焊焊枪上的磁感应线圈，并通过横向磁场导磁杆作用使其在焊丝端部熔滴区域产生磁场，产生的磁场作用于熔滴；磁场磁力线通过磁感应线圈和熔滴区域形成闭合回路；通过检测电弧电压信号的上升沿和下降沿控制励磁脉冲电流的通断，实现与焊接过程的同步；磁感应线圈磁场产生的洛伦兹力，与熔滴原有的电磁收缩力、斑点压力、等离子流力、表面张力等相互作用，通过调节励磁脉冲电流及焊接电流的大小改变熔滴的形态，从而改善焊缝成形，提高焊接程稳定性。本发明所述装置及方法尤其适用于大电流低飞溅CO2气体保护焊。
The invention discloses a droplet shape control device and method for carbon dioxide gas shielded welding. The device and method use an excitation power source to generate an excitation pulse current, supply a magnetic induction coil installed on a CO2 gas shielded welding torch through a wire, and pass it through a wire. The action of the transverse magnetic field magnetizing rod makes it generate a magnetic field in the droplet area at the end of the welding wire, and the generated magnetic field acts on the droplet; the magnetic field line of the magnetic field forms a closed loop through the magnetic induction coil and the droplet area; by detecting the rising edge and falling edge of the arc voltage signal Control the on-off of the excitation pulse current to achieve synchronization with the welding process; the Lorentz force generated by the magnetic field of the magnetic induction coil interacts with the original electromagnetic shrinkage force, spot pressure, plasma flow force, and surface tension of the droplet. The size of the excitation pulse current and the welding current changes the shape of the droplet, thereby improving the weld formation and improving the stability of the welding process. The device and method of the present invention are especially suitable for high current and low spatter CO 2 gas shielded welding.
Description
技术领域technical field
本发明涉及CO2气体保护焊接领域，特别是涉及一种二氧化碳气体保护焊的熔滴形态控制装置及方法。The invention relates to the field of CO2 gas shielded welding, in particular to a droplet shape control device and method for carbon dioxide gas shielded welding.
背景技术Background technique
CO2(二氧化碳)气体保护焊是采用纯CO2气体作为保护气的熔化极气体保护焊，由于具有成本低廉、高效节能、抗锈、抗裂能力强、低氢、焊接变形小、适用于全位置焊接、便于实现机械化和自动化等诸多优点，在现代工业中应用广泛。CO2气体保护焊有短路过渡、滴状过渡和射滴过渡等几种熔滴过渡方式，其中以短路过渡的方式使用最为广泛。短路过渡CO2气体保护焊时存在大量金属飞溅和焊缝成型差的问题，改善焊缝成形的一种方法是让熔滴均匀稳定的过渡到熔池中。人们采用了许多有效的方法对熔滴的形态进行优化，主要涉及熔滴尺寸的研究。有文献介绍，CO2气体保护焊短路过渡过程中，熔滴尺寸与焊接电流成反比，与电弧电压成正比，随着焊丝的干伸长增加，熔滴的尺寸先减小后增大，焊接速度对熔滴尺寸几乎无影响。也有文献报道，通过对焊接过程中的电流信号进行数学处理，建立焊丝熔化模型，通过控制燃弧初期脉冲电流的宽度调整燃弧能量的高低，随着燃弧脉冲电流宽度的增加，熔滴尺寸单调增加，实现对熔滴尺寸的控制。还有文献通过在焊丝中加入K2CO3(碳酸钾)，Na2CO3(碳酸钠)等活化物质，改变电弧形态及熔滴过渡形态，电弧的弧根扩展，过渡形态由原来的大颗粒过渡变为细小颗粒过渡，熔滴的尺寸减小。可见目前改变熔滴尺寸的研究已经取得了一定的成果，但是对于熔滴形状的改变却鲜有报道。相关实验表明，熔滴形状的改变也能够提升熔滴过渡稳定性。因此，研究出对焊丝端部的熔滴进行控制，改变熔滴的形态，由原来的圆锥体、带尖角的球状或椭球状变为半球体和无尖角的圆润球状或椭球状，对提升熔滴过渡稳定性具有重要意义。CO 2 (carbon dioxide) gas shielded welding is a MIG/MAG welding that uses pure CO 2 gas as shielding gas. Due to its low cost, high efficiency and energy saving, rust resistance, strong crack resistance, low hydrogen Position welding, easy to achieve mechanization and automation and many other advantages are widely used in modern industry. There are several droplet transfer methods in CO 2 gas shielded welding, such as short-circuit transfer, droplet transfer and droplet transfer, among which short-circuit transfer is the most widely used. There are a lot of metal spatter and poor weld formation in short-circuit transition CO 2 gas shielded welding. One way to improve the weld formation is to make the droplets transition into the molten pool uniformly and stably. Many effective methods have been used to optimize the droplet morphology, mainly involving the study of the droplet size. According to literature, in the short-circuit transition process of CO 2 gas shielded welding, the size of the droplet is inversely proportional to the welding current and proportional to the arc voltage. As the dry elongation of the welding wire increases, the size of the droplet first decreases and then increases. Velocity has little effect on droplet size. It has also been reported in the literature that the welding wire melting model is established by mathematically processing the current signal in the welding process, and the arc energy is adjusted by controlling the width of the pulse current at the initial stage of the arc. Monotonically increasing to achieve control over droplet size. There are also literatures by adding K 2 CO 3 (potassium carbonate), Na 2 CO 3 (sodium carbonate) and other activating substances to the welding wire to change the arc shape and the droplet transition shape, the arc root of the arc expands, and the transition shape changes from the original large. The particle transition becomes a fine particle transition, and the size of the droplets decreases. It can be seen that the research on changing the size of the droplet has achieved certain results, but there are few reports on the change of the shape of the droplet. Relevant experiments show that the change of droplet shape can also improve the droplet transition stability. Therefore, it is studied to control the droplet at the end of the welding wire and change the shape of the droplet from the original cone, spherical or ellipsoid with sharp corners to hemisphere and rounded spherical or ellipsoid without sharp corners. It is of great significance to improve the stability of droplet transition.
发明内容SUMMARY OF THE INVENTION
本发明的目的是提供一种二氧化碳气体保护焊的熔滴形态控制装置及方法，以解决现有技术仅对熔滴尺寸进行优化，对熔滴过渡稳定性的提升有限的问题。The purpose of the present invention is to provide a droplet shape control device and method for carbon dioxide gas shielded welding, so as to solve the problem that the prior art only optimizes the size of the droplet and has limited improvement in the stability of the droplet transition.
为实现上述目的，本发明提供了如下方案：For achieving the above object, the present invention provides the following scheme:
一种二氧化碳气体保护焊的熔滴形态控制装置，包括：励磁电源装置、磁头装置、霍尔电压传感器以及CO2气体保护焊机；所述励磁电源装置包括：励磁电源和控制系统；所述控制系统分别与所述励磁电源的输入端以及所述霍尔电压传感器的输出端连接；所述励磁电源的输出端与所述磁头装置的磁感应线圈连接；所述霍尔电压传感器的输入端与所述CO2气体保护焊机的输出端连接，用于采集所述CO2焊机的输出端的电弧电压信号并传送至所述控制系统；所述磁头装置包括磁感应线圈、横向磁场导磁杆以及磁感应线圈保护壳；所述磁感应线圈套设在所述CO2气体保护焊机的焊枪上；所述磁感应线圈外侧设置有所述磁感应线圈保护壳；所述磁感应线圈保护壳的外侧设置有所述横向磁场导磁杆；由所述励磁电源产生励磁脉冲电流，通过导线供给安装在所述焊枪上的磁感应线圈，并通过所述横向磁场导磁杆作用在所述焊枪的焊丝端部熔滴区域产生磁场；产生的所述磁场作用于熔滴，所述磁场的磁力线通过所述磁感应线圈和所述熔滴区域形成闭合回路。A droplet shape control device for carbon dioxide gas shielded welding, comprising: an excitation power supply device, a magnetic head device, a Hall voltage sensor and a CO2 gas shielded welding machine; the excitation power supply device comprises: an excitation power supply and a control system; the control The system is respectively connected with the input end of the excitation power supply and the output end of the Hall voltage sensor; the output end of the excitation power supply is connected with the magnetic induction coil of the magnetic head device; the input end of the Hall voltage sensor is connected with the The output end of the CO 2 gas shielded welding machine is connected to collect the arc voltage signal of the output end of the CO 2 welding machine and transmit it to the control system; the magnetic head device includes a magnetic induction coil, a transverse magnetic field magnetic rod and a magnetic induction Coil protective casing; the magnetic induction coil is sleeved on the welding torch of the CO 2 gas shielded welding machine; the magnetic induction coil protective casing is provided outside the magnetic induction coil; the lateral Magnetic field magnetizing rod; excitation pulse current is generated by the excitation power supply, which is supplied to the magnetic induction coil installed on the welding torch through the wire, and is generated by the transverse magnetic field magnetizing rod acting on the droplet area of the welding wire end of the welding gun. Magnetic field; the generated magnetic field acts on the droplet, and the magnetic field lines of the magnetic field form a closed loop through the magnetic induction coil and the droplet area.
可选的，所述横向磁场导磁杆包括：左侧导磁杆和右侧导磁杆；所述左侧导磁杆的一端与所述磁感应线圈保护壳的底部连接；所述右侧导磁杆的一端与所述磁感应线圈保护壳的顶部连接；所述左侧导磁杆的另一端与所述右侧导磁杆的另一端相对。Optionally, the transverse magnetic field magnetizing rod includes: a left magnetizing rod and a right magnetizing rod; one end of the left magnetizing rod is connected to the bottom of the magnetic induction coil protective shell; One end of the magnetic rod is connected to the top of the magnetic induction coil protective shell; the other end of the left magnetic conductive rod is opposite to the other end of the right magnetic conductive rod.
一种二氧化碳气体保护焊的熔滴形态控制方法，所述方法基于所述的一种二氧化碳气体保护焊的熔滴形态控制装置，所述方法包括：A droplet shape control method for carbon dioxide gas shielded welding, the method is based on the described droplet shape control device for carbon dioxide gas shielded welding, and the method includes:
霍尔电压传感器采集CO2气体保护焊机的输出端的电弧电压信号，并将所述电弧电压信号发送到控制系统；The Hall voltage sensor collects the arc voltage signal of the output end of the CO2 gas shielded welding machine, and sends the arc voltage signal to the control system;
所述控制系统检测所述电弧电压信号的上升沿和下降沿；the control system detects the rising edge and the falling edge of the arc voltage signal;
当所述控制系统检测到所述电弧电压信号的上升沿时，所述控制系统接通所述励磁电源，所述励磁电源为磁感应线圈提供励磁脉冲电流；When the control system detects the rising edge of the arc voltage signal, the control system turns on the excitation power supply, and the excitation power supply provides excitation pulse current for the magnetic induction coil;
所述磁感应线圈在通入所述励磁脉冲电流时产生洛伦兹力，所述励磁脉冲电流产生的洛伦兹力与所述CO2气体保护焊机的焊枪的焊接电流产生的电磁收缩力、斑点压力、等离子流力以及所述焊枪的焊丝端部熔滴自身的表面张力相互作用，影响所述熔滴的形态；The magnetic induction coil generates a Lorentz force when the excitation pulse current is supplied, and the Lorentz force generated by the excitation pulse current and the electromagnetic contraction force generated by the welding current of the welding torch of the CO 2 gas shielded welding machine, The interaction of spot pressure, plasma flow force and the surface tension of the droplet itself at the wire end of the welding torch affects the shape of the droplet;
通过调节所述励磁脉冲电流及所述焊接电流的大小改变所述熔滴的形态；Change the shape of the droplet by adjusting the magnitude of the excitation pulse current and the welding current;
当所述控制系统检测到所述电弧电压信号的下降沿时，所述控制系统断开所述励磁电源，所述励磁电源停止为所述磁感应线圈提供所述励磁脉冲电流。When the control system detects the falling edge of the arc voltage signal, the control system disconnects the excitation power supply, and the excitation power supply stops providing the excitation pulse current to the magnetic induction coil.
可选的，所述励磁脉冲电流的调节范围为100-200A。Optionally, the adjustment range of the excitation pulse current is 100-200A.
可选的，所述焊枪的焊接电流的调节范围为140-200A。Optionally, the adjustment range of the welding current of the welding torch is 140-200A.
可选的，所述通过调节所述励磁脉冲电流及所述焊接电流的大小改变所述熔滴的形态，具体包括：Optionally, changing the shape of the droplet by adjusting the magnitude of the excitation pulse current and the welding current specifically includes:
通过调节所述励磁脉冲电流及所述焊接电流的大小，将所述熔滴的形态由圆锥体状、带尖角的球状或椭球状变为半球体状或无尖角的圆润球状或椭球状。By adjusting the magnitude of the excitation pulse current and the welding current, the shape of the droplet is changed from a cone, a spherical or ellipsoidal shape with sharp corners to a hemispherical shape or a rounded spherical or ellipsoidal shape without sharp corners .
根据本发明提供的具体实施例，本发明公开了以下技术效果：According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:
本发明公开了一种二氧化碳气体保护焊的熔滴形态控制装置及方法，所述装置及方法采用励磁电源装置产生励磁脉冲电流，通过导线供给安装在CO2气体保护焊焊枪上的磁感应线圈，并通过横向磁场导磁杆作用使其在焊丝端部熔滴区域产生磁场，产生的磁场作用于熔滴；磁场磁力线通过磁感应线圈和熔滴区域形成闭合回路；通过检测电弧电压信号的上升沿和下降沿控制励磁脉冲电流的通断，实现与焊接过程的同步；磁感应线圈磁场产生的洛伦兹力，与熔滴原有的电磁收缩力，斑点压力，等离子流力、表面张力等相互作用，通过调节励磁脉冲电流及焊接电流的大小改变熔滴的形态，从而改善焊缝成形，提高焊接程稳定性。本发明所述装置及方法尤其适用于大电流低飞溅CO2气体保护焊。The invention discloses a droplet shape control device and method for carbon dioxide gas shielded welding. The device and method use an excitation power supply device to generate an excitation pulse current, supply a magnetic induction coil installed on a CO2 gas shielded welding torch through a wire, and Through the action of the transverse magnetic field magnetizing rod, a magnetic field is generated in the droplet area at the end of the welding wire, and the generated magnetic field acts on the droplet; the magnetic field lines of the magnetic field form a closed loop through the magnetic induction coil and the droplet area; by detecting the rising edge and falling of the arc voltage signal The on-off of the excitation pulse current is controlled to realize synchronization with the welding process; the Lorentz force generated by the magnetic field of the magnetic induction coil interacts with the original electromagnetic shrinkage force, spot pressure, plasma flow force and surface tension of the droplet. Adjust the size of the excitation pulse current and the welding current to change the shape of the droplet, thereby improving the welding seam formation and improving the stability of the welding process. The device and method of the present invention are especially suitable for high current and low spatter CO 2 gas shielded welding.
附图说明Description of drawings
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings required in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some of the present invention. In the embodiments, for those of ordinary skill in the art, other drawings can also be obtained according to these drawings without creative labor.
图1为本发明提供的二氧化碳气体保护焊的熔滴形态控制装置以及实验装置的结构示意图；Fig. 1 is the structural representation of the droplet shape control device and the experimental device of carbon dioxide gas shielded welding provided by the present invention;
图2为本发明提供的短路过渡CO2气体保护焊的有/无励磁脉冲电流时熔滴形态变化图。FIG. 2 is a diagram showing the change of droplet morphology with/without excitation pulse current in the short-circuit transition CO 2 gas shielded welding provided by the present invention.
符号说明：Symbol Description:
1电脑、2工作台及工件、3激光背光源、4焊接电源、5励磁电源装置、6霍尔电压传感器、7焊枪、8磁感应线圈保护壳、9磁感应线圈、10焊丝、11横向磁场导磁杆、12高速摄像机。1 computer, 2 workbench and workpiece, 3 laser backlight, 4 welding power source, 5 excitation power supply device, 6 hall voltage sensor, 7 welding torch, 8 magnetic induction coil protective shell, 9 magnetic induction coil, 10 welding wire, 11 transverse magnetic field magnetic permeability pole, 12 high-speed cameras.
具体实施方式Detailed ways
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
本发明的目的是提供一种二氧化碳气体保护焊的熔滴形态控制装置及方法，以解决现有技术仅对熔滴尺寸进行优化，对熔滴过渡稳定性的提升有限的问题。The purpose of the present invention is to provide a droplet shape control device and method for carbon dioxide gas shielded welding, so as to solve the problem that the prior art only optimizes the size of the droplet and has limited improvement in the stability of the droplet transition.
为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图和具体实施方式对本发明作进一步详细的说明。In order to make the above objects, features and advantages of the present invention more clearly understood, the present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.
图1为本发明提供的二氧化碳气体保护焊的熔滴形态控制装置以及实验装置的结构示意图。如图1所示，一种二氧化碳气体保护焊的熔滴形态控制装置，包括：励磁电源装置5、磁头装置、霍尔电压传感器6以及CO2气体保护焊机。所述励磁电源装置5包括：励磁电源和控制系统。所述控制系统分别与所述励磁电源的输入端以及所述霍尔电压传感器6的输出端连接；所述励磁电源的输出端与所述磁头装置的磁感应线圈9连接。所述霍尔电压传感器6的输入端与所述CO2气体保护焊机的输出端连接，用于采集所述CO2焊机的输出端的电弧电压信号并传送至所述控制系统。FIG. 1 is a schematic structural diagram of a droplet shape control device and an experimental device for carbon dioxide gas shielded welding provided by the present invention. As shown in Figure 1, a droplet shape control device for carbon dioxide gas shielded welding includes: an excitation
所述磁头装置包括磁感应线圈9、横向磁场导磁杆11以及磁感应线圈保护壳8；所述磁感应线圈9套设在所述CO2气体保护焊机的焊枪上。所述磁感应线圈9外侧设置有所述磁感应线圈保护壳8。所述磁感应线圈保护壳8的外侧设置有所述横向磁场导磁杆11。由所述励磁电源产生励磁脉冲电流，通过导线供给安装在所述焊枪7上的磁感应线圈9，并通过所述横向磁场导磁杆11作用在所述焊枪7的焊丝10的端部熔滴区域产生磁场；产生的所述磁场作用于熔滴，所述磁场的磁力线通过所述磁感应线圈9和所述熔滴区域形成闭合回路。The magnetic head device includes a
具体的，所述横向磁场导磁杆11包括：左侧导磁杆和右侧导磁杆；所述左侧导磁杆的一端与所述磁感应线圈保护壳8的底部连接；所述右侧导磁杆的一端与所述磁感应线圈保护壳8的顶部连接；所述左侧导磁杆的另一端与所述右侧导磁杆的另一端相对。Specifically, the transverse magnetic
所述熔滴形态控制装置的工作过程为：The working process of the droplet shape control device is:
(1)由励磁电源产生励磁脉冲电流，通过导线供给安装在CO2气体保护焊焊枪上的磁感应线圈9，并通过横向磁场导磁杆11的作用使其在焊丝10端部熔滴区域产生磁场；(1) The excitation pulse current is generated by the excitation power supply, and the
(2)产生的磁场作用于熔滴；磁场磁力线通过磁感应线圈9和熔滴区域形成闭合回路；(2) The generated magnetic field acts on the droplet; the magnetic field lines of the magnetic field form a closed loop through the
(3)通过检测焊接电流信号中的燃弧信号，完成励磁脉冲电流的引入；检测电流信号中的短路信号，切断励磁脉冲电流，实现对熔滴形态的控制，具体的，从焊机的输出端取出电弧电压信号，接入霍尔电压传感器6。霍尔电压传感器6的输出信号接到励磁电源装置5。当励磁电源装置5采集到霍尔电压传感器6的输出(电弧电压)的上升沿信号，励磁电源装置5即刻给磁感应线圈9提供励磁脉冲电流；当励磁电源装置5采集到霍尔电压传感器6的输出(电弧电压)的下降沿信号，励磁电源装置5即刻切断励磁脉冲电流。(3) By detecting the arc signal in the welding current signal, the introduction of the excitation pulse current is completed; the short circuit signal in the current signal is detected, and the excitation pulse current is cut off to realize the control of the droplet shape, specifically, from the output of the welding machine The arc voltage signal is taken out from the terminal and connected to the Hall voltage sensor 6 . The output signal of the Hall voltage sensor 6 is connected to the excitation
(4)所述励磁脉冲电流的电磁脉冲产生的洛伦兹力，与熔滴上原有的电磁收缩力、斑点力、等离子流力、表面张力等相互作用，共同改变熔滴的受力状态。因此可以通过调节励磁脉冲电流装置5的励磁脉冲电流大小改变洛伦兹力大小，以及通过调节所述CO2气体保护焊机的焊枪7的焊接电流产生的电磁收缩力、斑点压力以及等离子流力的大小来改变熔滴受力状态，进而改变熔滴的形态。具体通过调节励磁脉冲电流(100-200A)大小来调节磁感应强度，磁脉冲的频率与所述CO2气体保护焊熔滴过渡频率保持一致。通过调节所述焊枪7的焊接电流(140-200A)大小来调节电磁收缩力、斑点压力以及等离子流力的大小。(4) The Lorentz force generated by the electromagnetic pulse of the excitation pulse current interacts with the original electromagnetic shrinkage force, spot force, plasma flow force, surface tension, etc. on the droplet to jointly change the force state of the droplet. Therefore, the magnitude of the Lorentz force can be changed by adjusting the magnitude of the excitation pulse current of the excitation pulse
基于所述的一种二氧化碳气体保护焊的熔滴形态控制装置，本发明还提供一种二氧化碳气体保护焊的熔滴形态控制方法，所述方法包括：Based on the described droplet shape control device for carbon dioxide gas shielded welding, the present invention also provides a droplet shape control method for carbon dioxide gas shielded welding, the method comprising:
所述霍尔电压传感器6采集CO2气体保护焊机的输出端的电弧电压信号，并将所述电弧电压信号发送到控制系统；The Hall voltage sensor 6 collects the arc voltage signal of the output end of the CO 2 gas shielded welding machine, and sends the arc voltage signal to the control system;
所述控制系统检测所述电弧电压信号的上升沿和下降沿；the control system detects the rising edge and the falling edge of the arc voltage signal;
当所述控制系统检测到所述电弧电压信号的上升沿时，所述控制系统接通所述励磁电源，所述励磁电源为磁感应线圈提供励磁脉冲电流；When the control system detects the rising edge of the arc voltage signal, the control system turns on the excitation power supply, and the excitation power supply provides excitation pulse current for the magnetic induction coil;
所述磁感应线圈9在通入所述励磁脉冲电流时产生洛伦兹力，所述励磁脉冲电流产生的洛伦兹力与所述CO2气体保护焊机的焊枪7的焊接电流产生的电磁收缩力、斑点压力、等离子流力以及所述焊枪7的焊丝10端部熔滴自身的表面张力相互作用，影响所述熔滴的形态；The
通过调节所述励磁脉冲电流及所述焊接电流的大小改变所述熔滴的形态；具体的，通过调节所述励磁脉冲电流及所述焊接电流的大小，将所述熔滴的形态由圆锥体状、带尖角的球状或椭球状变为半球体状或无尖角的圆润球状或椭球状；所述励磁脉冲电流的调节范围为100-200A；所述焊枪7的焊接电流的调节范围为140-200A。The shape of the droplet is changed by adjusting the magnitude of the excitation pulse current and the welding current; specifically, by adjusting the magnitude of the excitation pulse current and the welding current, the shape of the droplet is changed from a cone to a cone. The spherical or ellipsoidal shape with sharp corners becomes hemispherical or rounded spherical or ellipsoidal shape without sharp corners; the adjustment range of the excitation pulse current is 100-200A; the adjustment range of the welding current of the
当所述控制系统检测到所述电弧电压信号的下降沿时，所述控制系统断开所述励磁电源，所述励磁电源停止为所述磁感应线圈9提供所述励磁脉冲电流。When the control system detects the falling edge of the arc voltage signal, the control system disconnects the excitation power supply, and the excitation power supply stops providing the excitation pulse current to the
本发明装置及方法的实验验证步骤如下：The experimental verification steps of the device and method of the present invention are as follows:
步骤一：实验选用板厚5mm的Q235低碳钢作为焊接试件，选择合适CO2气体保护焊的焊接工艺参数，包括焊接电流、焊接电压、送丝速度、保护气体流量、干伸长量以及焊丝10端部距工件的距离等。Step 1: Q235 low carbon steel with a plate thickness of 5mm was selected as the welding specimen for the experiment, and the welding process parameters suitable for CO 2 gas shielded welding were selected, including welding current, welding voltage, wire feeding speed, shielding gas flow rate, dry elongation and The distance between the end of the
步骤二：接线。将焊机的正、负极分别接到焊枪7和工件2上；将励磁电源装置5的两输出端接到磁感应线圈9的两端，形成闭合回路；将磁感应线圈9与冷却水循环系统连接。Step 2: Wiring. Connect the positive and negative electrodes of the welding machine to the
步骤三：焊接。将焊枪7调节到合适的焊接位置后保持不动，以便利于拍摄熔滴形态。工件所在的工作台与送丝速度等相关参数配合后，按照相应的速度移动。开启励磁电源装置5和水冷系统。Step 3: Soldering. After adjusting the
步骤四：熔滴形态的采集。根据焊枪7的位置调整高速摄像机12的位置，将焊丝10端部置于镜头的中心部位，固定好高速摄像机12的位置后，通过电脑1清楚地观察到熔滴的状态。Step 4: Collection of droplet morphology. Adjust the position of the high-
步骤五：电磁磁脉冲的引入。采集到CO2气体保护焊的燃弧信号后传递给励磁电源装置5，励磁电源装置5接收到信号后产生励磁脉冲电流，励磁脉冲电流供给磁感应线圈9后产生磁场。燃弧结束后短路开始，将信号再次反馈给励磁电源装置5，励磁电源装置5停止供电，磁感应线圈9停止产生磁场。由此在燃弧过程中完成电磁脉冲的引入。Step 5: Introduction of electromagnetic pulse. After collecting the arc signal of CO2 gas shielded welding, it is transmitted to the excitation
步骤六：通过调节励磁脉冲电流的大小，调节磁感应强度的大小，改变洛伦兹力的大小，进而影响熔滴的受力状态，实现熔滴形态的改变。Step 6: By adjusting the magnitude of the excitation pulse current, adjusting the magnitude of the magnetic induction, and changing the magnitude of the Lorentz force, the force state of the droplet is affected, and the shape of the droplet is changed.
在步骤三中的焊接电流的调节范围为140～200A；焊接速度为8mm/s；步骤六中的励磁脉冲电流的调节范围为100～200A。The adjustment range of the welding current in the third step is 140-200A; the welding speed is 8 mm/s; the adjustment range of the excitation pulse current in the sixth step is 100-200A.
实验及测试结果：Experiment and test results:
实验选用直径为1.2mm的H08Mn2Si牌号的焊丝对厚度为5mm的Q235低碳钢板进行焊接，焊机型号MAG-350RL，励磁电源装置采用自制的MCWE-315，焊丝10干伸长为14mm。本发明通过高速摄像机12拍摄的熔滴过渡过程对熔滴的形态进行观测和分析。In the experiment, the H08Mn2Si brand welding wire with a diameter of 1.2 mm was used to weld the Q235 low carbon steel plate with a thickness of 5 mm. The present invention observes and analyzes the shape of the droplet through the droplet transition process photographed by the high-
图2为本发明提供的短路过渡CO2气体保护焊的有/无励磁脉冲电流时熔滴形态变化图。如图2所示，展示的是“燃弧阶段-短路阶段-短路结束”完整一个周期的熔滴过渡过程。不同实验参数(焊接电流、励磁脉冲电流)的熔滴形态有所差异，实验数据如表1所示：FIG. 2 is a diagram showing the change of droplet morphology with/without excitation pulse current in the short-circuit transition CO 2 gas shielded welding provided by the present invention. As shown in Figure 2, it shows the droplet transfer process of a complete cycle of "arcing stage-short-circuit stage-short-circuit end". The droplet morphology of different experimental parameters (welding current, excitation pulse current) is different. The experimental data are shown in Table 1:
表1不同实验参数下的熔滴形态及焊缝形貌Table 1 Droplet morphology and weld morphology under different experimental parameters
由图2和表1所示的实验结果可知，通过本发明提供的二氧化碳气体保护焊的熔滴形态控制装置及方法，将短路过渡CO2气体保护焊的熔滴由原来的圆锥体、带尖角的球状或椭球状变为半球体和无尖角的圆润球状或椭球状，改善了焊缝成形，且改善熔滴过渡每个周期熔滴形态和尺寸的一致性，降低飞溅，提高了焊接过程的稳定性。It can be seen from the experimental results shown in FIG. 2 and Table 1 that the droplet shape control device and method for carbon dioxide gas shielded welding provided by the present invention can change the droplet of short-circuit transition CO 2 gas shielded welding from the original cone, with a tip. The spherical or ellipsoidal shape of the corners is changed to a hemisphere and a rounded spherical or ellipsoidal shape without sharp corners, which improves the weld formation and improves the consistency of droplet shape and size in each cycle of droplet transfer, reduces spatter, and improves welding. process stability.
本说明书中各个实施例采用递进的方式描述，每个实施例重点说明的都是与其他实施例的不同之处，各个实施例之间相同相似部分互相参见即可。The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments, and the same and similar parts between the various embodiments can be referred to each other.
本文中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想；同时，对于本领域的一般技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处。综上所述，本说明书内容不应理解为对本发明的限制。In this paper, specific examples are used to illustrate the principles and implementations of the present invention. The descriptions of the above embodiments are only used to help understand the methods and core ideas of the present invention; meanwhile, for those skilled in the art, according to the present invention There will be changes in the specific implementation and application scope. In conclusion, the contents of this specification should not be construed as limiting the present invention.
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