CN111421206A - Welding power supply control method, controller, control circuit and welding system - Google Patents
Welding power supply control method, controller, control circuit and welding system Download PDFInfo
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- CN111421206A CN111421206A CN202010285400.7A CN202010285400A CN111421206A CN 111421206 A CN111421206 A CN 111421206A CN 202010285400 A CN202010285400 A CN 202010285400A CN 111421206 A CN111421206 A CN 111421206A
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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
- B23K9/095—Monitoring or automatic control of welding parameters
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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
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
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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
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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
- B23K9/32—Accessories
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05F—SYSTEMS FOR REGULATING ELECTRIC OR MAGNETIC VARIABLES
- G05F1/00—Automatic systems in which deviations of an electric quantity from one or more predetermined values are detected at the output of the system and fed back to a device within the system to restore the detected quantity to its predetermined value or values, i.e. retroactive systems
- G05F1/02—Regulating electric characteristics of arcs
Abstract
The invention relates to the field of welding, and discloses a welding power supply control method, a controller, a control circuit and a welding system, wherein the welding power supply control method comprises the following steps: firstly, obtaining a statistical value which is the number of times of failure of the welding state of the welding power supply is identified, secondly, determining a control mode of the welding power supply according to the statistical value and a preset threshold value, and finally, controlling the working state of the welding power supply according to the control mode of the welding power supply. Therefore, the method identifies the failure condition according to the welding state of the welding power supply, determines the control modes of different welding power supplies, further accurately controls the welding power supply, and ensures the working stability of the whole welding system.
Description
Technical Field
The invention relates to the field of welding, in particular to a welding power supply control method, a controller, a control circuit and a welding system.
Background
In the gas shielded welding of the consumable electrode, the consumable welding wire is used as an electrode, an electric arc burnt between the continuously fed welding wire and a workpiece to be welded is used as a heat source to melt the welding wire and base metal, a welding power supply provides energy for an electric welding device, the generation and the extinguishment of the electric arc are controlled, and then the welding process is controlled. Wherein, welding power supply's output current can direct influence molten drop transition process and molten drop size etc. and then influences whole welding process's stability.
The existing welding power supply control method is not strong in anti-interference performance and cannot accurately control a welding power supply, so that electric arc energy loss, welding spatter increase and welding process instability are easily caused.
Disclosure of Invention
An object of the embodiments of the present invention is to provide a welding power control method, a controller, a control circuit and a welding system, so as to improve the stability of the welding process.
In order to solve the above technical problem, one technical solution adopted by the embodiments of the present invention is:
in a first aspect, an embodiment of the present invention provides a welding power supply control method applied to a gas metal arc welding system, where the method includes:
acquiring a statistical value, wherein the statistical value is the number of times that the welding state of the welding power supply is identified to be invalid;
determining a control mode of the welding power supply according to the statistical value and a preset threshold value;
and controlling the working state of the welding power supply according to the control mode of the welding power supply.
In some embodiments, the control mode comprises a natural response control mode or a current waveform adjustment control mode, and the determining the control mode of the welding power supply based on the statistical value and a preset threshold comprises:
judging whether the statistic value is larger than the preset threshold value or not;
if so, selecting the control mode of the welding power supply as a natural response control mode;
and if not, selecting the control mode of the welding power supply as a current waveform adjustment control mode.
In some embodiments, said controlling an operational state of said welding power supply according to a control mode of said welding power supply comprises:
when the control mode of the welding power supply is a natural response control mode, controlling the welding power supply to output a first current according to set parameters;
and when the control mode of the welding power supply is a current waveform adjustment control mode, controlling the welding power supply to output a second current according to a welding feedback signal of the welding power supply and the set parameter.
In some embodiments, the method further comprises:
acquiring a welding feedback signal of the welding power supply;
identifying the welding state of the welding power supply according to the welding feedback signal to generate an identification result, wherein the welding state comprises an arcing state and a short circuit state;
and determining the statistical value according to the identification result.
In some embodiments, said determining said statistical value according to the recognition result comprises:
judging whether the identification is invalid or not according to the identification result;
if yes, accumulating the current statistical values by preset values and performing assignment processing to obtain the final statistical values.
In a second aspect, an embodiment of the present invention provides a controller, including:
at least one processor; and
a memory communicatively coupled to the at least one processor; wherein the memory stores instructions executable by the at least one processor to enable the at least one processor to perform a welding power supply control method as described above.
In a third aspect, an embodiment of the present invention provides a welding power control circuit for a gas metal arc welding system, the circuit including:
the welding power supply control circuitry comprises:
the sampling circuit is connected with the welding power supply and is used for sampling the welding power supply feedback signal;
a drive circuit connected to the welding power supply for driving the welding power supply;
and the controller is respectively connected with the sampling circuit and the driving circuit and is used for controlling the working state of the welding power supply according to the welding power supply feedback signal.
In some embodiments, the sampling circuit includes a voltage sampling circuit and a current sampling circuit, the voltage sampling circuit and the current sampling circuit both being connected to the welding power source and the controller, respectively, the voltage sampling circuit being configured to sample an output voltage of the welding power source, and the current sampling circuit being configured to sample an output current of the welding power source.
In a third aspect, embodiments of the present invention also provide a welding system, including:
a welding power supply for providing energy to an arc load; and
the welding power supply control circuit is connected with the welding power supply and used for controlling the working state of the welding power supply.
The embodiment of the invention has the beneficial effects that: different from the situation in the prior art, in the embodiment of the present invention, first, a statistical value is obtained, where the statistical value is the number of times that the welding state of the welding power supply is identified to be invalid, then, a control mode of the welding power supply is determined according to the statistical value and a preset threshold, and finally, the working state of the welding power supply is controlled according to the control mode of the welding power supply. Therefore, the method identifies the failure condition according to the welding state of the welding power supply, determines the control modes of different welding power supplies, further accurately controls the welding power supply, and ensures the working stability of the whole welding system.
Drawings
FIG. 1 is a schematic diagram of a welding power supply control circuit according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the output current of a welding power supply using a natural response control mode in accordance with an embodiment of the present invention;
FIG. 3 is a schematic diagram of a welding power supply output current using a current waveform regulation control scheme in accordance with an embodiment of the present invention;
FIG. 4 is a schematic diagram of a welding power supply output current using a current waveform adjustment control scheme in accordance with another embodiment of the present invention;
FIG. 5 is a schematic diagram of a welding power control circuit according to an embodiment of the present invention;
FIG. 6 is a schematic structural diagram of a controller according to an embodiment of the present invention;
FIG. 7 is a schematic structural diagram of a welding power control apparatus according to an embodiment of the present invention;
FIG. 8 is a flow chart illustrating a method for controlling a welding power supply according to an embodiment of the present invention;
FIG. 9 is a schematic flow chart of step 52 of FIG. 8;
FIG. 10 is a schematic flow chart of step 53 in FIG. 8;
FIG. 11 is a flow chart illustrating a method for controlling a welding power supply according to another embodiment of the present invention;
fig. 12 is a schematic flow chart of step 56 in fig. 11.
Detailed Description
In order to facilitate an understanding of the invention, the invention is described in more detail below with reference to the accompanying drawings and detailed description. It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for descriptive purposes only.
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. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
Referring to fig. 1, fig. 1 is a schematic structural diagram of a welding power application scenario according to an embodiment of the present invention. As shown in fig. 1, the welding system is specifically a consumable electrode arc welding system, and the consumable electrode arc welding apparatus 10 includes: a welding power source 11, a welding wire 12, an arc 13, a base material 14, and a wire feeder 15, wherein the welding power source 11 provides energy to the welding wire 12, the arc 13, and the base material 14 to melt the welding wire 12, maintain the arc 13, and heat the base material 14, respectively. The welding wire 12 is fed into the welding gun wire feeding tube by the feeder device 15 at a certain speed, the welding wire is melted by the power supply arc 13, and the feeding speed of the welding wire 12 is consistent with the melting speed of the welding wire 12, so that the stability of the welding process can be ensured, and therefore, the feeding speed of the welding wire is an important factor influencing the stability of the welding process.
Gas metal arc welding (gas metal arc welding), which is simply referred to as gas metal arc welding, and gas metal arc welding, may be referred to as metal inert gas arc welding or metal active gas arc welding. Refers to an arc welding method using an externally added gas as an arc medium and protecting the arc and the welding zone. The automatic welding process is an automatic or semi-automatic process, wherein the automatic welding needs to continuously feed welding wires, and argon or helium is fed from a nozzle of a welding torch for protection. The welding power source can adopt direct current and alternating current. The arc division can be divided into spherical arc, jet arc, pulsed jet arc and short-circuit arc welding. The gas metal arc welding is mainly used for welding aluminum and nonferrous metals at the beginning of development of gas metal arc welding, and has higher welding efficiency.
When welding is needed, firstly, a welding power supply 11 provides power for each device, a user sets various parameters of the welding device, such as gas, welding wire materials, welding voltage, welding current and the like, then the user presses a welding gun switch, the welding power supply 11 enters an arc striking stage, a molten pool and a welding area formed by melting a welding wire 12 and a base metal 14 by an electric arc 13 can effectively prevent the harmful effect of ambient air under the protection of inert gas or active gas, and welding is completed through a molten drop transition process. The molten drop transition refers to the whole process that molten metal at the end of the welding wire 12 or the welding rod forms molten drops under the heat action of the electric arc 13, and the molten drops are separated from the end of the welding wire 12 and are transferred to a molten pool under various forces. It has a direct relation with the stability of the welding process, the formation of the welding seam, the size of the spatter and the like, and finally influences the welding quality and the production efficiency.
For gas shielded welding, one of the forms of droplet transition is short-circuit transition, specifically, when the current is small and the voltage of the electric arc 13 is low, the arc length is short, the droplet is not grown into a large droplet and is contacted with a molten pool to form a liquid metal short circuit, the electric arc 13 is extinguished, then the metal droplet is transited into the molten pool under the action of surface tension and electromagnetic contraction force, and the electric arc 13 is reignited after the droplet falls off, so that the transition mode is alternately carried out. The short circuit transition is alternately arcing and arc extinguishing. And when short circuit is in transition, the average welding current is smaller.
For gas-shielded welding, the load state is often switched between arcing and short-circuiting due to the short-circuit transition of the metal droplet. Moreover, the transient changes of output current and voltage are caused by the transition process from arc burning to short circuit and from short circuit to arc burning, and the welding spatter and welding seam forming are greatly influenced. The reasons why the welding spatter is directly affected by the dynamic characteristics of the power supply are: the height of the short-circuit current peak value and the speed of the growth rate are directly influenced by the dynamic response speed of the welding machine.
If the dynamic response is too fast, the peak value of the short-circuit current is too high, the growth rate is too fast, before a short-circuit liquid bridge is formed, explosion and splashing are caused, a short-circuit transition form cannot be formed, and the splashing is characterized by high frequency and small particles; if the dynamic response is too slow, the increase rate of the short-circuit current is slow, the peak value is small, the magnetic shrinkage force generated by the current is not enough to ensure the smooth transition of the short-circuit liquid bridge, the short-circuit transition time is long, and the generated splashing characteristics are as follows: the frequency is low and the particles are coarse.
Therefore, it is required that the welding power source 11 have an appropriate short-circuit current increase rate to avoid large spatters. The short circuit current has little effect on the heating of the welding joint, the penetration and the forming of the welding seam, and the penetration and the forming of the welding seam are mainly influenced by the arcing energy, namely the current and the voltage of the arcing.
Because the short-circuit process exists during welding, the power supply voltage cannot be too high, and the arcing current is small in a steady state, so that the current change process after the short circuit is finished is an important component of the arcing capacity. That is, the dynamic characteristics of the welding power supply 11 have a significant effect on weld formation and penetration. The slower the dynamic characteristic is, the longer the current transition time after the short circuit is finished, the larger the provided arcing capability is, the better the weld formation is, and the larger the penetration is. However, the slow dynamic characteristic can lead to the current increase rate being too slow, so that the splashing is serious and the stability of the electric arc is even damaged. Therefore, the welding power supply 11 must be properly and precisely controlled to meet the requirements of the welding process and ensure the stability of the welding process.
The control modes of the welding power supply 11 include two control modes, a natural response control mode and a current waveform adjustment control mode. Referring to fig. 2, fig. 2 is a schematic diagram of output current of a welding power supply using a natural response control mode according to an embodiment of the present invention, where an abscissa of the schematic diagram represents time and an ordinate of the schematic diagram represents output current, as shown in fig. 2. When the welding power supply is controlled by adopting a natural response control mode, the short circuit and the arcing state do not need to be distinguished, and the process of molten drop transition is only related to voltage setting, voltage feedback and voltage loop parameters. This mode is simple to control, and does not require special judgment about the feedback signals of the voltage and current of the welding power supply 11, reducing the complexity of the system. When the voltage ring parameters are reasonably set, a stable welding process can be realized in a partial current section. In addition, the method has low sensitivity to welding peripheral factors, and even if strong electromagnetic interference exists, the waveform of the current cannot be greatly influenced. However, the droplet transfer process cannot be controlled in a targeted manner, and the sizes of droplets are inconsistent, so that the energy loss of the electric arc and the increase of welding spatter are caused.
Referring to fig. 3, fig. 3 is a schematic diagram of an output current of a welding power supply using a current waveform adjustment control mode according to an embodiment of the present invention, where an abscissa of the schematic diagram represents time and an ordinate represents the output current, as shown in fig. 3. When the welding power supply 11 is controlled by adopting the current waveform adjusting control mode, each stage of molten drop transition needs to be distinguished, the shape of the current waveform is adjusted in different stages, the size of the molten drop is controlled, a better molten drop transition effect and a better molten pool heating effect are achieved, meanwhile, welding spatter is reduced, and the welding penetration is adjusted. The process needs to detect the voltage and current feedback signals of the power supply and then realize the judgment of the short circuit and the arcing stage in the welding process through a specific hardware filtering and judging circuit or a software algorithm.
Generally, the welding power supply 11 is controlled by adopting a current waveform adjustment control mode, the welding process of the full current section is stable, the arc energy is sufficient, and the welding spatter is small. However, the working conditions are complex during actual welding, ideal welding conditions cannot be guaranteed under certain working conditions, and welding feedback signals are influenced by electromagnetic interference factors, such as the curved arrangement of a power supply power wire and a signal sampling wire; the signal line and other strong interference equipment are wired in parallel; strong electromagnetic interference sources exist in the power grid. When the interference signal exceeds the filtering range of the software and the hardware, the judgment of the short circuit and the arcing process is influenced, and the analysis and the judgment of the feedback signal are also influenced, so that the control of the welding power supply 11 is influenced.
Referring to fig. 4, fig. 4 is a schematic diagram of an output current of a welding power supply using a current waveform adjustment control mode according to another embodiment of the present invention, where the abscissa of the schematic diagram represents time and the ordinate represents the output current, as shown in fig. 4. Wherein, the solid line current line represents the ideal situation, the ideal output current line of the welding power supply 11, the dotted line current line represents the interference situation, the actual output current line of the welding power supply 11, it can be seen from the figure that, when actually welding, the welding feedback signal is affected by the interference factor, the identification and judgment of the welding process are also affected, when the number of times of failure judgment in unit time is too many, the actual output current of the welding power supply 11 can not well follow the ideal output current, thereby causing deviation to the welding, and affecting the stability and welding quality of the welding process. Therefore, in the welding process, the welding power supply 11 needs to be controlled by adopting a proper control mode to input wires, so that the welding power supply outputs proper current, and the stability of the welding process is improved.
Referring to fig. 5, fig. 5 is a schematic structural diagram of a welding power supply control circuit according to an embodiment of the present invention, which is applied to a gas metal arc welding system, as shown in fig. 5, the welding power supply control circuit 20 includes a sampling circuit 21, a driving circuit 22, and a controller 23, the sampling circuit 21 is connected to the welding power supply 11 for sampling a feedback signal of the welding power supply 11, the driving circuit 22 is connected to the welding power supply 11 for driving the welding power supply 11, and the controller 23 is respectively connected to the sampling circuit 21 and the driving circuit 22 for controlling a working state of the welding power supply 11 according to the feedback signal of the welding power supply.
In some embodiments, with continued reference to fig. 5, the sampling circuit 21 includes a voltage sampling circuit 211 and a current sampling circuit 212, the voltage sampling circuit 211 and the current sampling circuit 212 are respectively connected to the welding power supply 11 and the controller 23, the voltage sampling circuit 211 is configured to sample an output voltage of the welding power supply 11, and the current sampling circuit 212 is configured to sample an output current of the welding power supply 11.
First, the voltage sampling circuit 211 and the current sampling circuit 212 transmit the sampled output voltage and output current of the welding power source 11 to the controller 23 as feedback signals of the welding power source 11, the controller 23 analyzes and processes the feedback signals of the welding power source 11, the controller 23 identifies the welding state of the welding power source 11 according to the feedback signals, the welding state includes an arcing state and a short-circuit state, and the controller 23 identifies the welding state by various methods, which can be set by a user according to the need, for example, the controller 23 compares the sampled voltage of the welding power source 11 with a first threshold, if the sampled voltage is less than the first threshold, the current welding state is identified as the short-circuit state, if the sampled voltage is greater than the first set value, the current welding state is identified as the arcing state, the user can set an allowable error, and under an error condition, and carrying out corresponding identification judgment. For another example, the controller 23 compares the sampled voltage of the welding power source 11 with a second set value, recognizes the current welding state as a short-circuit state if the rate of change exceeds a negative second set value, and recognizes the current welding state as an arcing state if the rate of change exceeds a positive second set value. Therefore, the controller 23 recognizes the welding state of the welding power source 11 based on the welding feedback signal, and generates a recognition result.
Then, the controller 23 determines a statistical value according to the identification result, where the statistical value is the number of times that the welding state of the welding power supply 11 is identified as failed, specifically, the controller 23 determines whether the identification is failed according to the identification result, where the identification failure means that the identification result is not consistent with the actual welding state, and there are many methods for determining whether the identification is failed, and the user can set the statistical value as needed, for example, if the controller 23 identifies the welding state as a short-circuit state and then immediately identifies the welding state as an arc-burning state, or if the controller 23 identifies the welding state as an arc-burning state and then immediately identifies the welding state as a short-circuit state, then it determines that the identification is failed. After determining that the identification fails, the controller 23 accumulates the current statistical values by a preset value and performs assignment processing to obtain a final statistical value, and if the identification fails next time, the controller 23 accumulates the statistical values by the preset value again to obtain the final statistical value, and so on. The preset value can be set according to the user requirement, and in the embodiment of the invention, the preset value is one.
Finally, the controller 23 determines the value of the statistical value in a certain time, and in the embodiment of the present invention, the controller 23 may determine the value of the statistical value in a unit time. The controller 23 determines the control mode of the welding power supply 11 according to the statistical value and a preset threshold, specifically, the controller 23 determines whether the statistical value is greater than the preset threshold, if so, selects the control mode of the welding power supply 11 as a natural response control mode, and if not, selects the control mode of the welding power supply 11 as a current waveform adjustment control mode. The controller 23 generates a control signal to control the driving circuit 22 to generate a corresponding driving signal to act on the welding power supply 11 according to the control mode of the welding power supply 11, thereby controlling the operating state of the welding power supply 11. When the control mode of the welding power supply 11 is the natural response control mode, the welding power supply 11 is controlled to output a first current according to the set parameter, and when the control mode of the welding power supply 11 is the current waveform adjustment control mode, the welding power supply 11 is controlled to output a second current according to the welding feedback signal of the welding power supply 11 and the set parameter.
Therefore, the welding power supply control circuit counts the short circuit state and the arcing state to judge failure times, determines the control mode of the welding power supply, can switch the control mode of the output current of the welding power supply in time when the welding process is greatly fluctuated due to the interference of electromagnetism and the like, determines the proper control mode, avoids causing welding defects, ensures the stability of the welding process of a full current section, has sufficient arc energy and little welding spatter.
In the various embodiments described above, the controller may be a general purpose processor, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), a single chip, an arm (acorn RISC machine) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination of these components. Also, the controller may be any conventional processor, controller, microcontroller, or state machine. A controller may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
As shown in fig. 6, the controller 30 (internal controller or external controller) includes: at least one processor 31 and a memory 32 communicatively coupled to the at least one processor 31; in fig. 6, one processor 31 is taken as an example. The processor 31 and the memory 32 may be connected by a bus or other means, as exemplified by the bus connection in fig. 6.
Wherein the memory 32 stores instructions executable by the at least one processor 31 to enable the at least one processor 31 to execute the control logic of the welding power supply control described above, the instructions being executable by the at least one processor 3.
Therefore, the controller 30 can determine the control mode of the welding power supply according to the statistical value reflecting the identification failure times of the welding state of the welding power supply and the preset threshold, and when the welding process fluctuates greatly due to interference of electromagnetism and the like, the control mode of the output current of the welding power supply can be switched in time to determine a proper control mode, thereby avoiding welding defects and ensuring the stability of the welding process in the full current section.
As another aspect of the embodiments of the present invention, a welding power supply control apparatus is provided. The welding power supply control device is implemented as a software system that may be stored within the controller 22 as illustrated in fig. 4 and 5. The welding power supply control device comprises a plurality of instructions, wherein the instructions are stored in a memory, and a processor can access the memory and call the instructions to execute so as to complete the control logic for controlling the welding power supply.
As shown in fig. 7, the welding power control apparatus 40 includes a first obtaining module 41 for obtaining a statistical value, where the statistical value is the number of times that the welding state of the welding power is identified to fail; a first determining module 42, configured to determine a control mode of the welding power supply according to the statistical value and a preset threshold; a control module 43 configured to control a working state of the welding power supply according to a control mode of the welding power supply.
Therefore, the controller can determine the control mode of the welding power supply according to the statistical value reflecting the welding state identification failure times of the welding power supply and the preset threshold value, so that the welding power supply is accurately controlled, when the welding process is greatly fluctuated due to interference of electromagnetism and the like, the control mode of the output current of the welding power supply can be timely switched, a proper control mode is determined, welding defects are avoided, and the stability of the welding process of the full current section is ensured.
In some embodiments, with continuing reference to fig. 7, the control mode includes a natural response control mode or a current waveform adjustment control mode, and the first determining module 42 includes a determining unit 421 for determining whether the statistical value is greater than the preset threshold; a first selecting unit 422 for selecting a control mode of the welding power supply to be a natural response control mode; a second selection unit 423 for selecting the control mode of the welding power supply to be a current waveform adjustment control mode.
In some embodiments, with continued reference to fig. 7, the control module 43 includes a first control unit 431 configured to control the welding power supply to output a first current according to a set parameter when the control mode of the welding power supply is a natural response control mode; a second control unit 432, configured to control the welding power supply to output a second current according to a welding feedback signal of the welding power supply and the setting parameter when the control mode of the welding power supply is a current waveform adjustment control mode.
In some embodiments, the welding power supply control device 40 further includes a second obtaining module 44 configured to obtain a welding feedback signal of the welding power supply; the identification module 45 is configured to identify a welding state of the welding power supply according to the feedback signal, and generate an identification result, where the welding state includes an arc state and a short circuit state; a second determining module 46, configured to determine the statistical value according to the identification result.
In some embodiments, the second determining module 46 includes a judging unit 461, configured to judge whether the identification is failed according to the identification result; the accumulation unit 462 is configured to accumulate the current statistics value by a preset value and perform assignment processing to obtain a final statistics value.
For example, the welding power control method may be implemented in an electronic device having a suitable type of processor with computing capabilities, such as a single chip, a Digital Signal Processing (DSP), a Programmable logic Controller (P L C), and so on.
Functions corresponding to the welding power supply control methods of the various embodiments described below are stored in the form of instructions in a memory of the electronic device, and when the functions corresponding to the welding power supply control methods of the various embodiments described below are to be executed, a processor of the electronic device accesses the memory, and invokes and executes the corresponding instructions to implement the functions corresponding to the welding power supply control methods of the various embodiments described below.
The memory, as a non-transitory computer-readable storage medium, may be used to store non-transitory software programs, non-transitory computer-executable programs, and modules, such as program instructions/modules (e.g., the various modules and units described in fig. 7) corresponding to the welding power control apparatus 40 in the above-described embodiments, or steps corresponding to the welding power control method in the below-described embodiments. The processor executes various functional applications and data processing of the welding power supply control device 40 by executing nonvolatile software programs, instructions, and modules stored in the memory, that is, functions of the various modules and units of the welding power supply control device 40 according to the following embodiments, or functions of the steps corresponding to the welding power supply control method according to the following embodiments.
The memory may include high speed random access memory and may also include non-volatile memory, such as at least one magnetic disk storage device, flash memory device, or other non-volatile solid state storage device. In some embodiments, the memory optionally includes memory located remotely from the processor, and such remote memory may be coupled to the processor via a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The program instructions/modules stored in the memory, when executed by the one or more processors, perform the welding power supply control method of any of the method embodiments described above, e.g., perform the various steps shown in fig. 8-11 described in the embodiments below; the functions of the various modules and units described with respect to fig. 7 may also be implemented.
As shown in fig. 8, the welding power control method 50 includes:
and step 53, controlling the working state of the welding power supply according to the control mode of the welding power supply.
By adopting the method, the control mode of the welding power supply can be determined according to the statistical value reflecting the identification failure times of the welding state of the welding power supply and the preset threshold value, the working state of the welding power supply is accurately controlled, when the welding process is greatly fluctuated due to the interference of electromagnetism and the like, the control mode of the output current of the welding power supply can be timely switched, the proper control mode is determined, the welding defect is avoided, and the stability of the welding process of the full current section is ensured.
In some embodiments, as shown in fig. 9, the control mode includes a natural response control mode or a current waveform adjustment control mode, and step 52 includes:
522, if yes, selecting the control mode of the welding power supply as a natural response control mode;
step 523, if not, selecting the control mode of the welding power supply as a current waveform adjustment control mode.
In some embodiments, as shown in fig. 10, the welding power control method 53 includes:
step 531, controlling the welding power supply to output a first current according to a set parameter when the control mode of the welding power supply is a natural response control mode;
and 532, controlling the welding power supply to output a second current according to the welding feedback signal of the welding power supply and the set parameter when the control mode of the welding power supply is a current waveform adjustment control mode.
In some embodiments, as shown in fig. 11, the welding power supply control method 50 further comprises:
step 55, identifying the welding state of the welding power supply according to the feedback signal, and generating an identification result, wherein the welding state comprises an arcing state and a short-circuit state;
and step 56, determining the statistic value according to the identification result.
In some embodiments, as shown in fig. 12, step 56 comprises:
and 562, if yes, accumulating the current statistical values by preset values and performing assignment processing to obtain the final statistical values.
Since the apparatus embodiment and the method embodiment are based on the same concept, the contents of the method embodiment may refer to the apparatus embodiment on the premise that the contents do not conflict with each other, and are not described herein again.
As yet another aspect of an embodiment of the present invention, an embodiment of the present invention provides a non-transitory computer-readable storage medium having stored thereon computer-executable instructions for causing a welding system to perform a welding power supply control method as described in any of the above, for example, to perform a welding power supply control method as described in any of the above method embodiments, for example, to perform a welding power supply control apparatus as described in any of the above apparatus embodiments.
By adopting the method, the control mode of the welding power supply can be determined according to the statistical value reflecting the identification failure times of the welding state of the welding power supply and the preset threshold value, when the welding process is greatly fluctuated due to the interference of electromagnetism and the like, the control mode of the output current of the welding power supply can be timely switched, the proper control mode is determined, the welding defect is avoided, and the stability of the welding process in the full current section is ensured.
It should be noted that the description of the present invention and the accompanying drawings illustrate preferred embodiments of the present invention, but the present invention may be embodied in many different forms and is not limited to the embodiments described in the present specification, which are provided as additional limitations to the present invention and to provide a more thorough understanding of the present disclosure. Moreover, the above technical features are combined with each other to form various embodiments which are not listed above, and all the embodiments are regarded as the scope of the present invention described in the specification; further, modifications and variations will occur to those skilled in the art in light of the foregoing description, and it is intended to cover all such modifications and variations as fall within the true spirit and scope of the invention as defined by the appended claims.
Claims (9)
1. A welding power supply control method is applied to a gas metal arc welding system and is characterized by comprising the following steps:
acquiring a statistical value, wherein the statistical value is the number of times that the welding state of the welding power supply is identified to be invalid;
determining a control mode of the welding power supply according to the statistical value and a preset threshold value;
and controlling the working state of the welding power supply according to the control mode of the welding power supply.
2. The method of claim 1, wherein the control mode comprises a natural response control mode or a current waveform adjustment control mode, and wherein determining the control mode for the welding power supply based on the statistical value and a predetermined threshold comprises:
judging whether the statistic value is larger than the preset threshold value or not;
if so, selecting the control mode of the welding power supply as a natural response control mode;
and if not, selecting the control mode of the welding power supply as a current waveform adjustment control mode.
3. The method of claim 2, wherein the controlling the operating state of the welding power supply according to the control mode of the welding power supply comprises:
when the control mode of the welding power supply is a natural response control mode, controlling the welding power supply to output a first current according to set parameters;
and when the control mode of the welding power supply is a current waveform adjustment control mode, controlling the welding power supply to output a second current according to a welding feedback signal of the welding power supply and the set parameter.
4. The method according to any one of claims 1-3, further comprising:
acquiring a welding feedback signal of the welding power supply;
identifying the welding state of the welding power supply according to the welding feedback signal to generate an identification result, wherein the welding state comprises an arcing state and a short circuit state;
and determining the statistical value according to the identification result.
5. The method of claim 4, wherein said determining said statistical value according to said identification result comprises:
judging whether the identification is invalid or not according to the identification result;
if yes, accumulating the current statistical values by preset values and performing assignment processing to obtain the final statistical values.
6. A controller, comprising:
at least one processor; and
a memory communicatively coupled to the at least one processor; wherein the memory stores instructions executable by the at least one processor to enable the at least one processor to perform the welding power supply control method of any of claims 1 to 5.
7. A welding power supply control circuit for use in a gas metal arc welding system, the welding power supply control circuit comprising:
the sampling circuit is connected with the welding power supply and is used for sampling the welding power supply feedback signal;
a drive circuit connected to the welding power supply for driving the welding power supply;
the controller of claim 6, wherein the controller is coupled to the sampling circuit and the driving circuit, respectively, for controlling the operating state of the welding power supply according to the welding power supply feedback signal.
8. The welding power supply control circuit of claim 7, wherein the sampling circuit comprises a voltage sampling circuit and a current sampling circuit, the voltage sampling circuit and the current sampling circuit both coupled to the welding power supply and the controller, respectively, the voltage sampling circuit configured to sample an output voltage of the welding power supply, and the current sampling circuit configured to sample an output current of the welding power supply.
9. A welding system, comprising:
a welding power supply for providing energy to an arc load; and
the welding power supply control circuitry of any of claims 7 to 8, coupled to the welding power supply, to control an operating state of the welding power supply.
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