CN111805058A - Special welding machine system for arc method metal rapid forming and control method thereof - Google Patents
Special welding machine system for arc method metal rapid forming and control method thereof Download PDFInfo
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- CN111805058A CN111805058A CN202010369636.9A CN202010369636A CN111805058A CN 111805058 A CN111805058 A CN 111805058A CN 202010369636 A CN202010369636 A CN 202010369636A CN 111805058 A CN111805058 A CN 111805058A
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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
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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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
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
- B23K9/067—Starting the arc
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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
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Arc Welding In General (AREA)
Abstract
The invention relates to a special welding machine system for metal rapid forming by an arc method and a control method thereof. The system comprises a controller, a frame, an arc power supply, a wire feeding assembly and a voltage comparison device; a metal wire is arranged in the wire feeding assembly; a three-dimensional movement device is arranged on the rack, a welding gun head and a welding bottom plate which are connected with the wire feeding assembly are respectively arranged on the three-dimensional movement device, and a metal wire penetrates into the welding gun head; the welding gun head and the welding bottom plate are respectively and electrically connected with an arc power supply; the voltage comparison device is provided with a first voltage detection end, a second voltage detection end and a time delay switch, the first voltage detection end is electrically connected with the welding gun head, the second voltage detection end is electrically connected with the welding bottom plate, and the time delay switch is connected in series in a connecting circuit of the welding gun head and the arc power supply or in a connecting circuit of the welding bottom plate and the arc power supply. The control method adopts the system. The invention controls the instantaneous short-circuit time through the voltage comparison device to reduce the heat accumulation and avoid the problem of generating thermal stress.
Description
Technical Field
The invention relates to a special welding machine system for metal rapid forming by an arc method and a control method thereof, belonging to the technical field of metal rapid printing and forming.
Background
According to the knowledge of the applicant, the metal rapid printing and forming technology is a digital manufacturing technology which adopts high-energy beams as heat sources and realizes the dieless forming of components through material layer by layer accumulation. The principle of the metal part rapid printing and forming technology is that metal powder or wire materials are synchronously melted and accumulated according to a path set by software under heating conditions of electric arc, laser or electron beam and the like, and finally a designed part entity is formed.
The proportion of the application quantity of the manufacturing industry in the world to large-scale complex key structural parts is an important technical index for measuring the advancement of important equipment such as military, aviation, aerospace and medical treatment. The traditional processing mode of large-scale complicated key structure spare is mainly forging, casting, welding etc. and it is mostly "subtract material manufacturing" mode, has that the process time is long, and processing technology is complicated, and processing equipment is expensive and to a great deal of shortcomings such as processing operating personnel individual technical requirement height.
In order to solve the problem that the traditional processing mode is difficult to prepare large-scale complex key structural parts, the metal rapid printing and forming technology is an advanced and feasible technical approach. The currently common metal rapid printing and forming method mainly comprises selective laser cladding (SLM), Selective Laser Sintering (SLS), selective Electron Beam Melting (EBM) and the like.
The heat source equipment is a core component of the metal rapid printing and forming equipment, and the advancement of the heat source equipment directly determines the advancement of the metal rapid printing and forming equipment. At present, the high-end heat source of the metal rapid printing and forming equipment in China mainly adopts imported high-power lasers, plasma generators or electron beam generators, the equipment is expensive and difficult to maintain, the core technology of the equipment is foreign, the access for obtaining the high-end heat source equipment in China is difficult, and meanwhile, the equipment has high requirements on printing materials and technicians, so that the price of the whole forming equipment is directly overhigh, and the corresponding use cost is overhigh. The method is difficult to popularize and apply, can only be used in some special fields, such as military industry, aerospace industry and the like, greatly influences the application of the method in the metal part forming industry, and improves the efficiency of actual production and life.
However, even the heat sources of these expensive forming equipments have the disadvantages of too short service life, too small printing range, difficult maintenance, etc., and the complex structural members printed and formed by the equipment also have the defects of low density, insufficient dimensional and surface precision, poor mechanical and processing properties, anisotropic performance, etc.
The arc method metal rapid prototyping is a 3D printing technology based on an arc welding process, and uses a special welding machine system as a heat source. Compared with the high-end heat sources such as the high-power laser, the plasma generator or the electron beam generator, the high-end heat source has the remarkable advantages of low price, high forming speed, wide material source, low requirement on personnel and places and the like. The application of the electric arc method metal rapid forming technology not only greatly reduces the manufacturing cost of the electric arc method metal rapid forming equipment, but also greatly reduces the use cost. With the increasing application of large-scale complex key structural components in the aviation industry, the electric arc method metal rapid forming technology has a huge potential market due to the unique advantages of the electric arc method metal rapid forming technology in the processing of the large-scale complex key structural components. Research shows that compared with the traditional manufacturing process, the welding rapid forming technology can effectively reduce the manufacturing cost of the complex titanium alloy part by about 62.5 percent, the material utilization rate reaches more than 80 percent, and the supply period can be greatly reduced. The electric arc method metal rapid forming technology has very wide prospect in the metal forming industry.
At present, the domestic electric arc method metal rapid forming welding machine also has some problems, wherein the most fatal is the heat control problem, when a structural part is printed to a certain height, the compression deformation of parts is often caused by thermal stress, the formed structural part is seriously and directly scrapped, and even the successfully printed structural part also has the defects of overhigh hardness, large processing difficulty and the like. Meanwhile, too high arcing time can cause pollution such as noise, strong light and the like.
The generation of the thermal stress is mainly because the metal melting needs very large energy, and most of the energy is finally converted into heat energy, the heat energy not only melts the metal material to form a molten pool, but also increases the temperature of the whole structural member matrix to cause the size of the metal molten pool to be continuously increased, when the molten pool is not cooled and solidified, the metal molten pool collapses, and high-temperature metal liquid in the molten pool flows out of the molten pool, so two problems are caused, firstly, the size precision exceeds the expected range, and the interference phenomenon can occur when the next layer is printed; the other point is that the position is lower than the expected position, when the next layer is printed, the molten pool is broken without lower support, the metal liquid flows out of the molten pool more, or the negative pole is formed without contacting with the bottom plate, the non-arcing phenomenon is generated, and the printing failure is directly caused. In summary, how to solve the problem of thermal stress is a core problem in the whole electric arc method metal rapid prototyping technology.
The invention patents of application No. CN201911287290.1 and application publication No. CN110899482A disclose a thermoplastic alloy 3D printing system based on Joule heat, the wire feeding device and the hot roller are relatively fixed, the wire feeding port of the wire feeding device is positioned at one side of the hot roller, the hot roller and the molding substrate are respectively connected with the cathode and the anode of a Joule heat power supply, the wire feeding device and the molding substrate can move relatively, the wire feeding device is used for conveying printed wires to the molding substrate, then the wires to be printed are pressed onto the molding substrate through the hot roller, the hot roller and the molding substrate form a loop, and the conductive wires soften materials instantly at the contact end of the hot roller and the substrate; the forming substrate is fixed on the moving platform, the upper end of the moving platform is provided with a radiator, the upper end of the radiator is fixed with a heating plate through a radiating bracket, and the forming substrate is fixed on the heating plate; the heating plate is connected with a heating power supply, can realize the control by temperature of the formed substrate, enables the printing area to realize a constant temperature environment, and tries to solve the problems of cracking, warping, deformation and the like caused by thermal stress due to overlarge temperature gradient in the 3D printing process of metal. However, the temperature control means of the forming substrate adopted in the technical solution is actually difficult to solve the aforementioned thermal stress problem, and the means can eliminate a certain thermal stress at most on a unidirectional printing line segment, while for 3D printing, the printing direction cannot be only one direction, the 3D printing plane is a complex plane figure, and obviously the means cannot eliminate the thermal stress in all directions in the plane; furthermore, this approach is practically difficult to solve for thermal stress problems at bridge spans, bridges, etc., due to the lack of underlying support.
Disclosure of Invention
The invention aims to: aiming at the problems in the prior art, the special welding machine system for the rapid metal forming by the arc method is provided, the problem of thermal stress in the rapid metal forming technology by the arc method can be solved, and the special welding machine system is ingenious in structural design, low in use and maintenance cost and wide in material adaptability. Meanwhile, a corresponding control method is also provided.
The technical scheme for solving the technical problems of the invention is as follows:
a special welder system for arc method metal rapid prototyping comprises a controller and a frame; the device is characterized by also comprising an electric arc power supply, a wire feeding component and a voltage comparison device; a metal wire is arranged in the wire feeding assembly, and the controlled end of the wire feeding assembly is connected with the control end of the controller; the rack is provided with a three-dimensional motion device, and the controlled end of the three-dimensional motion device is connected with the control end of the controller; the three-dimensional movement device is respectively provided with a welding gun head and a welding bottom plate which are connected with the wire feeding assembly, and the metal wire penetrates into the welding gun head; the welding gun head and the welding bottom plate are respectively and electrically connected with an arc power supply; the voltage comparison device is provided with a first voltage detection end, a second voltage detection end and a time delay switch, the first voltage detection end is electrically connected with the welding gun head, the second voltage detection end is electrically connected with the welding baseplate, and the time delay switch is connected in series in a connecting circuit of the welding gun head and the arc power supply or in a connecting circuit of the welding baseplate and the arc power supply.
When the system is operated, on one hand, the three-dimensional motion device drives the welding gun head and the welding bottom plate to perform motion actions under the control of the controller, and the wire feeding assembly conveys metal wires; on the other hand, the voltage comparison device monitors the real-time voltage of the welding gun head (and the metal wire material output by the welding gun head) and the welding bottom plate in real time, and operates to disconnect the arc power supply when the real-time voltage is smaller than a preset voltage threshold value, and then operates to connect the arc power supply. Therefore, the control on the instantaneous short circuit time can be realized, the metal rapid forming can be smoothly completed by an electric arc method, and the thermal stress concentration caused by excessive heat can be avoided, so that the thermal stress problem in the electric arc method metal rapid forming technology is effectively solved.
The technical scheme of the invention is further perfected as follows:
preferably, the voltage comparing device comprises a voltage threshold setter, an AD converting circuit, a gate comparator, and an operational amplifier; the delay switch is a delay relay; the first voltage detection end and the second voltage detection end are respectively connected with an AD conversion circuit, and the AD conversion circuit, the gate circuit comparator, the operational amplifier and the delay switch are sequentially and electrically connected; the voltage threshold setting device is electrically connected with the gate circuit comparator.
By adopting the preferred scheme, the specific structure of the voltage comparison device can be further optimized, wherein the voltage threshold setting device can set a preset voltage threshold, the time delay relay can set the timing time, the AD conversion circuit converts the real-time voltage measured by the first voltage detection end and the second voltage detection end into a digital signal and sends the digital signal to the gate circuit comparator, the gate circuit comparator compares the real-time voltage with the preset voltage threshold, and when the real-time voltage is smaller than the preset voltage threshold, the operational amplifier sends a signal to the time delay relay; the delay relay starts timing and disconnects the arc power supply at the end of timing, but starts timing again and connects the arc power supply at the end of timing.
Preferably, the rack comprises a horizontally arranged base and a longitudinally arranged mounting plate, wherein the base is perpendicular to the mounting plate and fixedly connected with the mounting plate.
By adopting the optimal scheme, the specific structure of the rack can be further optimized, and a foundation is laid for the installation and layout of other components.
Preferably, the three-dimensional motion device is composed of an X-axis motion assembly, a Y-axis motion assembly and a Z-axis motion assembly; the base of the rack is provided with a groove extending along the Y axis, the mounting plate of the rack is provided with a slot, the slot is positioned above the groove, and two slot walls of the slot are positioned at two sides of the groove;
the Y-axis motion assembly is arranged in a groove of the base, and the welding bottom plate is arranged on the Y-axis motion assembly; the Z-axis movement assembly is arranged on two sides of the groove of the mounting plate, the X-axis movement assembly is arranged on the Z-axis movement assembly, the welding gun head is arranged on the X-axis movement assembly, and the welding gun head is positioned above the welding bottom plate;
the controlled end of the three-dimensional motion device is composed of a controlled end of an X-axis motion assembly, a controlled end of a Y-axis motion assembly and a controlled end of a Z-axis motion assembly, and the controlled end of the X-axis motion assembly, the controlled end of the Y-axis motion assembly and the controlled end of the Z-axis motion assembly are respectively connected with the control end of the controller.
By adopting the preferable scheme, the specific structure of the three-dimensional motion device can be further optimized. The welding gun head can horizontally move along the X axis and/or vertically move along the Z axis under the drive of the X axis movement assembly and the Z axis movement assembly; the welding bottom plate can horizontally move along the Y axis under the driving of the Y axis moving component.
More preferably, the Y-axis motion assembly comprises a Y-axis driving motor, a coupler, a Y-axis lead screw, a horizontal slide, and a pair of Y-axis rails; the Y-axis driving motor and the Y-axis track are respectively and fixedly connected with the base; the Y-axis tracks are positioned on two sides of the Y-axis driving motor; an output shaft of the Y-axis driving motor is in transmission connection with a Y-axis screw rod through a coupler, and two ends of the Y-axis screw rod are supported on the base through bearing seats respectively and form a revolute pair; the horizontal sliding seat and each Y-axis rail respectively form a sliding pair, the bottom of the horizontal sliding seat is in threaded connection with a Y-axis screw rod, and the horizontal sliding seat and each Y-axis rail form a threaded moving pair; the welding bottom plate is fixedly connected with the top surface of the horizontal sliding seat; the controlled end of the Y-axis motion assembly is the controlled end of a Y-axis drive motor;
the Z-axis motion assembly comprises a pair of Z-axis driving motors, a pair of couplers, a pair of Z-axis lead screws, a pair of Z-axis rails and a vertical sliding seat; the Z-axis driving motor, the shaft couplers and the Z-axis screw rods are in one-to-one correspondence; the Z-axis driving motor and the Z-axis track are respectively and fixedly connected with the mounting plate; the Z-axis driving motor, the coupling, the Z-axis lead screw and the Z-axis track are respectively positioned at two sides of the slot; the output shaft of the Z-axis driving motor is in transmission connection with a corresponding Z-axis screw rod through a corresponding coupler, and two ends of the Z-axis screw rod are respectively supported on the mounting plate through bearing seats to form a revolute pair; the vertical sliding seat and each Z-axis track respectively form a sliding pair, and the bottom of the vertical sliding seat is in threaded connection with each Z-axis screw rod and forms a threaded moving pair; the X-axis motion assembly is arranged on the vertical sliding seat; the controlled end of the Z-axis motion assembly is the controlled end of a pair of Z-axis drive motors;
the X-axis motion assembly comprises an X-axis drive motor, a coupler, an X-axis lead screw, a transverse sliding seat and a pair of X-axis rails; the X-axis driving motor and the X-axis track are respectively and fixedly connected with the vertical sliding seat; the X-axis track is positioned on two sides of the X-axis driving motor; an output shaft of the X-axis driving motor is in transmission connection with an X-axis lead screw through a coupler, and two ends of the X-axis lead screw are supported on the vertical sliding seat through bearing seats respectively to form a revolute pair; the transverse sliding seat and each X-axis track respectively form a sliding pair, the bottom of the transverse sliding seat is in threaded connection with the X-axis screw rod, and the transverse sliding seat and the X-axis screw rod form a threaded moving pair; the welding gun head is fixedly connected with the transverse sliding seat; the controlled end of the X-axis motion assembly is the controlled end of an X-axis drive motor.
By adopting the preferable scheme, the specific structures of the X-axis motion assembly, the Y-axis motion assembly and the Z-axis motion assembly can be further optimized.
Preferably, the wire feed assembly comprises a wire spool transition and a wire feeder; the wire disc transition device is supported at the top of the rack mounting plate; the wire feeder is arranged on the three-dimensional movement device and is positioned above the welding gun head; the metal wire penetrates into the welding gun head through the wire disc transition device and the wire feeder in sequence; the controlled end of the wire feeding assembly is the controlled end of the wire feeder.
By adopting the preferred scheme, the specific structure of the wire feeding assembly can be further optimized.
Preferably, the arc power supply is a direct current arc power supply with an IGBT, and the maximum withstand direct current voltage of the arc power supply is more than 600V; the anode of the arc power supply is electrically connected with the welding gun head, and the cathode of the arc power supply is electrically connected with the welding bottom plate; the welding gun head and the welding bottom plate are made of metal materials respectively.
With this preferred solution, the specific details of the arc power supply can be further optimized. The direct-current arc power supply has a high-performance Insulated Gate Bipolar Transistor (IGBT), is very suitable for being applied to a current transformation system with direct-current voltage of 600V or above, and has the advantages of high input impedance, low conduction voltage drop, low saturation voltage reduction, high current-carrying density, low driving power, high switching speed and the like.
Preferably, the system further comprises a power supply, wherein the power supply is a generator, a mains supply, industrial electricity or an electric storage battery; the power supply is electrically connected with the controller, the arc power supply, the wire feeding assembly, the voltage comparison device and the three-dimensional movement device through cables.
With this preferred approach, other specific details of the system can be further optimized.
The invention also proposes:
a control method of a welding machine system is characterized in that the special welding machine system for the electric arc method metal rapid forming is adopted; the control method comprises the following steps:
firstly, starting a welding machine system; one side of the electric arc power supply is electrified to the metal wire through the welding gun head, and the other side of the electric arc power supply is electrified to the welding bottom plate; the voltage comparison device monitors real-time voltage between the metal wire and the welding bottom plate through a first voltage detection end and a second voltage detection end of the voltage comparison device;
secondly, the controller controls the three-dimensional motion device to execute motion actions according to the input motion control instruction, and controls the wire feeding assembly to execute wire feeding actions according to the input wire feeding control instruction;
thirdly, the metal wire continuously moves downwards from the welding gun head and extends to the welding bottom plate; when the metal wire is about to contact the welding baseplate, the voltage applied to the metal wire and the welding baseplate breaks down the air and generates an electric arc which heats and melts the end of the metal wire to form a metal droplet; when the voltage breaks through air and generates an electric arc, the voltage comparison device monitors that the real-time voltage continuously drops, and when the real-time voltage is smaller than a preset voltage threshold value, the voltage comparison device executes a first time delay action, and the time is reserved so that the electric arc continuously heats the end part of the metal wire to enable metal liquid drops to be increased and dropped to a welding bottom plate and form a molten pool; when the first time delay action is finished, the time delay switch of the voltage comparison device disconnects the arc power supply, and the voltage comparison device executes a second time delay action to reserve time for separating the metal wire from the molten pool; when the second time delay action is finished, the time delay switch of the voltage comparison device is connected with an electric arc power supply, so that the electric arc power supply is electrified to the metal wire through the welding gun head while being electrified to the welding bottom plate;
the first time delay action and the second time delay action are respectively that a time delay switch of the voltage comparison device starts to time and finishes timing when the timing time reaches a preset value;
and fourthly, turning to the second step, continuing the metal printing process until the final printing and forming are finished, and ending the control method.
In the control method, when the metal wire is about to contact with the welding bottom plate, the voltage breaks through air and generates an electric arc, the electric arc voltage can be rapidly reduced due to short circuit, the current can be rapidly increased, the end part of the metal wire is melted under the heating of the high-temperature electric arc to form metal liquid drops, and the metal liquid drops are dropped to the welding bottom plate and form a molten pool. The inventor finds that a channel is formed between a metal wire and a welding bottom plate by a liquid metal molten pool, and the temperature of the current printing part can be increased by heat generated by short-circuit current, which is an important reason for generating the problem of thermal stress concentration; a voltage comparison device is added, at the moment of generating a short circuit phenomenon, a real-time voltage is monitored to be reduced to be lower than a threshold value, then a time delay action is executed, then an electric arc power supply is disconnected, the formation of a short circuit channel is inhibited, and the problem that a large amount of useless short circuit current generates high heat energy can be solved, so that the problem of thermal stress in the electric arc method metal rapid forming technology is effectively solved.
The technical scheme of the invention is further perfected as follows:
preferably, the controller is in communication connection with an external computer;
the second step further comprises: and the external computer models the printed target, slices the model in layers, obtains a motion control instruction and a wire feeding control instruction according to slice data, and inputs the motion control instruction and the wire feeding control instruction into the controller.
With this preferred embodiment, the specific details of the second step can be further optimized.
Compared with the prior art, the invention monitors the real-time voltage through the voltage comparison device and compares the real-time voltage with the set voltage threshold value to control the on-off of the current between the arc power supply and the metal wire/welding bottom plate, thereby controlling the instantaneous short-circuit time, reducing the heat accumulation of a molten pool and a structural member during printing and avoiding the problem of generating thermal stress; the control on the heat stress aggregation can reduce the mechanical hardness of the printed complex structural part and improve the plasticity of the structural part, thereby improving the processability of the structural part; the control of the instantaneous short circuit time can reduce the welding noise and strong light pollution generated during arc striking; in addition, compared with heat sources such as laser, plasma and electron beams, the cost is lower, the forming efficiency of the wire is higher than that of a powder laying mode, and meanwhile, the material is saved.
Drawings
Fig. 1 is a schematic view of the overall structure of a system according to embodiment 1 of the present invention.
Fig. 2 is a schematic circuit diagram of a system according to embodiment 1 of the present invention.
Fig. 3 is a circuit configuration diagram of a voltage comparison device according to embodiment 1 of the present invention.
Fig. 4 is a schematic view of a rack structure in embodiment 1 of the present invention.
Fig. 5 is a schematic view of a Y-axis moving component of embodiment 1 of the present invention.
Fig. 6 is a schematic view of an X-axis and Z-axis movement assembly according to embodiment 1 of the present invention.
Fig. 7 is a schematic main flow chart of embodiment 2 of the present invention.
Fig. 8 is a schematic process diagram of the third step in embodiment 2 of the present invention.
Detailed Description
The invention is described in further detail below with reference to embodiments and with reference to the drawings. The invention is not limited to the examples given.
Example 1
As shown in fig. 1 and fig. 2, the special welder system for arc metal rapid prototyping of the present embodiment includes a controller and a rack 01, wherein the controller is connected to an external computer in a communication manner; the device also comprises an arc power supply 02, a wire feeding assembly 03 and a voltage comparison device 04; a metal wire material 05 is arranged in the wire feeding component 03, and the controlled end of the wire feeding component 03 is connected with the control end of the controller; the rack 01 is provided with a three-dimensional motion device 06, and the controlled end of the three-dimensional motion device 06 is connected with the control end of the controller; the three-dimensional motion device 06 is respectively provided with a welding gun head 07 connected with the wire feeding assembly 03 and a welding bottom plate 08, and a metal wire 05 penetrates through the welding gun head 07; the welding gun head 07 and the welding bottom plate 08 are respectively and electrically connected with an arc power supply 02; the voltage comparison device 04 is provided with a first voltage detection end a, a second voltage detection end B and a delay switch, wherein the first voltage detection end a is electrically connected with the welding gun head 07, the second voltage detection end B is electrically connected with the welding baseplate 08, and the delay switch is connected in series in a connecting circuit of the welding gun head 07 and the arc power supply 02 (or in a connecting circuit of the welding baseplate 08 and the arc power supply 02).
Specifically, as shown in fig. 3, the voltage comparing device 04 includes a voltage threshold setter, an AD conversion circuit, a gate comparator, and an operational amplifier; the delay switch is a delay relay; the first voltage detection end A and the second voltage detection end B are respectively connected with an AD conversion circuit, and the AD conversion circuit, the gate circuit comparator, the operational amplifier and the delay switch are sequentially and electrically connected; the voltage threshold setter is electrically connected to the gate comparator.
As shown in fig. 4, the rack 01 includes a horizontally disposed base 09 and a longitudinally disposed mounting plate 10, wherein the base 09 is perpendicular to the mounting plate 10 and the two are fixedly connected.
Specifically, the three-dimensional motion device 06 is composed of an X-axis motion component, a Y-axis motion component, and a Z-axis motion component; the base 09 of the rack 01 is provided with a groove 11 extending along the Y axis, the mounting plate 10 of the rack 01 is provided with a slot 12, the slot 12 is located above the groove 11, and two slot walls of the slot 12 are located at two sides of the groove 11.
The Y-axis motion assembly is arranged in a groove 11 of the base 09, and the welding bottom plate 08 is arranged on the Y-axis motion assembly; the Z-axis movement assembly is arranged on two sides of the groove 12 of the mounting plate 10, the X-axis movement assembly is arranged on the Z-axis movement assembly, the welding gun head 07 is arranged on the X-axis movement assembly, and the welding gun head 07 is located above the welding bottom plate 08.
The controlled end of the three-dimensional motion device 06 is composed of a controlled end of an X-axis motion component, a controlled end of a Y-axis motion component and a controlled end of a Z-axis motion component, and the controlled end of the X-axis motion component, the controlled end of the Y-axis motion component and the controlled end of the Z-axis motion component are respectively connected with the control end of the controller.
Specifically, as shown in fig. 5, the Y-axis motion assembly includes a Y-axis drive motor 13, a coupling, a Y-axis lead screw 14, a horizontal slide 15, and a pair of Y-axis rails 16; the Y-axis driving motor 13 and the Y-axis track 16 are respectively and fixedly connected with the base 09; the Y-axis tracks 16 are positioned on both sides of the Y-axis drive motor 13; an output shaft of the Y-axis driving motor 13 is in transmission connection with a Y-axis screw rod 14 through a coupler, and two ends of the Y-axis screw rod 14 are respectively supported on the base 09 through bearing seats and form a revolute pair; the horizontal sliding seat 15 and each Y-axis rail 16 respectively form a sliding pair, the bottom of the horizontal sliding seat 15 is in threaded connection with the Y-axis screw rod 14, and the horizontal sliding seat and the Y-axis screw rod form a threaded moving pair (not shown); the welding bottom plate 08 is fixedly connected with the top surface of the horizontal sliding seat 15; the controlled end of the Y-axis motion assembly is the controlled end of the Y-axis drive motor 13.
As shown in fig. 6, the Z-axis motion assembly includes a pair of Z-axis driving motors 17, a pair of couplings, a pair of Z-axis lead screws 18, a pair of Z-axis rails 19, and a vertical sliding seat 20; the Z-axis driving motor 17, the shaft couplers and the Z-axis screw rods 18 are in one-to-one correspondence; the Z-axis driving motor 17 and the Z-axis track 19 are respectively fixedly connected with the mounting plate 10; the Z-axis driving motor 17, the shaft coupling, the Z-axis screw rod 18 and the Z-axis track 19 are respectively positioned at two sides of the slot 12; an output shaft of the Z-axis driving motor 17 is in transmission connection with a corresponding Z-axis screw rod 18 through a corresponding coupler, and two ends of the Z-axis screw rod 18 are respectively supported on the mounting plate 10 through bearing seats to form a revolute pair; the vertical sliding seat 20 and each Z-axis track 19 respectively form a sliding pair, and the bottom of the vertical sliding seat 20 is in threaded connection with each Z-axis screw rod 18 to form a threaded moving pair; the X-axis motion assembly is arranged on the vertical sliding seat 20; the controlled end of the Z-axis motion assembly is the controlled end of a pair of Z-axis drive motors 17.
The X-axis movement assembly comprises an X-axis driving motor 21, a coupler, an X-axis screw rod 22, a transverse sliding seat 23 and a pair of X-axis rails 24; the X-axis driving motor 21 and the X-axis track 24 are respectively and fixedly connected with the vertical sliding seat 20; the X-axis rails 24 are located on both sides of the X-axis drive motor 21; an output shaft of the X-axis driving motor 21 is in transmission connection with an X-axis lead screw 22 through a coupler, and two ends of the X-axis lead screw 22 are supported on the vertical sliding seat 20 through bearing seats respectively to form a revolute pair; the transverse sliding seat 23 and each X-axis track 24 respectively form a sliding pair, the bottom of the transverse sliding seat 23 is in threaded connection with the X-axis screw rod 22, and the transverse sliding seat and the X-axis screw rod form a threaded moving pair; the welding gun head 07 is fixedly connected with the transverse sliding seat 23; the controlled end of the X-axis motion assembly is the controlled end of the X-axis drive motor 21.
Specifically, as shown in fig. 4, the wire feed assembly 03 includes a wire spool transition 25 and a wire feeder 26; the wire reel transition device 25 is supported on the top of the rack mounting plate 10; the wire feeder 26 is arranged on the three-dimensional movement device 06 and is positioned above the welding gun head 07; the metal wire 05 penetrates into the welding gun head 07 through a wire disc transition device 25 and a wire feeder 26 in sequence; the controlled end of the wire feed assembly 03 is the controlled end of the wire feeder 26.
The arc power supply 02 is a direct-current arc power supply with an IGBT, and the maximum bearing direct-current voltage of the arc power supply 02 is more than 600V; the anode of the arc power supply 02 is electrically connected with the welding gun head 07, and the cathode is electrically connected with the welding baseplate 08; the welding gun head 07 and the welding bottom plate 08 are made of metal materials respectively.
In addition, the system of the embodiment also comprises a power supply, wherein the power supply is a generator, a commercial power, an industrial power or an electric storage battery; the power supply is electrically connected with the controller, the arc power supply 02, the wire feeding assembly 03, the voltage comparison device 04 and the three-dimensional movement device 06 through cables.
Example 2
The control method of the welding machine system of the embodiment adopts the special welding machine system for the electric arc method metal rapid forming of the embodiment 1; as shown in fig. 7, the control method of the present embodiment includes:
firstly, starting a welding machine system; the arc power supply 02 energizes the metal wire 05 through the torch head 07 and energizes the welding baseplate 08 at the same time; the voltage comparison device 04 monitors real-time voltage between the metal wire 05 and the welding baseplate 08 through a first voltage detection end A and a second voltage detection end B of the voltage comparison device;
secondly, modeling the printed target by an external computer, slicing the model in a layering manner, obtaining a motion control instruction and a wire feeding control instruction according to slicing data, and inputting the motion control instruction and the wire feeding control instruction into a controller; the controller controls the three-dimensional motion device 06 to execute motion action according to the input motion control instruction, and controls the wire feeding component 03 to execute wire feeding action according to the input wire feeding control instruction;
thirdly, as shown in fig. 8, the metal wire 05 continuously moves downwards from the welding gun head 07 and extends to the welding baseplate 08; when the metal wire 05 is about to contact the weld shoe 08, the voltage applied to the metal wire 05 and the weld shoe 08 breaks down the air and creates an arc that heats and melts the end of the metal wire 05 to form a metal droplet; when the voltage breaks through air and generates an electric arc, the voltage comparison device 04 monitors that the real-time voltage continuously drops, and when the real-time voltage is smaller than a preset voltage threshold, the voltage comparison device 04 executes a first time delay action, and the electric arc is left for continuing heating the end part of the metal wire 05, so that metal liquid drops are increased and dropped to the welding bottom plate 08 to form a molten pool; when the first delay action is finished, the delay switch of the voltage comparison device 04 disconnects the arc power supply 02, and the voltage comparison device 04 executes a second delay action, so that time is reserved for enabling the metal wire material 05 to be separated from the molten pool; when the second delay action is finished, a delay switch of the voltage comparison device 04 is connected with the arc power supply 02, so that the arc power supply energizes the metal wire material 05 through the welding gun head 07 and energizes the welding baseplate 08 at the same time;
the first delay action and the second delay action are respectively that the delay switch of the voltage comparison device 04 starts timing and finishes timing when the timing time reaches a preset value;
and fourthly, turning to the second step, continuing the metal printing process until the final printing and forming are finished, and ending the control method.
In addition to the above embodiments, the present invention may have other embodiments. All technical solutions formed by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the claims of the present invention.
Claims (10)
1. A special welder system for arc method metal rapid prototyping comprises a controller and a frame; the device is characterized by also comprising an electric arc power supply, a wire feeding component and a voltage comparison device; a metal wire is arranged in the wire feeding assembly, and the controlled end of the wire feeding assembly is connected with the control end of the controller; the rack is provided with a three-dimensional motion device, and the controlled end of the three-dimensional motion device is connected with the control end of the controller; the three-dimensional movement device is respectively provided with a welding gun head and a welding bottom plate which are connected with the wire feeding assembly, and the metal wire penetrates into the welding gun head; the welding gun head and the welding bottom plate are respectively and electrically connected with an arc power supply; the voltage comparison device is provided with a first voltage detection end, a second voltage detection end and a time delay switch, the first voltage detection end is electrically connected with the welding gun head, the second voltage detection end is electrically connected with the welding baseplate, and the time delay switch is connected in series in a connecting circuit of the welding gun head and the arc power supply or in a connecting circuit of the welding baseplate and the arc power supply.
2. The special welder system for metal rapid prototyping by the electric arc method as set forth in claim 1, wherein said voltage comparing device comprises a voltage threshold setting device, an AD converting circuit, a gate comparator, an operational amplifier; the delay switch is a delay relay; the first voltage detection end and the second voltage detection end are respectively connected with an AD conversion circuit, and the AD conversion circuit, the gate circuit comparator, the operational amplifier and the delay switch are sequentially and electrically connected; the voltage threshold setting device is electrically connected with the gate circuit comparator.
3. The special welder system for metal rapid prototyping by the arc process as set forth in claim 2, wherein said frame comprises a horizontally disposed base and a longitudinally disposed mounting plate, said base being perpendicular to and fixedly connected to said mounting plate.
4. The special welder system for metal rapid prototyping by the electric arc method as set forth in claim 3, wherein said three-dimensional moving device is composed of an X-axis moving component, a Y-axis moving component, and a Z-axis moving component; the base of the rack is provided with a groove extending along the Y axis, the mounting plate of the rack is provided with a slot, the slot is positioned above the groove, and two slot walls of the slot are positioned at two sides of the groove;
the Y-axis motion assembly is arranged in a groove of the base, and the welding bottom plate is arranged on the Y-axis motion assembly; the Z-axis movement assembly is arranged on two sides of the groove of the mounting plate, the X-axis movement assembly is arranged on the Z-axis movement assembly, the welding gun head is arranged on the X-axis movement assembly, and the welding gun head is positioned above the welding bottom plate;
the controlled end of the three-dimensional motion device is composed of a controlled end of an X-axis motion assembly, a controlled end of a Y-axis motion assembly and a controlled end of a Z-axis motion assembly, and the controlled end of the X-axis motion assembly, the controlled end of the Y-axis motion assembly and the controlled end of the Z-axis motion assembly are respectively connected with the control end of the controller.
5. The special welder system for metal rapid prototyping by the arc process of claim 4 wherein said Y-axis motion assembly comprises a Y-axis drive motor, a coupler, a Y-axis lead screw, a horizontal slide, and a pair of Y-axis rails; the Y-axis driving motor and the Y-axis track are respectively and fixedly connected with the base; the Y-axis tracks are positioned on two sides of the Y-axis driving motor; an output shaft of the Y-axis driving motor is in transmission connection with a Y-axis screw rod through a coupler, and two ends of the Y-axis screw rod are supported on the base through bearing seats respectively and form a revolute pair; the horizontal sliding seat and each Y-axis rail respectively form a sliding pair, the bottom of the horizontal sliding seat is in threaded connection with a Y-axis screw rod, and the horizontal sliding seat and each Y-axis rail form a threaded moving pair; the welding bottom plate is fixedly connected with the top surface of the horizontal sliding seat; the controlled end of the Y-axis motion assembly is the controlled end of a Y-axis drive motor;
the Z-axis motion assembly comprises a pair of Z-axis driving motors, a pair of couplers, a pair of Z-axis lead screws, a pair of Z-axis rails and a vertical sliding seat; the Z-axis driving motor, the shaft couplers and the Z-axis screw rods are in one-to-one correspondence; the Z-axis driving motor and the Z-axis track are respectively and fixedly connected with the mounting plate; the Z-axis driving motor, the coupling, the Z-axis lead screw and the Z-axis track are respectively positioned at two sides of the slot; the output shaft of the Z-axis driving motor is in transmission connection with a corresponding Z-axis screw rod through a corresponding coupler, and two ends of the Z-axis screw rod are respectively supported on the mounting plate through bearing seats to form a revolute pair; the vertical sliding seat and each Z-axis track respectively form a sliding pair, and the bottom of the vertical sliding seat is in threaded connection with each Z-axis screw rod and forms a threaded moving pair; the X-axis motion assembly is arranged on the vertical sliding seat; the controlled end of the Z-axis motion assembly is the controlled end of a pair of Z-axis drive motors;
the X-axis motion assembly comprises an X-axis drive motor, a coupler, an X-axis lead screw, a transverse sliding seat and a pair of X-axis rails; the X-axis driving motor and the X-axis track are respectively and fixedly connected with the vertical sliding seat; the X-axis track is positioned on two sides of the X-axis driving motor; an output shaft of the X-axis driving motor is in transmission connection with an X-axis lead screw through a coupler, and two ends of the X-axis lead screw are supported on the vertical sliding seat through bearing seats respectively to form a revolute pair; the transverse sliding seat and each X-axis track respectively form a sliding pair, the bottom of the transverse sliding seat is in threaded connection with the X-axis screw rod, and the transverse sliding seat and the X-axis screw rod form a threaded moving pair; the welding gun head is fixedly connected with the transverse sliding seat; the controlled end of the X-axis motion assembly is the controlled end of an X-axis drive motor.
6. The special welder system for rapid metal forming by an electric arc method as claimed in claim 3, wherein the wire feeding assembly comprises a wire reel transition device and a wire feeder; the wire disc transition device is supported at the top of the rack mounting plate; the wire feeder is arranged on the three-dimensional movement device and is positioned above the welding gun head; the metal wire penetrates into the welding gun head through the wire disc transition device and the wire feeder in sequence; the controlled end of the wire feeding assembly is the controlled end of the wire feeder.
7. The special welder system for metal rapid prototyping by the arc process as set forth in claim 1, wherein said arc power supply is a dc arc power supply with IGBT, and the maximum withstand dc voltage of said arc power supply is more than 600V; the anode of the arc power supply is electrically connected with the welding gun head, and the cathode of the arc power supply is electrically connected with the welding bottom plate; the welding gun head and the welding bottom plate are made of metal materials respectively.
8. The special welder system for the metal rapid prototyping by the arc process as set forth in any one of the claims 1 to 7, characterized in that the system further comprises a power supply source, wherein the power supply source is a generator, a commercial power, an industrial power, or an accumulator battery; the power supply is electrically connected with the controller, the arc power supply, the wire feeding assembly, the voltage comparison device and the three-dimensional movement device through cables.
9. A control method of a welding machine system is characterized in that the special welding machine system for the electric arc method metal rapid prototyping of any claim 1 to 8 is adopted; the control method comprises the following steps:
firstly, starting a welding machine system; one side of the electric arc power supply is electrified to the metal wire through the welding gun head, and the other side of the electric arc power supply is electrified to the welding bottom plate; the voltage comparison device monitors real-time voltage between the metal wire and the welding bottom plate through a first voltage detection end and a second voltage detection end of the voltage comparison device;
secondly, the controller controls the three-dimensional motion device to execute motion actions according to the input motion control instruction, and controls the wire feeding assembly to execute wire feeding actions according to the input wire feeding control instruction;
thirdly, the metal wire continuously moves downwards from the welding gun head and extends to the welding bottom plate; when the metal wire is about to contact the welding baseplate, the voltage applied to the metal wire and the welding baseplate breaks down the air and generates an electric arc which heats and melts the end of the metal wire to form a metal droplet; when the voltage breaks through air and generates an electric arc, the voltage comparison device monitors that the real-time voltage continuously drops, and when the real-time voltage is smaller than a preset voltage threshold value, the voltage comparison device executes a first time delay action, and the time is reserved so that the electric arc continuously heats the end part of the metal wire to enable metal liquid drops to be increased and dropped to a welding bottom plate and form a molten pool; when the first time delay action is finished, the time delay switch of the voltage comparison device disconnects the arc power supply, and the voltage comparison device executes a second time delay action to reserve time for separating the metal wire from the molten pool; when the second time delay action is finished, the time delay switch of the voltage comparison device is connected with an electric arc power supply, so that the electric arc power supply is electrified to the metal wire through the welding gun head while being electrified to the welding bottom plate;
the first time delay action and the second time delay action are respectively that a time delay switch of the voltage comparison device starts to time and finishes timing when the timing time reaches a preset value;
and fourthly, turning to the second step, continuing the metal printing process until the final printing and forming are finished, and ending the control method.
10. The welder system control method of claim 9, wherein the controller is communicatively coupled to an external computer;
the second step further comprises: and the external computer models the printed target, slices the model in layers, obtains a motion control instruction and a wire feeding control instruction according to slice data, and inputs the motion control instruction and the wire feeding control instruction into the controller.
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