CN111922492A - A magnetic field-assisted integrated hot wire submerged arc welding device - Google Patents
A magnetic field-assisted integrated hot wire submerged arc welding device Download PDFInfo
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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
- B23K9/18—Submerged-arc 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
- B23K9/12—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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Abstract
本发明属于焊接设备技术领域,具体涉及一种多丝埋弧焊设备。一种磁场辅助下集成热丝埋弧焊接装置,包括主枪体、辅枪体,所述辅枪体设置在主枪体的后端,用于向主枪体内送入焊丝,所述主枪体内沿焊道方向平行设置三个送丝管;三个送丝管内分别为第一焊丝、第二焊丝和第三焊丝;其中第一焊丝和第二焊丝分别与起弧电源连接,用于与工件起弧;第三焊丝与辅助电源连接,被所述辅助电源加热后,用于填充焊缝;所述主枪体的前端设有喷嘴。本发明整套焊接装置尺寸较小,在外加磁场作用下三丝形成的电弧形成一个耦合电弧,在显著降低焊接过程热输入的同时提高焊缝熔敷率,细化晶粒,降低合金元素的烧损,减少焊缝内应力,避免焊接变形,令焊缝整体的强度和韧性显著提高,获得理想深宽比焊缝。
The invention belongs to the technical field of welding equipment, in particular to a multi-wire submerged arc welding equipment. An integrated hot wire submerged arc welding device assisted by a magnetic field includes a main gun body and an auxiliary gun body, the auxiliary gun body is arranged at the rear end of the main gun body, and is used for feeding welding wire into the main gun body. Three wire feeding tubes are arranged in parallel along the direction of the welding bead in the body; the first welding wire, the second welding wire and the third welding wire are respectively arranged in the three wire feeding tubes; wherein the first welding wire and the second welding wire are respectively connected with the arc starting power source for connecting with the arc starting power source. The workpiece starts arcing; the third welding wire is connected to the auxiliary power source, and after being heated by the auxiliary power source, it is used to fill the welding seam; the front end of the main gun body is provided with a nozzle. The whole welding device of the invention has a small size, and the arc formed by the three wires forms a coupled arc under the action of an external magnetic field, which can significantly reduce the heat input in the welding process and at the same time improve the welding seam deposition rate, refine the crystal grains, and reduce the burning of alloy elements. It reduces the internal stress of the weld, avoids welding deformation, significantly improves the overall strength and toughness of the weld, and obtains the ideal aspect ratio weld.
Description
技术领域technical field
本发明属于焊接设备技术领域,具体涉及一种多丝埋弧焊设备。The invention belongs to the technical field of welding equipment, in particular to a multi-wire submerged arc welding equipment.
背景技术Background technique
埋弧焊是电弧在焊剂层下燃烧进行焊接的方法,因其生产效率高、焊缝质量高、焊接变形小、无弧光及烟尘少等一系列优点深受国内外大型企业的青睐,主要用于压力容器、铁路车辆、重型机械等领域,适用于低碳钢、低合金钢、不锈钢以及镍基合金等材料的焊接。近年来,国内外焊接学者先后研究多种高效优质的焊接方法,但未对埋弧焊的应用领域产生较大影响。Submerged arc welding is a welding method in which the arc burns under the flux layer. It is favored by large enterprises at home and abroad because of a series of advantages such as high production efficiency, high welding seam quality, small welding deformation, no arc light and less smoke and dust. It is suitable for welding of low carbon steel, low alloy steel, stainless steel and nickel-based alloys in the fields of pressure vessels, railway vehicles, and heavy machinery. In recent years, domestic and foreign welding scholars have studied a variety of high-efficiency and high-quality welding methods, but they have not had a great impact on the application field of submerged arc welding.
截至目前,超过80mm以上的钢板等焊接材料在实际工业中应用越来越多,原有单丝埋弧焊和双丝埋弧焊虽可实现厚板的连接,但厚板的多层多道焊接导致热输入量较大令焊缝组织晶粒粗大,影响接头的力学性能。多丝埋弧焊是指同时使用两根以上焊丝完成一条焊缝的埋弧焊接方法,相对单丝埋弧焊和双丝埋弧焊,其特点在于焊接时将所需的能量分配到不同的焊丝上,因此使用较细的焊丝、较小的焊接电流和较大的焊接速度就可实现焊道的一次成形,相邻焊丝之间可视为前丝的预热以及后丝的预热,在实际焊接过程中,可通过调节焊丝之间的排列方式、焊丝间距、焊丝倾角与电弧功率等来获得所需的焊缝形状与尺寸,多丝相辅相成,显著提高焊接生产效率和焊缝质量。Up to now, more and more welding materials such as steel plates over 80mm have been used in the actual industry. Although the original single-wire submerged arc welding and double-wire submerged arc welding can realize the connection of thick plates, the multi-layer and multi-channel thick plates The large amount of heat input caused by welding makes the grains of the weld structure coarse, which affects the mechanical properties of the joint. Multi-wire submerged arc welding refers to a submerged arc welding method that uses two or more wires at the same time to complete a weld. Compared with single-wire submerged arc welding and double-wire submerged arc welding, it is characterized in that the required energy is distributed to different parts during welding. Therefore, the welding bead can be formed at one time by using thinner welding wire, smaller welding current and larger welding speed. In the actual welding process, the required shape and size of the weld can be obtained by adjusting the arrangement of the welding wires, the distance between the welding wires, the inclination angle of the welding wire and the arc power.
集成冷丝埋弧焊(ICETM)是在两根平行的热丝中间插入一根冷丝,利用热丝多余的热量来熔化焊丝。在焊接时。两根热丝由一个直流电机驱动以相同速度送丝,冷丝由一个独立的送丝机送丝,冷丝送丝速度可独立控制。该方法可大幅度提高焊接生产效率,增加焊接速度,降低焊剂消耗,实现高效高质量的低成本焊接。但该方法核心技术受限于国外,设备成本较高,此外,对于较大厚板时因冷丝消耗部分焊接热输入,导致焊接过程仍需多层多道,降低焊接效率。Integrated Cold Wire Submerged Arc Welding (ICE TM ) involves inserting a cold wire between two parallel hot wires and using the excess heat of the hot wires to melt the wire. when welding. The two hot wires are fed by a DC motor at the same speed, and the cold wires are fed by an independent wire feeder, and the feeding speed of the cold wires can be independently controlled. The method can greatly improve the welding production efficiency, increase the welding speed, reduce the flux consumption, and realize high-efficiency, high-quality and low-cost welding. However, the core technology of this method is limited by foreign countries, and the equipment cost is high. In addition, for larger thick plates, the cold wire consumes part of the welding heat input, resulting in the welding process still requiring multiple layers and multiple passes, reducing the welding efficiency.
发明内容SUMMARY OF THE INVENTION
本发明的目的是为了克服现有技术的不足,提供一种新型埋弧焊接设备,该设备在两根与主电源连接的焊丝后方加入了一根不连接主电源的焊丝为热丝,前方两焊丝形成电弧会对后方焊丝预热,额外的独立电源对该焊丝加热,二者高温协同熔化该焊丝,实现集成热丝功能,该焊枪可以在相同的熔覆效率下,达到最小的热输入,减少了因为埋弧焊热输入高,加热速度快,局部过热而造成的焊缝组织相变恶化,对大电流,快速焊接的埋弧焊尤为重要,能明显提升接头组织的力学性能并减小焊缝变形量,提高产品质量。The purpose of the present invention is to overcome the deficiencies of the prior art, and to provide a new type of submerged arc welding equipment. The equipment adds a welding wire that is not connected to the main power source behind the two welding wires connected to the main power source as a hot wire. The arc formed by the welding wire will preheat the rear welding wire, and the additional independent power source will heat the welding wire. The two high temperature synergistically melt the welding wire to realize the integrated hot wire function. The welding torch can achieve the minimum heat input under the same cladding efficiency. It reduces the deterioration of the weld structure due to high heat input, fast heating speed and local overheating of submerged arc welding. It is especially important for submerged arc welding of high current and rapid welding, which can significantly improve the mechanical properties of the joint structure and reduce the Weld deformation, improve product quality.
实现集成热丝功能,该焊枪可以在相同的熔覆效率下,达到最小的热输入,减少了因为埋弧焊热输入高,加热速度快,局部过热而造成的焊缝组织相变恶化,对大电流,快速焊接的埋弧焊尤为重要,能明显提升接头组织的力学性能并减小焊缝变形量,提高产品质量。Realizing the integrated hot wire function, the welding torch can achieve the minimum heat input under the same cladding efficiency, reducing the deterioration of the weld structure caused by the high heat input, fast heating speed and local overheating of submerged arc welding. Submerged arc welding with high current and rapid welding is particularly important, which can significantly improve the mechanical properties of the joint structure, reduce the deformation of the weld, and improve the quality of the product.
为实现上述目的,本发明采用的技术方案是:一种磁场辅助下集成热丝埋弧焊接装置,包括主枪体、辅枪体,所述辅枪体设置在主枪体的后端,用于向主枪体内送入焊丝,所述主枪体内沿焊接方向平行设置三个送丝管;三个送丝管内分别为第一焊丝、第二焊丝和第三焊丝;其中第一焊丝和第二焊丝分别与起弧电源连接,用于与工件起弧;第三焊丝与辅助电源连接,被所述辅助电源加热后,用于填充焊缝;所述主枪体的前端设有喷嘴。In order to achieve the above purpose, the technical scheme adopted in the present invention is: a magnetic field-assisted integrated hot wire submerged arc welding device, comprising a main gun body and an auxiliary gun body, the auxiliary gun body is arranged at the rear end of the main gun body, and is In order to feed the welding wire into the main gun body, three wire feeding tubes are arranged in parallel along the welding direction in the main gun body; the first welding wire, the second welding wire and the third welding wire are respectively in the three wire feeding tubes; The second welding wire is respectively connected with the arc starting power source for starting arc with the workpiece; the third welding wire is connected with the auxiliary power source, and after being heated by the auxiliary power source, it is used to fill the welding seam; the front end of the main gun body is provided with a nozzle.
作为本发明的一种优选方式,所述第一焊丝连接直流电源。As a preferred mode of the present invention, the first welding wire is connected to a DC power source.
作为本发明的一种优选方式,所述第二焊丝连接脉冲交流电源。As a preferred mode of the present invention, the second welding wire is connected to a pulsed AC power source.
作为本发明的另一种优选方式,所述主枪体的前部外侧设有磁场发生装置;所述磁场发生装置与交流电源连接,通过周期性的磁场方向变化改变第一焊丝电弧的偏转方向。As another preferred mode of the present invention, a magnetic field generating device is provided on the outer side of the front part of the main gun body; the magnetic field generating device is connected to the AC power supply, and changes the deflection direction of the first welding wire arc through periodic changes in the direction of the magnetic field .
进一步优选地,所述第三焊丝的送丝管为陶瓷送丝管;陶瓷送丝管上设有镂空结构。Further preferably, the wire feeding tube of the third welding wire is a ceramic wire feeding tube; the ceramic wire feeding tube is provided with a hollow structure.
进一步优选地,所述的第三焊丝通过热丝电极与辅助电源连接,所述热丝电极进入所述镂空结构与陶瓷送丝管内的第三焊丝接触,对经过热丝电极两个导电块之间的焊丝进行加热。Further preferably, the third welding wire is connected to the auxiliary power source through a hot wire electrode, and the hot wire electrode enters the hollow structure and contacts the third welding wire in the ceramic wire feeding tube, and the connection between the two conductive blocks of the hot wire electrode is opposite. The welding wire in between is heated.
作为本发明的一种优选方式,第一焊丝和第二焊丝的送丝管为紫铜送丝管,起弧电源通过电极块接触紫铜送丝管管壁将焊接电流传递到管内的焊丝上。As a preferred mode of the present invention, the wire feeding tubes of the first welding wire and the second welding wire are copper wire feeding tubes, and the arc starting power source transfers the welding current to the welding wire in the tube through the electrode block contacting the tube wall of the copper wire feeding tube.
作为本发明的一种优选方式,所述的辅枪体包括送丝机构和送丝软管,所述送丝软管连接于三个送丝管的末端,所述送丝机构通过送丝软管将三根焊丝分别送入三个送丝管内。As a preferred mode of the present invention, the auxiliary gun body includes a wire feeding mechanism and a wire feeding hose, the wire feeding hose is connected to the ends of the three wire feeding tubes, and the wire feeding mechanism passes the wire feeding soft The tube feeds the three welding wires into the three wire feed tubes respectively.
进一步优选地,所述的送丝机构由三组送丝行星轮组成,三组送丝行星轮相互之间等距排列。Further preferably, the wire feeding mechanism is composed of three sets of wire feeding planetary wheels, and the three sets of wire feeding planetary wheels are arranged at equal distances from each other.
作为本发明的一种优选方式,所述喷嘴内部设有稳弧器。As a preferred mode of the present invention, an arc stabilizer is provided inside the nozzle.
与传统的埋弧焊枪相比,本发明的有益效果如下:Compared with the traditional submerged arc welding torch, the beneficial effects of the present invention are as follows:
(1)整套焊接装置尺寸较小,可实现大厚板窄间隙焊接,且每个送丝装置中均含有多个十字行星轮,对焊丝产生一个向前进给的拉力,保证较长距离送丝,实现长距离的有效焊接。(1) The whole set of welding device is small in size, which can realize welding of large and thick plates and narrow gaps, and each wire feeding device contains multiple cross planetary gears, which generate a forward feeding tension on the welding wire and ensure long-distance wire feeding. , to achieve effective welding over long distances.
(2)焊接电弧共包括三个:第一焊丝电弧、第二焊丝电弧、第三焊丝电弧。由直流电源产生的第一焊丝电弧位于前端,匙孔工件,获得不同深度的熔深,且在外加磁场作用下会发生偏转,解决电弧磁偏吹等问题,并通过直流电源的大小和磁场方向改变电弧的偏转幅度和偏转方向,进而控制电弧焊接的有效区域,成功解决深厚板侧壁未熔合等关键问题。中间的脉冲交流电源产生的第二焊丝电弧主要用小电流大电压来控制焊缝的成型和控制熔深,并在外加磁场作用下令中丝形成稳定的焊接电弧,获得光滑的焊缝表面,改善焊缝成形。第三焊丝主要起到填充盖面作用,在辅助电源的预热作用下,焊丝熔敷速度加快,增大熔覆面积,焊接速度得到提高。(2) There are three welding arcs: the first welding wire arc, the second welding wire arc, and the third welding wire arc. The first welding wire arc generated by the DC power supply is located at the front end, and the keyhole workpiece obtains different depths of penetration, and will deflect under the action of an external magnetic field, so as to solve the problem of arc magnetic deflection and other problems, and through the size of the DC power supply and the direction of the magnetic field Change the deflection amplitude and deflection direction of the arc, and then control the effective area of arc welding, and successfully solve the key problems such as deep plate sidewall failure. The second welding wire arc generated by the pulse AC power supply in the middle mainly uses small current and high voltage to control the formation of the weld and control the penetration depth, and under the action of the external magnetic field, the middle wire forms a stable welding arc to obtain a smooth weld surface and improve the Weld forming. The third welding wire mainly plays the role of filling and covering. Under the preheating effect of the auxiliary power supply, the welding wire deposition speed is accelerated, the deposition area is increased, and the welding speed is improved.
(3)外加磁场作用下三丝形成的电弧形成一个耦合电弧,在显著降低焊接过程热输入的同时提高焊缝熔敷率,细化晶粒,降低合金元素的烧损,减少焊缝内应力,避免焊接变形,令焊缝整体的强度和韧性均显著提高,获得理想的深宽比焊缝。(3) Under the action of an external magnetic field, the arc formed by the three wires forms a coupled arc, which significantly reduces the heat input during the welding process while improving the weld deposition rate, refining the grains, reducing the burning loss of alloying elements, and reducing the internal stress of the weld. , avoid welding deformation, significantly improve the overall strength and toughness of the weld, and obtain an ideal aspect ratio weld.
(4)针对大厚板,因焊接熔覆效率和熔深的提升,显著减少焊接层数,进而减少焊剂消耗,在获得平滑的焊缝表面的基础上显著降低焊接成本。(4) For large and thick plates, due to the improvement of welding cladding efficiency and penetration depth, the number of welding layers is significantly reduced, thereby reducing flux consumption, and significantly reducing welding costs on the basis of obtaining a smooth weld surface.
附图说明Description of drawings
图1为本发明实施例提供的磁场辅助下集成热丝埋弧焊接装置的左视图;1 is a left side view of an integrated hot wire submerged arc welding device under the assistance of a magnetic field provided by an embodiment of the present invention;
图2为本发明实施例提供的磁场辅助下集成热丝埋弧焊接装置的三维透视图;2 is a three-dimensional perspective view of an integrated hot wire submerged arc welding device under the assistance of a magnetic field provided by an embodiment of the present invention;
图3为本发明实施例提供的磁场辅助下集成热丝埋弧焊接装置的半剖视图;3 is a half cross-sectional view of an integrated hot wire submerged arc welding device assisted by a magnetic field provided by an embodiment of the present invention;
图4为本发明实施例提供的磁场辅助下集成热丝埋弧焊接装置内部结构立体示意图(左前方向);4 is a three-dimensional schematic diagram (left front direction) of the internal structure of the integrated hot wire submerged arc welding device under the magnetic field assistance provided by the embodiment of the present invention;
图5为本发明实施例提供的磁场辅助下集成热丝埋弧焊接装置内部结构立体示意图(右后方向);FIG. 5 is a three-dimensional schematic diagram (rear right direction) of the internal structure of the integrated hot wire submerged arc welding device under the magnetic field assistance provided by the embodiment of the present invention;
图6为陶瓷送丝管的结构示意图;Fig. 6 is the structural representation of the ceramic wire feeding tube;
图7为绝缘块的结构示意图;Fig. 7 is the structural representation of insulating block;
图8为绝缘块的三维透视图;8 is a three-dimensional perspective view of an insulating block;
图9为绝缘胶垫的结构示意图;9 is a schematic structural diagram of an insulating rubber pad;
图10为热丝电极结构示意图;Figure 10 is a schematic diagram of the structure of the hot wire electrode;
图11为电极块的结构示意图:a.直流电极块、b.交流电极块;Figure 11 is a schematic structural diagram of an electrode block: a. DC electrode block, b. AC electrode block;
图12为电磁铁外壳结构示意图;Figure 12 is a schematic diagram of the structure of the electromagnet shell;
图13为电磁铁线圈结构示意图;Figure 13 is a schematic diagram of the structure of the electromagnet coil;
图中,1.喷嘴;2.稳弧器;3.电极绝缘块;4.电磁铁外壳;5.电磁铁控制箱;6.电磁铁线圈;7.主枪体外壳;8.直流电极块;9.交流电极块;10.绝缘胶垫;11.热丝电极固定块;12.热丝电极;13. 第一紫铜送丝管;14. 第二紫铜送丝管;15.陶瓷送丝管;16.主枪体尾端固定块;17.辅枪体外壳;18.送丝软管固定板;19.十字行星轮载板;20.送丝软管;21.十字行星轮;22.镂空结构;23.导电块;24.绝缘棒。In the figure, 1. Nozzle; 2. Arc stabilizer; 3. Electrode insulating block; 4. Electromagnet shell; 5. Electromagnet control box; 6. Electromagnet coil; 7. Main gun body shell; 8. DC electrode block ; 9. AC electrode block; 10. Insulating rubber pad; 11. Hot wire electrode fixing block; 12. Hot wire electrode; 13. The first copper wire feeding tube; 14. The second copper wire feeding tube; 15. Ceramic wire feeding tube; 16. Main gun body tail end fixing block; 17. Auxiliary gun body shell; 18. Wire feeding hose fixing plate; 19. Cross planetary carrier plate; 20. Wire feeding hose; 21. Cross planetary gear; 22 . Hollow structure; 23. Conductive block; 24. Insulating rod.
具体实施方式Detailed ways
为了便于理解本发明,下面结合附图和具体实施例,对本发明进行更详细的说明。附图中给出了本发明的较佳的实施例。但是,本发明可以以许多不同的形式来实现,并不限于本说明书所描述的实施例。相反地,提供这些实施例的目的是使对本发明的公开内容的理解更加透彻全面。In order to facilitate understanding of the present invention, the present invention will be described in more detail below with reference to the accompanying drawings and specific embodiments. Preferred embodiments of the invention are shown in the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described in this specification. Rather, these embodiments are provided so that a thorough and complete understanding of the present disclosure is provided.
正如背景技术所介绍的,为提高焊接熔敷率,降低焊接热输入,本发明对热丝电源做了调整,引弧时后丝受辅助电源预热,温度控制系统使加热过程缓慢增加,并且存在梯度温度补偿,使引弧过程更稳定;可变磁场方向的磁场发生装置产生的磁场,对前后焊丝产生影响,提高了熔深和熔宽,降低了热输入,提高了熔覆效率,保证了焊缝的力学性能和成形美观,而且设备加装了十字行星轮解决了长距离送丝不稳的问题使焊缝质量进一步提升。As described in the background art, in order to improve the welding deposition rate and reduce the welding heat input, the present invention adjusts the power supply of the hot wire, the wire is preheated by the auxiliary power supply after the arc is struck, and the temperature control system makes the heating process increase slowly, and There is gradient temperature compensation, which makes the arc striking process more stable; the magnetic field generated by the magnetic field generator with variable magnetic field direction affects the front and rear welding wires, improves the penetration depth and width, reduces the heat input, improves the cladding efficiency, and ensures The mechanical properties and appearance of the weld are improved, and the equipment is equipped with a cross planetary gear to solve the problem of unstable wire feeding over long distances, which further improves the quality of the weld.
本发明提供的其中一个实施例是:一种磁场辅助下集成热丝埋弧焊接装置,其外部结构如图1所示,主要包括主枪体Ⅰ和辅枪体Ⅱ两部分。辅枪体Ⅱ通过主枪体尾端固定块与主枪体Ⅰ嵌合。在主枪体Ⅰ的前侧下部设有磁场发生装置,用于产生磁场。One of the embodiments provided by the present invention is: an integrated hot wire submerged arc welding device assisted by a magnetic field, the external structure of which is shown in FIG. The auxiliary gun body II is fitted with the main gun body I through the fixing block at the end of the main gun body. The lower part of the front side of the main gun body I is provided with a magnetic field generating device for generating a magnetic field.
参照附图1、2所示,辅枪体Ⅱ位于主枪体Ⅰ的上部,包括辅枪体外壳17和其内部的送丝软管20、送丝软管固定板18,三组十字行星轮及其相关结构件。Referring to Figures 1 and 2, the auxiliary gun body II is located on the upper part of the main gun body I, including the auxiliary
辅枪体外壳17为完全相同的两部分,最上方凹槽内嵌入了十字行星轮载板19,十字行星轮载板19下方的凹槽内部设有送丝软管固定板18,辅枪体外壳17最下方与主枪体Ⅰ连接。The auxiliary
参照图2、3、4所示,十字行星轮载板19为确定三组十字行星轮21相互之间位置之所用,十字行星轮电机通过四颗定位螺钉固定于十字行星轮载板19下方,三组十字行星轮21相互之间等距排列。十字行星轮21整体结构下相隔8.7mm为送丝软管固定板18,也由相应的辅枪体外壳内的凹槽固定,送丝软管固定板18上表面三个穿丝孔为漏斗状,与十字行星轮出丝孔平行,下方为螺纹孔,用于连接送丝软管20。送丝软管固定板18下方为三根送丝管。两侧的送丝管分别通过送丝软管20与十字行星轮连接,中间的送丝管直接穿入送丝软管固定板18中间的孔与十字行星轮连接。Referring to Figures 2, 3 and 4, the cross planetary
送丝机构为焊接过程提供稳定性,和满足长距离送丝的需要,焊丝经由外界送丝软管进入十字行星轮减速箱,依次通过十字行星轮21内部各结构件,最后进入送丝软管固定板18,经过矫直的焊丝分别经由送丝软管进入不同的送丝管。The wire feeding mechanism provides stability for the welding process and meets the needs of long-distance wire feeding. The welding wire enters the cross planetary gear reducer through the external wire feeding hose, passes through the internal structural parts of the cross
参照附图2、3、4、5所示,主枪体包括主枪体外壳7和内部的电弧产生系统和热丝系统。主枪体外壳7最上端设有主枪体尾端固定块16。作为主枪体和辅枪体的连接部件,主枪体尾端固定块16两侧的突出块嵌于辅枪体外壳17内相应凹槽上。尾部固定块的垂直面上设有供三根送丝管通过的通孔和外部电源线缆通过的通孔。Referring to Figures 2, 3, 4, and 5, the main gun body includes a main
主枪体外壳7内设置三个平行的送丝管,分别是第一紫铜送丝管13、第二紫铜送丝管14和陶瓷送丝管15。三根送丝管各相距13.75mm,其中,第一紫铜送丝管13负责运输第一焊丝,第二紫铜送丝管14用于负责运输第二焊丝;陶瓷送丝管15则负责运输第三焊丝。Three parallel wire feeding tubes are arranged in the main
第一紫铜送丝管13通过直流电极块8与直流电源相连接,第二紫铜送丝管14通过交流电极块9与脉冲交流电源相连接。陶瓷送丝管15上设有镂空结构22,如图6所示,通过镂空结构22使第三焊丝与热丝电极12相接触。陶瓷送丝管15绝缘的特性让辅助电源连接到焊枪内部的热丝电极12不会短路,同时通过焊丝电阻热加热热丝电极12正负极之间的焊丝。The first copper
主枪体外壳7的前端是喷嘴1。喷嘴1内部安装有耐高温绝缘的稳弧器2,进入三个送丝管内的焊丝最终会被送进入稳弧器2,起弧后由稳弧器2稳定电弧。The front end of the main
三个送丝管从上至下依次经过主枪体尾端固定块16、热丝电极固定块11、绝缘胶垫10、电极绝缘块3、以及稳弧器2,上述材料均为绝缘材料,保证焊丝与枪体不连电。The three wire feed tubes pass through the main gun body tail
电极绝缘块3上含有两个凹槽,如图7所示,用于固定直流电极块8和交流电极块9,并且防止电极与枪体联电。电极绝缘块3中心区域有供三根送丝管通过的孔,如图8所示,其上方有绝缘胶垫10,固定三根送丝管的位置。The
绝缘胶垫10的结构如图9所示,其上方为热丝电极固定块11,热丝电极固定块11置于主枪体外壳7内部的凹槽内,并且下表面与绝缘胶垫10上表面接触,热丝电极固定块11上设有与热丝电极12配合的凹槽,用于固定热丝电极12并使热丝电极12与枪体绝缘。The structure of the insulating
热丝电极12中间为绝缘实心塑料杆24,通过螺钉与金属铜制成的上、下导电块23连接,如图10所示,整体作为热丝电极12,通过外部辅助电源导线分别连接上、下导电块,电流流过焊丝,通过电阻热预热两个导电块之间的焊丝。The middle of the
电极绝缘块3上固定的直流电极块8和脉冲交流电极块9分别与第一紫铜送丝管13和第二紫铜送丝管紧密贴合,保证焊接电流完全传递到第一焊丝和第二焊丝上。直流电极块8和交流电极块的结构类似,分别如图11a和11b所示,通过电极块上的U型凹槽与紫铜送丝管的外壁紧密贴合。The
而进入陶瓷送丝管15的第三焊丝在经过主枪体尾端固定块16后,通过陶瓷送丝管15上镂空的位置与热丝电极12相接触,经过辅助电源的预热成为热丝,然后在陶瓷送丝管15内依次经过热丝电极固定块11、绝缘胶垫10、电极绝缘块3、稳弧器2,最后被预热后的热丝直接进入前方两焊丝制造的熔池之中,在第一焊丝的主电弧所产生的电弧热作用下熔化为填充金属参与到焊接反应当中。The third welding wire entering the ceramic
喷嘴1通过螺钉固定在主枪体外壳7前端。主枪体外壳7与喷嘴1相连偏上的位置固定有电磁铁控制箱5,下端连接着电磁铁外壳4,如图12所示,保护电磁铁线圈6。电磁铁线圈6位于电磁铁外壳4内部,如图13所示,电磁铁线圈6与交流电源连接。通电后,电磁铁线圈6在第一焊丝的前方形成左右方向的磁场。The
电磁铁线圈6在整个焊接过程中始终工作,通过调节电磁铁控制箱5的参数控制焊道最前端与直流电源连接的第一焊丝所产生的电弧,改变电弧摆动的频率和方向,同时通过调节直流电源参数改变电弧摆动幅度,保证焊接大熔宽和高的熔覆效率。The electromagnet coil 6 always works during the whole welding process. By adjusting the parameters of the electromagnet control box 5, the arc generated by the first welding wire connected to the DC power source at the front end of the weld bead is controlled, and the frequency and direction of the arc swing are changed. The parameters of DC power supply change the amplitude of arc swing to ensure large welding width and high cladding efficiency.
本实施例的磁场辅助下集成热丝埋弧焊接装置,内部含有第一焊丝、第二焊丝、第三焊丝(热丝),且每个焊丝均配有单独的焊接电源。焊接时,三根焊丝以平行沿焊道方向前后排列的方式沿着焊接方向实现焊接,第一焊丝可垂直于焊接工件或者向前倾斜与工件呈20-80°夹角,第三焊丝(热丝)通常向后倾斜,与工件呈现30-80°夹角,第二焊丝垂直于工件焊接,也可以与工件呈现一定角度。The magnetic field-assisted integrated hot wire submerged arc welding device in this embodiment contains a first welding wire, a second welding wire, and a third welding wire (hot wire), and each welding wire is equipped with a separate welding power source. During welding, the three welding wires are arranged in parallel along the direction of the bead to realize welding along the welding direction. ) is usually inclined backward, presenting an angle of 30-80° with the workpiece, and the second welding wire is perpendicular to the workpiece for welding, and it can also present a certain angle with the workpiece.
第一焊丝与直流电源连接,第二焊丝则与脉冲交流电源相连接,第三焊丝连接辅助电源。通过控制第一焊丝的电流大小来控制焊缝的熔深,第二焊丝起到进一步增加熔深和改善焊道成形的作用,第三焊丝(热丝)通过辅助电源可以预热焊丝,加大焊丝的熔化速度,提高焊接速度。辅助电源可以为直流电源,也可以为交流电源。The first welding wire is connected to the DC power source, the second welding wire is connected to the pulsed AC power source, and the third welding wire is connected to the auxiliary power source. The penetration depth of the welding seam is controlled by controlling the current of the first welding wire, the second welding wire plays the role of further increasing the penetration depth and improving the welding bead formation, and the third welding wire (hot wire) can preheat the welding wire through the auxiliary power supply, increasing The melting speed of the welding wire increases the welding speed. The auxiliary power supply can be either a DC power supply or an AC power supply.
电磁铁线圈6在交流电源的作用下,周期性改变电磁铁极性。前方的第一焊丝产生的电弧在磁场的作用下,实现周期性偏向,电弧周期性的左右偏向近似于焊枪摆动但是更直接的影响焊接区域的热输入,这样保证了不改变电流的前提下减小了熔深增大了熔覆面积,通过对电磁铁电流强弱的控制可以控制电弧摆动幅度,控制电弧焊接的有效区域和焊缝区以及热影响区的面积,降低热输入在细化晶粒上有显著作用,而由于第一电弧所带来的成形不美观和熔深减少的问题可由后续两根焊丝改善。The electromagnet coil 6 periodically changes the polarity of the electromagnet under the action of the AC power supply. The arc generated by the first welding wire in front realizes periodic deflection under the action of the magnetic field. The periodic left and right deflection of the arc is similar to the swing of the welding torch but directly affects the heat input of the welding area, which ensures that the current is not changed. The smaller the penetration depth, the larger the cladding area. By controlling the current strength of the electromagnet, the amplitude of the arc swing can be controlled, the effective area of the arc welding, the area of the weld zone and the heat-affected zone can be controlled, and the heat input in the refined grain can be reduced. There is a significant effect on the grain, and the problems of unsightly forming and reduced penetration caused by the first arc can be improved by the subsequent two welding wires.
中间的第二焊丝主要用小电流大电压来控制焊缝的成型和进一步提高熔深,电源采用为交流脉冲电源,当电弧电流在峰值区间内,焊丝电流为零,此时不会产生磁偏吹,当焊丝通电时,电弧基值电流很小,仅能维持电弧燃烧,焊丝通电产生磁场进而产生安培力拉扯电弧,但是电弧基值电流很小,无法对母材造成不利影响,因此中间的焊丝可以稳定电弧,获得光滑的焊缝表面,改善焊缝成形。The second welding wire in the middle mainly uses small current and high voltage to control the forming of the weld and further improve the penetration depth. Blow, when the welding wire is energized, the arc base value current is very small, which can only maintain the arc combustion, and the welding wire is energized to generate a magnetic field to generate ampere force to pull the arc, but the arc base value current is very small and cannot cause adverse effects on the base metal, so the middle The welding wire stabilizes the arc, obtains a smooth weld surface, and improves weld formation.
最后方的第三焊丝(热丝),作为填充金属,增大熔覆面积,并且在外加电源的辅助下,焊丝熔化速度足够快,焊接速度可以极大提高,进而减少了整个焊接过程的实际热输入,减少了合金元素的烧损,减低了焊缝内应力,细化了晶粒使焊缝整体的强度和韧性显著提高。The third welding wire (hot wire) at the back, as the filler metal, increases the cladding area, and with the aid of an external power source, the welding wire melts fast enough, and the welding speed can be greatly improved, thereby reducing the actual welding process. The heat input reduces the burning loss of alloying elements, reduces the internal stress of the weld, refines the grains, and significantly improves the overall strength and toughness of the weld.
本实施例的磁场辅助下集成热丝埋弧焊接装置,在外置磁场的作用下,改善焊接温度场的分布,形成一体式耦合电弧,以最小的热输入下实现高熔敷率焊接,避免因热输入量过大导致的焊缝组织粗化,显著提高接头力学性能并减小焊缝变形量,提高焊缝接头质量,此外,脉冲模式的优点也得以应用,良好的引弧性能,热输入量小,抗气孔性能好。外加磁场与各电弧的协同效应亦尤为重要,可以在保证在不增大热输入的基础上通过控制电弧形态进而改变熔宽和熔深。The magnetic field-assisted integrated hot wire submerged arc welding device in this embodiment improves the distribution of the welding temperature field under the action of an external magnetic field, forms an integrated coupled arc, and achieves high deposition rate welding with minimal heat input, avoiding the risk of The coarsening of the weld structure caused by the excessive heat input significantly improves the mechanical properties of the joint, reduces the deformation of the weld, and improves the quality of the weld joint. In addition, the advantages of the pulse mode are also applied, good arc ignition performance, heat input Small amount, good anti-porosity performance. The synergistic effect of the applied magnetic field and each arc is also particularly important, and the melting width and depth can be changed by controlling the arc shape without increasing the heat input.
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CN107717189A (en) * | 2017-09-30 | 2018-02-23 | 上海振华重工(集团)股份有限公司 | A kind of three wire bond rifles and multi-wire submerged-arc soldering method |
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CN211028505U (en) * | 2019-07-10 | 2020-07-17 | 中建钢构有限公司 | Dual-power three-wire submerged-arc welding device |
CN212652857U (en) * | 2020-08-11 | 2021-03-05 | 山东经典重工集团股份有限公司 | A magnetic field-assisted integrated hot wire submerged arc welding device |
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CN104093516A (en) * | 2011-12-23 | 2014-10-08 | 依赛彼公司 | An arc welding head and a welding arrangement |
CN104400197A (en) * | 2014-09-28 | 2015-03-11 | 张鸿昌 | Integrated intelligent temperature adjustable type hot wire submerged-arc welding device and method |
CN107717189A (en) * | 2017-09-30 | 2018-02-23 | 上海振华重工(集团)股份有限公司 | A kind of three wire bond rifles and multi-wire submerged-arc soldering method |
CN211028505U (en) * | 2019-07-10 | 2020-07-17 | 中建钢构有限公司 | Dual-power three-wire submerged-arc welding device |
CN110936100A (en) * | 2019-12-05 | 2020-03-31 | 威海东海船舶修造有限公司 | Portable underwater welding repair device and welding repair system |
CN212652857U (en) * | 2020-08-11 | 2021-03-05 | 山东经典重工集团股份有限公司 | A magnetic field-assisted integrated hot wire submerged arc welding device |
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Publication number | Priority date | Publication date | Assignee | Title |
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CN118237701A (en) * | 2024-02-28 | 2024-06-25 | 江苏旭美特环保科技有限公司 | Argon arc welding machine for intelligent floor washing machine production and manufacture |
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