CN112404670A - Automatic control system of submerged arc horizontal welding equipment - Google Patents
Automatic control system of submerged arc horizontal welding equipment Download PDFInfo
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- CN112404670A CN112404670A CN202011170813.7A CN202011170813A CN112404670A CN 112404670 A CN112404670 A CN 112404670A CN 202011170813 A CN202011170813 A CN 202011170813A CN 112404670 A CN112404670 A CN 112404670A
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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
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0953—Monitoring or automatic control of welding parameters using computing means
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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
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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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
The invention provides an automatic control system of a submerged arc horizontal welding device, the submerged arc horizontal welding device comprises a walking mechanism, a servo motor, a wire feeding mechanism, a servo motor, a welding gun up-down adjusting mechanism, a stepping motor, a welding gun front-back adjusting mechanism, a stepping motor, a welding gun angle adjusting mechanism and a stepping motor, wherein the automatic control system comprises: the welding machine comprises a walking servo driver, a wire feeding servo driver, a welding gun up-and-down adjusting stepping driver, a welding gun front-and-back adjusting stepping driver, a welding gun angle adjusting stepping driver and a digital welding machine; and an industrial computer. The automatic control system can accurately and stably control welding parameters, improve welding quality and efficiency, reduce labor cost and realize the tracing of welding records.
Description
Technical Field
The invention mainly relates to the technical field of welding control, in particular to an automatic control system of submerged arc horizontal welding equipment.
Background
For welding large containers such as CVs (steel containment vessels), welding deformation control is difficult due to high requirements for overall perpendicularity and ovality. At present, manual welding is still mainly used for welding CV, the construction period is long, and the dependence on high-skill welders is strong.
The submerged arc welding has large fusion depth and high production efficiency, is particularly suitable for welding long welding seams of medium and thick plates, but the prior submerged arc transverse welding equipment is heavy, and equipment is difficult to install and apply in the field construction environment; on the basis, the existing submerged arc welding control mainly adopts an analog circuit and an analog quantity signal for control or adopts simple digital control, the control structure is complex, a large number of sensors or feedback circuits are needed for processing, the response of a control system is slow, the accurate control of welding parameters cannot be realized, the stability in the welding process is poor, and particularly, the welding defects are easily generated at the welding starting stage and the welding arc receiving stage.
In addition, the automation degree of the existing control system is not high, the welding quality requirement of welding large containers such as CV (steel containment vessel) is high, especially nuclear grade welding materials cannot realize the tracing of welding parameters when welding defects occur, and the specific reasons of the welding defects are often difficult to judge.
Disclosure of Invention
The technical problem to be solved by the invention is to provide an automatic control system of submerged-arc horizontal welding equipment, which can accurately and stably control welding parameters, improve welding quality and efficiency, reduce labor cost, and simultaneously realize tracing of welding records and perfect welding process.
In order to solve the technical problems, the invention provides an automatic control system of a submerged arc horizontal welding device, wherein the submerged arc horizontal welding device comprises a travelling mechanism, a travelling servo motor for driving the travelling mechanism to move, a wire feeding mechanism, a wire feeding servo motor for driving the wire feeding mechanism to operate, a welding gun up-and-down adjusting mechanism, a welding gun up-and-down adjusting stepping motor for driving the welding gun up-and-down adjusting mechanism to move up and down, a welding gun front-and-back adjusting mechanism, a welding gun front-and-back adjusting stepping motor for driving the welding gun front-and-back adjusting mechanism to move back and forth, a welding gun angle adjusting mechanism and a welding gun angle adjusting stepping motor for driving the welding gun angle adjusting mechanism to operate, wherein the automatic control: the walking servo driver is configured to drive the walking servo motor to drive the walking mechanism to move according to a first operation instruction, and receive motion information fed back by the walking servo motor; the wire feeding servo driver is configured to drive the wire feeding servo motor to drive the wire feeding mechanism to operate according to a second operation instruction so as to feed and retreat the welding wire; the welding gun up-and-down adjusting stepping driver is configured to drive the welding gun up-and-down adjusting stepping motor to drive the welding gun up-and-down adjusting mechanism to move up and down according to a third operating instruction, so that the position of the welding gun relative to the center of a welding seam is adjusted; the welding gun front-back adjusting stepping driver is configured to drive the welding gun front-back adjusting stepping motor to drive the welding gun front-back adjusting mechanism to move back and forth according to a fourth operating instruction, so that the distance between the welding gun and a welding workpiece is adjusted; the welding gun angle adjusting stepping driver is configured to drive the welding gun angle adjusting stepping motor to drive the welding gun angle adjusting mechanism to move according to a fifth operation instruction, so that the angle of the welding wire fed into the welding pool through the welding gun into the welding pool is adjusted; a digital welder; and the industrial computer is connected with the walking servo driver, the wire feeding servo driver, the welding gun up-and-down adjusting stepping driver, the welding gun front-and-back adjusting stepping driver and the welding gun angle adjusting stepping driver through a first bus, and is connected with the digital welding machine through a second bus, and the industrial computer is configured as follows: setting parameters of a welding process; controlling the welding process; and sending the first to fifth operation instructions according to user operation in the welding process.
In an embodiment of the invention, the welding process parameters include operating mode, welding current, welding voltage, welding speed, and wire feed speed.
In one embodiment of the present invention, the welding process includes an arc initiation subroutine, a welding control subroutine, and an arc extinction control subroutine.
In one embodiment of the present invention, the wire feed servo drive has a manual mode and an automatic mode.
In an embodiment of the present invention, the manner of setting the welding process parameters by the industrial computer includes: receiving the setting of a user on welding process parameters; and matching welding process parameters by using a preset expert database according to the input parent metal information and welding material information.
In an embodiment of the present invention, the industrial computer is further configured to match a control strategy matched with the welding process parameters by using the expert database according to the input parent material information and welding material information.
In an embodiment of the invention, the industrial computer is further configured to: collecting welding process parameters and generating a recording file; and generating a data statistical report according to the record file.
In an embodiment of the invention, the first bus and the second bus are field buses.
In one embodiment of the present invention, the digital welder has a DeviceNet communication interface, and the digital welder is connected to the industrial computer via a DeviceNet master station communication circuit.
Compared with the prior art, the invention has the following advantages:
an industrial computer is used as a control core, an operation window of the equipment is provided, all parameters of the equipment are adjusted and controlled on the computer, all parameters of the welding equipment can be accurately set, automation of the submerged arc transverse welding equipment is realized, and the labor intensity of workers can be reduced;
meanwhile, the control idea of a field bus is adopted, the structure of a control system is simplified, a walking mechanism and a wire feeding mechanism are controlled by servo motors, stable output is realized by utilizing negative feedback regulation of the servo motors, uniform motion is achieved, a digital welding machine with a DeviceNet communication interface is adopted in a welding machine part, the stability of parameter output is ensured, and good welding quality is ensured by realizing accurate control of the motors and the welding machine;
the control system has certain intellectualization, is easy to use, can reduce the learning cost of operators, can ensure that welding parameters reach the best matching state by utilizing the built-in expert database, thereby ensuring the welding quality, simultaneously, welding construction records and welding parameters can be traced, the reason analysis of welding defects is convenient when welding seams are repaired, and the automatic welding process is perfected.
Drawings
FIG. 1 is a schematic structural diagram of a transverse submerged arc welding apparatus in an automatic control system of the transverse submerged arc welding apparatus according to an embodiment of the present invention;
FIG. 2 is a system block diagram of an automated control system for a submerged arc cross welding apparatus in accordance with one embodiment of the present invention;
FIG. 3 is a schematic view of an initialization process of an automatic control system of the submerged arc horizontal welding equipment according to an embodiment of the present invention;
FIG. 4 is a schematic control flow diagram of an automatic control system of the submerged arc horizontal welding equipment according to an embodiment of the present invention;
FIG. 5 is a schematic view of the control flow of the arc striking stage of the automatic control system of the submerged arc horizontal welding equipment according to one embodiment of the present invention;
fig. 6 is a schematic control flow diagram of the arc quenching stage of the automatic control system of the transverse submerged arc welding equipment according to the embodiment of the invention.
Detailed Description
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings used in the description of the embodiments will be briefly introduced below. It is obvious that the drawings in the following description are only examples or embodiments of the application, from which the application can also be applied to other similar scenarios without inventive effort for a person skilled in the art. Unless otherwise apparent from the context, or otherwise indicated, like reference numbers in the figures refer to the same structure or operation.
As used in this application and the appended claims, the terms "a," "an," "the," and/or "the" are not intended to be inclusive in the singular, but rather are intended to be inclusive in the plural unless the context clearly dictates otherwise. In general, the terms "comprises" and "comprising" merely indicate that steps and elements are included which are explicitly identified, that the steps and elements do not form an exclusive list, and that a method or apparatus may include other steps or elements.
The relative arrangement of the components and steps, the numerical expressions, and numerical values set forth in these embodiments do not limit the scope of the present application unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any particular value should be construed as merely illustrative, and not limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present application, it is to be understood that the orientation or positional relationship indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the orientation or positional relationship shown in the drawings, and are used for convenience of description and simplicity of description only, and in the case of not making a reverse description, these directional terms do not indicate and imply that the device or element being referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore, should not be considered as limiting the scope of the present application; the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "above … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of protection of the present application is not to be construed as being limited. Further, although the terms used in the present application are selected from publicly known and used terms, some of the terms mentioned in the specification of the present application may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein. Further, it is required that the present application is understood not only by the actual terms used but also by the meaning of each term lying within.
It will be understood that when an element is referred to as being "on," "connected to," "coupled to" or "contacting" another element, it can be directly on, connected or coupled to, or contacting the other element or intervening elements may be present. In contrast, when an element is referred to as being "directly on," "directly connected to," "directly coupled to" or "directly contacting" another element, there are no intervening elements present. Similarly, when a first component is said to be "in electrical contact with" or "electrically coupled to" a second component, there is an electrical path between the first component and the second component that allows current to flow. The electrical path may include capacitors, coupled inductors, and/or other components that allow current to flow even without direct contact between the conductive components.
Flowcharts are used in the various figures herein to illustrate the operations performed by systems according to embodiments of the present application. It should be understood that the preceding or following operations are not necessarily performed in the exact order in which they are performed. Rather, various steps may be processed in reverse order or simultaneously. Meanwhile, other operations are added to or removed from these processes.
An embodiment of the invention provides an automatic control system of a submerged arc horizontal welding device, which can accurately and stably ensure welding parameters, improve welding quality and efficiency and reduce labor cost.
Fig. 1 is a schematic structural view of a transverse submerged arc welding apparatus 10 in an automatic control system of the transverse submerged arc welding apparatus according to the embodiment of the present invention. The submerged arc horizontal welding equipment 10 comprises a traveling mechanism 11, a traveling servo motor 111 (not shown in the figure) for driving the traveling mechanism to move, a wire feeding mechanism 12, a wire feeding servo motor 121 (not shown in the figure) for driving the wire feeding mechanism to operate, a welding gun up-down adjusting mechanism 13, a welding gun up-down adjusting stepping motor 131 (not shown in the figure) for driving the welding gun up-down adjusting mechanism 13 to move up and down, a welding gun front-back adjusting mechanism 14, a welding gun front-back adjusting stepping motor 141 (not shown in the figure) for driving the welding gun front-back adjusting mechanism 14 to move back and forth, a welding gun angle adjusting mechanism (located at the position of the welding gun and not marked in figure 1 due to shielding of other structures in the figure) and a welding gun angle adjusting stepping motor (not shown in the figure.
With respect to the transverse submerged arc welding equipment 10 shown in fig. 1, fig. 2 is a schematic system structure diagram of an automatic control system 20 in the embodiment of the present invention, and the same structural parts in fig. 2 related to the transverse submerged arc welding equipment of fig. 1 are given the same reference numerals. The control system 20 shown in fig. 2 includes:
the walking servo driver is configured to drive the walking servo motor 111 to move according to the first operation instruction and receive motion information fed back by the walking servo motor 111;
the wire feeding servo driver is configured to drive the wire feeding servo motor 121 to drive the wire feeding mechanism 12 to operate according to a second operation instruction so as to feed and retract the welding wire;
the welding gun up-and-down adjusting stepping driver is configured to drive the welding gun up-and-down adjusting stepping motor 131 to drive the welding gun up-and-down adjusting mechanism 13 to move up and down according to a third operation instruction, so that the position of the welding gun 17 relative to the center of the welding seam is adjusted;
the welding gun forward and backward adjusting stepping driver is configured to drive the welding gun forward and backward adjusting stepping motor 141 to drive the welding gun forward and backward adjusting mechanism to move 14 according to the fourth operation instruction, so that the distance between the welding gun 17 and the welding workpiece is adjusted;
the welding gun angle adjusting stepping driver is configured to drive the welding gun angle adjusting stepping motor to drive the welding gun angle adjusting mechanism to move according to a fifth operation instruction, so that the angle of the welding wire fed into the welding pool through the welding gun 17 to be fed into the welding pool is adjusted;
a digital welder (which may be considered a welding power source and the necessary equipment to perform the welding operation, as indicated by the dashed box in fig. 2); and
the industrial computer is connected with the walking servo driver, the wire feeding servo driver, the welding gun up-and-down adjusting stepping driver, the welding gun front-and-back adjusting stepping driver and the welding gun angle adjusting stepping driver through a first bus, and is connected with the digital welding machine through a second bus. Illustratively, in the embodiment shown in FIG. 1, the industrial computer is an industrial tablet computer 16 with a screen.
In an embodiment of the present invention, the first bus and the second bus connecting the industrial computer and each of the servo/stepper driver and the digital welding machine are field buses.
Further, the industrial computer is configured to: setting parameters of a welding process; controlling the welding process; and sending out first to fifth operation instructions according to user operation in the welding process.
Illustratively, an industrial computer is used as a core of control, a walking servo driver, a wire feeding servo driver, a welding gun up-and-down adjusting stepping driver, a welding gun front-and-back adjusting stepping driver, a welding gun angle adjusting stepping driver and a submerged arc welding power supply are used as controlled objects, the industrial computer is connected with each controlled object through a field bus (RS-485/DeviceNet) and is in digital communication with each controlled object, mutual data interaction is realized, sensors such as current, voltage, speed and the like are avoided, the structure of a control system is simplified, and meanwhile, the wiring complexity of field equipment is avoided.
The walking servo driver is connected with the industrial computer through an RS-485 bus, and drives the walking servo motor 111 to operate by receiving an operation instruction of the industrial computer, so as to drive the walking mechanism 11 to move, and simultaneously feeds back the motion information to the walking servo driver, and the walking servo driver compares the received information fed back by the walking servo motor 111 with the operation instruction of the industrial computer, so as to achieve uniform motion. The running mechanism 11 drives the whole welding trolley 110 to move along the direction of the welding seam, so that the adjustment and control of the welding speed in the welding process are realized.
The wire feeding servo driver is also connected with the industrial computer through an RS-485 bus, and drives the wire feeding servo motor 121 to operate by receiving an operation instruction of the industrial computer, so as to achieve the operation of feeding, returning and the like of a welding wire.
In one embodiment of the present invention, the wire feed servo drive has a manual mode and an automatic mode. Illustratively, in the non-welding process, a manual mode is adopted to realize inching adjustment of the welding wire, such as: inching wire feeding and inching wire withdrawing functions; and in the welding process, the wire feeding servo driver adopts an automatic mode, when the system detects the welding starting operation, the system can automatically feed the welding wire, and when a welding stopping operation instruction is received, the system can automatically stop the feeding of the welding wire and perform the wire drawing back operation according to the set parameters. Similarly, the wire feeder 12 can achieve very stable wire feed based on feedback regulation of the wire feed servo motor 121 itself.
The welding gun up-and-down adjusting stepping driver, the welding gun front-and-back adjusting stepping driver and the welding gun angle adjusting stepping driver are connected with the industrial computer through RS-485 buses. Three actuators with different adjustment functions correspond to three mechanisms: a welding gun up-and-down adjusting mechanism 13, a welding gun front-and-back adjusting mechanism 14 and a welding gun angle adjusting mechanism. The three mechanisms are independent of each other for adjusting the spatial position of the welding gun 17 with respect to the welding workpiece, the angle at which the welding wire is fed, and the like.
Illustratively, the welding gun up-and-down adjustment stepping driver drives the welding gun up-and-down adjustment stepping motor 131 to operate, so as to drive the welding gun up-and-down adjustment mechanism 13 to move up and down, thereby adjusting the position of the welding gun 17 relative to the center of the welding seam; the welding gun forward and backward adjusting stepping driver drives the welding gun forward and backward adjusting stepping motor 141 to operate to drive the welding gun forward and backward adjusting mechanism 14 to move, so that the distance between the welding gun 17 and a welding workpiece is adjusted; the welding gun angle adjusting stepping driver drives the welding gun angle adjusting stepping motor to operate to drive the welding gun angle adjusting mechanism to move, so that the angle of the welding wire fed into the welding pool through the welding gun 17 to the welding pool is adjusted. The three stepping motors are all used for adjusting the relative position of the welding gun 17 and all can work in a manual mode.
In the embodiment of the present invention shown in FIG. 2, the digital welder has a DeviceNet communication interface and is connected to the industrial computer through a DeviceNet master station communication circuit.
In an exemplary embodiment, the digital welding machine is provided with a DeviceNet communication interface as a welding power supply, the welding machine is connected to a DeviceNet master station communication circuit through a DeviceNet bus, the DeviceNet master station communication circuit is connected to an industrial computer, the adjustment and control of parameters of the welding machine, a welding mode and welding start and stop are realized through the industrial computer, and meanwhile, real-time parameters output by the welding power supply are obtained through the bus.
The industrial computer is loaded with automatic control software as the core of the control system, and realizes setting and adjustment of all parameters of the submerged arc automatic transverse welding equipment 10 shown in fig. 1 and control of equipment functions, specifically including the following.
The submerged arc automatic cross welding control system 20 can set the working mode of the submerged arc welding power supply, i.e. CC/CV, and at the same time automatically match the corresponding set parameters. When the CV (constant voltage) mode is set, the control system 20 directly sets a welding voltage value, does not need to set a welding current value, directly matches the current value by controlling a welding power supply (namely, a digital welding machine), and sets a wire feeding speed value in the welding process, so that the system feeds a welding wire in a constant-speed wire feeding mode; when the mode is set to CC (constant current) mode, the control system 20 directly sets the welding current value without setting the welding voltage value, and the system feeds the welding wire in a variable speed feeding manner.
The submerged arc automatic cross welding control system 20 is provided with an expert database, and an operator can perform welding according to welding conditions, such as: the specification and model of the base material, the specification and model of the welding material, etc. are recorded in the control system, the control system 20 can automatically match the existing relevant process parameters, and give the optimal welding parameters and control strategies matched with the parameters, including the working mode of the welding power supply, the matching relationship between the parameter output of the welding power supply and the wire feeding speed, etc. Meanwhile, aiming at multilayer multi-pass welding, in the welding process, the system automatically matches expert parameters according to the number of welded layers, and meanwhile, for the applied expert parameters, an operator can finely adjust related parameters according to the actual welding condition so as to ensure that good welding quality is obtained.
The submerged automatic transverse welding control system 20 has the functions of collecting and recording welding process data in real time, after the welding process is started, the control system starts to collect real-time welding process parameters such as welding current, welding voltage, welding speed, wire feeding speed, welding heat input and the like according to a set frequency (default to 1Hz), and after the welding is finished, the control system automatically stops collecting and recording the data and generates a corresponding recording file in the background. Furthermore, a corresponding data statistical report is generated according to the recorded real-time parameters, an operator can review the real-time welding data in the control system, and for various generated reports, a technician can send or copy files to an office computer for data analysis or archiving. By adopting the working mode, the construction records on site can be reduced, the recording accuracy is improved, and when the welding seam detection has the welding defect, the related welding parameters can be traced, so that the analysis and the judgment of the welding defect are facilitated.
In order to better understand the automatic control system of the transverse submerged arc welding equipment, the initialization flow diagram of the automatic control system 20 of the transverse submerged arc welding equipment shown in fig. 2 is described below according to fig. 3.
As shown in fig. 3, after the main power switch is turned on, the welding power supply (i.e., the digital welding machine), the walking servo driver, the wire feeding servo driver, the welding gun up-and-down (shown as up-and-down in fig. 3) adjustment stepping driver, the welding gun front-and-back adjustment stepping driver, the welding gun angle adjustment stepping driver, and the industrial computer all perform power-on standby operations.
And after the initialization is finished, entering a main operation interface of the control system, wherein the main operation interface is provided with an adjusting button of each mechanism and is mainly used for adjusting the position of each mechanism relative to the welding seam, and meanwhile, the interface is provided with a welding starting button and a welding stopping button and is used for controlling the starting and stopping of the welding process.
Specifically, for the welding power supply (i.e. the digital welder) and each driver, after initialization, the operation of waiting for the communication command is executed, and after receiving the command, the data is sent, otherwise, the operation of waiting for the communication command is continued. For an industrial computer, after the industrial computer is powered on, the control program is first run to perform communication interface initialization, and then sends communication commands to the welding power supply (i.e., digital welder) and the drivers, and waits for a response. And after receiving the response, the data sending or data reading device carries out the operations of further receiving data input, controlling object response and/or executing data display, and otherwise, the communication command is continuously sent until the response is received.
Fig. 4 is a control flow diagram of an automatic control system for the submerged arc cross welding equipment shown in fig. 2.
In the embodiment shown in fig. 4, the manner in which the industrial computer sets the welding process parameters includes: receiving the setting of a user on welding process parameters; and matching welding process parameters by using a preset expert database according to the input parent metal information and welding material information.
In the embodiment of the invention shown in fig. 4, the welding process parameters include operating mode, welding current, welding voltage, welding speed, and wire feed speed. For example, as shown in fig. 4, in the parameter setting portion, the operator may set the parameters in the welding process separately on the control system operation interface. The set parameters may include: parameters such as the working mode of a welding power supply, welding current, welding voltage, welding speed, wire feeding speed and the like can be recorded, and meanwhile, parameter information such as specification and model of base metal and specification and model of welding materials can be recorded, so that data acquisition in the welding process is facilitated.
Preferably, in an embodiment of the present invention, the industrial computer is further configured to match a control strategy matched with the welding process parameters by using a preset expert database according to the input parent metal information and welding material information.
An operator can use an expert parameter function built in the control system, and in an expert parameter interface, the operator can input information such as specification and model of base metal, specification and model of welding material according to welding conditions, the control system can automatically match the existing relevant process parameters, and give the optimal welding parameters and control strategies matched with the parameters, including the matching relation between the working mode of the welding power supply, the parameter output of the welding power supply and the wire feeding speed, and the like.
Meanwhile, aiming at multilayer multi-pass welding, the expert parameters can be a group of expert parameter packages, in the welding process, the system can automatically match the expert parameters corresponding to the number of layers according to the number of welded layers, and under the condition of using the expert parameters, an operator can finely adjust the used parameters according to the actual welding condition so as to ensure that good welding quality is obtained.
In the embodiment of the present invention shown in fig. 4, the welding process includes an arc initiation subroutine, a welding control subroutine, and an arc extinction control subroutine.
After the parameters are set, an operator only needs to click a start button on an interface of the control system, the equipment starts to perform welding output, and the system automatically triggers an arc ignition subprogram.
Specifically, a control flow diagram of an arc starting subprogram is shown in fig. 5, after the starting of the program, the slow wire feeding is started first, the walking is started, the welding current and voltage are input, the arc starting is prepared, the normal wire feeding is executed after the arc starting is successful, otherwise, the welding current and voltage are continuously input until the arc starting is successful.
As shown in fig. 4, when the arc striking is successful, the welding control subroutine is entered, the system and the equipment are in the welding state, and in the welding state, the operator can finely adjust the welding parameters according to the actual situation, and when the welding is completed, the operator only needs to click a stop button on the interface of the control system, and the control system automatically enters the arc extinguishing control stage to complete the arc extinguishing.
Specifically, as shown in fig. 6, after the welding is stopped, the wire feeding is stopped, the welding current and the welding voltage are controlled to stop outputting, and the arc quenching process is completed.
Preferably, in an embodiment of the present invention, the industrial computer is further configured to collect welding process parameters and generate a record file; and generating a data statistical report according to the record file.
After the welding process is started, the control system starts to collect welding process parameters such as real-time welding current, welding voltage, welding speed, wire feeding speed, welding heat input and the like according to a set frequency (default to 1Hz), after the welding is finished, the control system automatically stops data collection and recording, generates a corresponding recording file in the background, generates a corresponding data statistical report according to the recorded real-time parameters, can review real-time welding data in the control system by an operator, and can send or copy files to an office computer for data analysis or archiving by technicians for various generated reports; meanwhile, when welding defects exist in the welding seam detection, related welding parameters can be traced, and the analysis and the judgment of the welding defects are facilitated.
Having thus described the basic concept, it will be apparent to those skilled in the art that the foregoing disclosure is by way of example only, and is not intended to limit the present application. Various modifications, improvements and adaptations to the present application may occur to those skilled in the art, although not explicitly described herein. Such modifications, improvements and adaptations are proposed in the present application and thus fall within the spirit and scope of the exemplary embodiments of the present application.
Also, this application uses specific language to describe embodiments of the application. Reference throughout this specification to "one embodiment," "an embodiment," and/or "some embodiments" means that a particular feature, structure, or characteristic described in connection with at least one embodiment of the present application is included in at least one embodiment of the present application. Therefore, it is emphasized and should be appreciated that two or more references to "an embodiment" or "one embodiment" or "an alternative embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, some features, structures, or characteristics of one or more embodiments of the present application may be combined as appropriate.
Aspects of the present application may be embodied entirely in hardware, entirely in software (including firmware, resident software, micro-code, etc.) or in a combination of hardware and software. The above hardware or software may be referred to as "data block," module, "" engine, "" unit, "" component, "or" system. The processor may be one or more Application Specific Integrated Circuits (ASICs), Digital Signal Processors (DSPs), digital signal processing devices (DAPDs), Programmable Logic Devices (PLDs), Field Programmable Gate Arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, or a combination thereof. Furthermore, aspects of the present application may be represented as a computer product, including computer readable program code, embodied in one or more computer readable media. For example, computer-readable media may include, but are not limited to, magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips … …), optical disks (e.g., Compact Disk (CD), Digital Versatile Disk (DVD) … …), smart cards, and flash memory devices (e.g., card, stick, key drive … …).
The computer readable medium may comprise a propagated data signal with the computer program code embodied therein, for example, on a baseband or as part of a carrier wave. The propagated signal may take any of a variety of forms, including electromagnetic, optical, and the like, or any suitable combination. The computer readable medium can be any computer readable medium that can communicate, propagate, or transport the program for use by or in connection with an instruction execution system, apparatus, or device. Program code on a computer readable medium may be propagated over any suitable medium, including radio, electrical cable, fiber optic cable, radio frequency signals, or the like, or any combination of the preceding.
Similarly, it should be noted that in the preceding description of embodiments of the application, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure aiding in the understanding of one or more of the embodiments. This method of disclosure, however, is not intended to require more features than are expressly recited in the claims. Indeed, the embodiments may be characterized as having less than all of the features of a single embodiment disclosed above.
Numerals describing the number of components, attributes, etc. are used in some embodiments, it being understood that such numerals used in the description of the embodiments are modified in some instances by the use of the modifier "about", "approximately" or "substantially". Unless otherwise indicated, "about", "approximately" or "substantially" indicates that the number allows a variation of ± 20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximations that may vary depending upon the desired properties of the individual embodiments. In some embodiments, the numerical parameter should take into account the specified significant digits and employ a general digit preserving approach. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the range are approximations, in the specific examples, such numerical values are set forth as precisely as possible within the scope of the application.
Although the present application has been described with reference to the present specific embodiments, it will be recognized by those skilled in the art that the foregoing embodiments are merely illustrative of the present application and that various changes and substitutions of equivalents may be made without departing from the spirit of the application, and therefore, it is intended that all changes and modifications to the above-described embodiments that come within the spirit of the application fall within the scope of the claims of the application.
Claims (9)
1. An automatic control system of submerged arc horizontal welding equipment, submerged arc horizontal welding equipment includes running gear, is used for driving running servo motor, wire feeding mechanism of running gear motion, is used for driving wire feeding servo motor, welder vertical adjustment mechanism of wire feeding mechanism moving, is used for driving welder vertical adjustment step motor that welder vertical adjustment mechanism reciprocated, welder front and back adjustment mechanism, is used for driving welder front and back adjustment step motor, welder angle adjustment mechanism and is used for driving welder angle adjustment step motor of welder angle adjustment mechanism moving around the welder front and back adjustment mechanism back-and-forth movement, wherein automatic control system includes:
the walking servo driver is configured to drive the walking servo motor to drive the walking mechanism to move according to a first operation instruction, and receive motion information fed back by the walking servo motor;
the wire feeding servo driver is configured to drive the wire feeding servo motor to drive the wire feeding mechanism to operate according to a second operation instruction so as to feed and retreat the welding wire;
the welding gun up-and-down adjusting stepping driver is configured to drive the welding gun up-and-down adjusting stepping motor to drive the welding gun up-and-down adjusting mechanism to move up and down according to a third operating instruction, so that the position of the welding gun relative to the center of a welding seam is adjusted;
the welding gun front-back adjusting stepping driver is configured to drive the welding gun front-back adjusting stepping motor to drive the welding gun front-back adjusting mechanism to move back and forth according to a fourth operating instruction, so that the distance between the welding gun and a welding workpiece is adjusted;
the welding gun angle adjusting stepping driver is configured to drive the welding gun angle adjusting stepping motor to drive the welding gun angle adjusting mechanism to move according to a fifth operation instruction, so that the angle of the welding wire fed into the welding pool through the welding gun into the welding pool is adjusted;
a digital welder; and
the industrial computer is connected with the walking servo driver, the wire feeding servo driver, the welding gun up-and-down adjusting stepping driver, the welding gun front-and-back adjusting stepping driver and the welding gun angle adjusting stepping driver through a first bus, and is connected with the digital welding machine through a second bus, and the industrial computer is configured as follows: setting parameters of a welding process; controlling the welding process; and sending the first to fifth operation instructions according to user operation in the welding process.
2. The automatic control system of submerged arc cross welding equipment according to claim 1, characterized in that the welding process parameters comprise working mode, welding current, welding voltage, welding speed and wire feed speed.
3. The automatic control system of transverse submerged arc welding equipment according to claim 1, characterized in that the welding process comprises an arc starting subprogram, a welding control subprogram and an arc extinguishing control subprogram.
4. The automated control system for transverse submerged arc welding equipment according to claim 1, wherein the wire feed servo drive has a manual mode and an automated mode.
5. The automatic control system of transverse submerged arc welding equipment according to claim 1, wherein the manner in which the industrial computer sets the welding process parameters comprises:
receiving the setting of a user on welding process parameters; and
and matching welding process parameters by using a preset expert database according to the input parent metal information and the input welding material information.
6. The automatic control system of submerged arc cross welding equipment according to claim 5, characterized in that the industrial computer is further configured to match out a control strategy matching the welding process parameters using the expert database based on the entered parent material information and welding material information.
7. The automated control system for transverse submerged arc welding equipment according to claim 1, wherein the industrial computer is further configured to:
collecting welding process parameters and generating a recording file; and
and generating a data statistical report according to the record file.
8. The automated control system of transverse submerged arc welding equipment according to claim 1, wherein the first and second buses are field buses.
9. The automated control system for submerged arc cross welding apparatus of claim 1, wherein the digital welder has a DeviceNet communication interface, the digital welder being connected to the industrial computer through a DeviceNet master station communication circuit.
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Application publication date: 20210226 |