CN112756743A - Automatic control device and control method for contact force-to-displacement conversion of electric spark deposition overlaying welding - Google Patents

Automatic control device and control method for contact force-to-displacement conversion of electric spark deposition overlaying welding Download PDF

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CN112756743A
CN112756743A CN202110178440.6A CN202110178440A CN112756743A CN 112756743 A CN112756743 A CN 112756743A CN 202110178440 A CN202110178440 A CN 202110178440A CN 112756743 A CN112756743 A CN 112756743A
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contact force
displacement
electrode
workpiece
floating
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CN112756743B (en
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韩红彪
李梦楠
李世康
刘何
杨鑫
侯玉杰
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Henan University of Science and Technology
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Henan University of Science and Technology
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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
    • 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
    • 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 relates to an automatic control device and a control method for converting contact force into displacement by electric spark deposition surfacing welding, wherein the automatic control device mainly comprises a feeding mechanism, a floating elastic mechanism, a gun clamping mechanism, a welding gun, an electric control system and the like, the contact force between an electrode and a workpiece is converted into the displacement of a floating sliding table, a non-contact displacement sensor is adopted for detection, the conversion from tension and pressure measurement to displacement measurement is realized, the strength of a mechanical system is improved, and the measurement of micro contact force can be realized; the contact force between the electrode and the workpiece is determined according to the displacement of the floating sliding table, the electrode is controlled to move along the axis of the electrode by the controller and the feeding mechanism, closed-loop control of the contact force is achieved, vibration between the electrode and the workpiece can be reduced by spring damping of the floating elastic mechanism, and the stability and reliability of automatic control of the contact force between the electrode and the workpiece in the deposition process are remarkably improved.

Description

Automatic control device and control method for contact force-to-displacement conversion of electric spark deposition overlaying welding
Technical Field
The invention relates to the technical field of electric spark deposition overlaying welding, in particular to an automatic control device and a control method for contact force-to-displacement conversion of the electric spark deposition overlaying welding.
Background
The electric spark processing is a processing method for removing materials, the electric spark deposition overlaying welding is a surface strengthening technology developed on the basis of the electric spark processing, special materials can be deposited and overlaid on the surface of a workpiece material, the hardness, the wear resistance, the heat resistance, the corrosion resistance, the fatigue strength, the service life and the like of the workpiece can be improved, and surface defects such as scratches, pitting corrosion, out-of-tolerance and the like on the surface of a precision mechanical part can be repaired.
Unlike the spark erosion removal process, the spark deposition bead welding process requires the electrode to be in constant contact with the workpiece for discharge and deposition bead welding. The process of automatic electric spark deposition is that an electrode moves on the surface of a workpiece along a certain track, and meanwhile, the electrode and the workpiece are ensured to be continuously discharged and deposited in a contact state, and the deposition layer is finished layer by layer. The contact state of the electrode and the workpiece directly influences the discharge mechanism and the mass transfer mechanism of the electrode, so that the quality and the production efficiency of a deposited layer are influenced.
In the process of electric spark deposition overlaying welding, the electrode and the workpiece need to be in continuous contact, when the contact force between the electrode and the workpiece is different, the contact area between the electrode and the workpiece is also different, and the size of the contact area directly influences the current density in the deposition process, so that the discharge and mass transfer processes are influenced, and the influence of the contact force on the contact state of the electrode and the workpiece is larger.
The electric spark deposition overlaying technology has many advantages, but the electric spark deposition overlaying technology is mainly applied to the field of repair and is not applied to batch production, and the reason for the electric spark deposition overlaying technology is that the automation technology of the electric spark deposition overlaying technology is not perfect and can only be completed by manual operation; manual operation is high in labor intensity, control over contact force is high in randomness, reliability and stability are not achieved, and quality and production efficiency of a deposition layer cannot be guaranteed; therefore, the automation of the electric spark deposition overlaying welding needs to control the relative motion track between the electrode and the workpiece, and the control of the contact force between the electrode and the workpiece is also key.
In order to obtain a high-quality coating, the contact force between the electrode and the workpiece cannot be too great, generally around 0.5N-2N; due to the fact that the contact surface of the electrode and the workpiece is uneven, short-circuit adhesion occurs between the electrode and the workpiece, and the like, when the electrode and the workpiece move relatively, large vibration can be generated, the impact force of the electrode and the workpiece is sometimes far larger than the contact force of the electrode and the workpiece, and the small force sensor is small in size and rigidity, so that the force sensor used for contact force control is often overloaded and fails. Because the friction force of the sliding part of the mechanical mechanism required for realizing the automatic control of the contact force is greater than the contact force between the electrode and the workpiece, the control precision of the contact force is influenced, and the control requirement cannot be met.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide an automatic control device and a control method for contact force-to-displacement conversion of electric spark deposition overlaying welding, which are used for solving the problems of precise control of tiny contact force between an electrode and a workpiece and electrode vibration in the electric spark deposition overlaying welding process, can precisely control the contact force between the electrode and the workpiece and have a vibration reduction function.
In order to achieve the purpose, the invention adopts the technical scheme that:
an automatic control device for contact force-to-displacement conversion of electric spark deposition surfacing comprises a mechanical system and an electric control system, wherein the mechanical system comprises a feeding mechanism, a floating elastic mechanism, a gun clamping mechanism and a welding gun; the feeding mechanism mainly comprises a feeding screw rod, a feeding sliding table and a feeding base; the floating elastic mechanism mainly comprises an upper base, an optical axis, a linear bearing, a lower base, a spring and a floating sliding table, wherein the upper base and the lower base are parallel to each other and are connected through the optical axis;
the mechanical system further comprises an adjusting plate A, an adjusting plate B and an adjusting plate C, the gun clamping mechanism is installed on the side face of a floating sliding table of the floating elastic mechanism through the adjusting plate C, the floating elastic mechanism is installed on the side face of the sliding table of the feeding mechanism through the adjusting plate B, the feeding mechanism is installed on the corresponding position of the electric spark deposition surfacing welding device through the adjusting plate A, the welding gun is fixed on the gun clamping mechanism, and an electrode is installed on the welding gun; the axes and the installation plane of the feeding mechanism and the welding gun are vertical to the horizontal plane; when the included angle between the welding gun and the workpiece is changed, the axis of the feeding mechanism and the axis of the welding gun are always kept parallel by rotating the adjusting plate A, the adjusting plate B and the adjusting plate C for adjustment, and the axis of the floating elastic mechanism is always kept vertical;
the electric control system comprises a controller, an A/D module, a displacement sensor, a stepping motor and a driver, wherein the displacement sensor is connected with the controller through the A/D module, calibrated contact force-displacement table data are stored in the controller, PID control software is arranged in the controller, an output interface of the controller is connected with the driver of the stepping motor, and the stepping motor is connected with a feeding mechanism.
Further, the included angle between the welding gun and the horizontally placed workpiece can be adjusted by a specific angle, and the specific angle comprises: 0 °, 15 °, 30 °, 45 °, 60 °, 75 °, 90 °.
Further, in the mechanical system, neglecting the frictional resistance of the optical axis to the floating slide table, the relationship between the contact force of the electrode and the workpiece and the displacement of the floating slide table is: fNiK (z0-zi), where z0 denotes the displacement of the floating slide at time t0, i.e., when the electrode workpiece is not in contact with it, zi denotes the displacement of the floating slide at time ti, and FNiAnd k is the elastic coefficient of the spring, and represents the supporting force of the workpiece on the electrode at the moment ti, namely the contact force between the electrode and the workpiece.
Further, when the relation of contact force-displacement is calibrated, the supporting force of the workpiece to the electrode, namely the contact force between the electrode and the workpiece, is directly measured by arranging a weighing sensor below the workpiece, the displacement of the floating sliding table is obtained through measurement of the displacement sensor, and therefore contact force-displacement corresponding data are obtained and stored in the controller.
By using the control method of the automatic control device for converting the contact force of the electric spark deposition overlaying welding into the displacement, the displacement table data of the floating sliding table corresponding to the calibrated contact force is stored in a controller of an electric control system, and meanwhile, the contact force required to be automatically maintained in the electric spark deposition process is set; in the electric spark deposition process, a controller continuously and periodically detects the input of a displacement sensor, the displacement data is converted into contact force according to contact force-displacement corresponding data, the contact force is compared with a set contact force value, the difference value of the contact force and the displacement is compared with an output signal generated by PID control software in the controller, a driver controls the rotation of a stepping motor, a feeding mechanism drives a welding gun and an electrode to move along the axis of the welding gun and the electrode, the electrode in contact with a workpiece pushes a floating sliding table to move correspondingly at the moment, so that the contact force between the electrode and the workpiece is changed correspondingly, and the automatic closed-loop control of the contact force is realized.
Has the advantages that:
1. the invention arranges a floating elastic mechanism between a feeding mechanism and a welding gun of the electric spark deposition overlaying welding, skillfully converts the contact force between an electrode and a workpiece into the displacement of a floating sliding table, adopts a non-contact displacement sensor to detect the displacement of the floating sliding table, realizes the conversion from tension pressure measurement to displacement measurement, can determine the contact force between the electrode and the workpiece according to the displacement of the floating sliding table after calibration, and controls the electrode to move along the axis by using a controller and the feeding mechanism, thereby realizing the closed-loop control of the contact force.
2. The invention does not adopt a force sensor but adopts a non-contact displacement sensor to measure the contact force, thereby not only improving the strength of a mechanical system, but also realizing the measurement of the micro contact force and obviously improving the reliability of the automatic control device of the contact force between the electrode and the workpiece.
3. The floating elastic mechanism adopts the ball linear bearing to be matched with the optical axis, and has smaller friction coefficient; the optical axis of the floating elastic mechanism is always in a vertical state, and the positive pressure between the floating sliding table and the optical axis is small, so that the friction between the floating sliding table and the optical axis is small, the automatic control of the small contact force between the electrode and the workpiece is ensured, and the control precision of the contact force can reach 0.5N.
4. The floating elastic mechanism has a vibration reduction function, and the spring damping of the floating elastic mechanism can reduce the vibration between the electrode and the workpiece and improve the stability of the deposition process.
5. The invention can adjust the included angle between the electrode and the workpiece in stages. When the included angle is adjusted, the optical axis of the floating elastic mechanism is always in a vertical state, and the axis of the feeding mechanism is always parallel to the axes of the welding gun and the electrode. When the electrode is damaged, the controller and the feeding mechanism drive the welding gun to move forwards along the axis of the welding gun, so that not only can the contact force be kept stable, but also the contact position of the electrode and a workpiece is kept unchanged, and the control precision of the movement position of the electrode in the automatic deposition process is ensured.
Drawings
FIG. 1 is an overall schematic of the present invention;
FIG. 2 is a force diagram of the floating spring mechanism with the weld gun out of contact with the workpiece;
FIG. 3 is a force diagram of the floating spring mechanism of the present invention during contact force-displacement calibration;
FIG. 4 is a schematic diagram of the contact force closed loop control of the present invention;
FIG. 5 is a mechanical portion schematic of an embodiment of the present invention;
FIG. 6 is a front view of an embodiment of the present invention with the torch vertical to the workpiece.
Reference numerals: 1. the device comprises a feeding mechanism, 2, adjusting plates A and 3, adjusting plates B and 4, a spring, 5, an upper base, 6, a displacement sensor, 7, a gun clamping mechanism, 8, adjusting plates C and 9, a floating sliding table, 10, a lower base, 11, a welding gun, 12, a motor, 13, a workpiece, 14, an optical axis, 15, a linear bearing, 16, an electric control system, 17, a stepping motor, 18, a weighing sensor, 19, a stand column, 20, a base, 21, an X-axis sliding table, 22, a Y-axis sliding table, 23 and a Z-axis sliding table.
Detailed Description
The invention is described in further detail below with reference to the figures and specific examples.
As shown in fig. 1, an automatic control device for contact force-to-displacement conversion of electric spark deposition overlaying welding mainly comprises a mechanical system and an electric control system 16, wherein the mechanical system comprises a feeding mechanism 1, a floating elastic mechanism, a gun clamping mechanism 7 and a welding gun 11; the feeding mechanism 1 mainly comprises a feeding screw, a feeding sliding table and a feeding base, wherein the feeding screw is arranged on the feeding base, and the feeding sliding table is driven to move through the rotation of the feeding screw; the floating elastic mechanism mainly comprises an upper base 5, an optical axis 14, a linear bearing 15, a lower base 10, a spring 4 and a floating sliding table 9, wherein the upper base 5 and the lower base 10 are parallel to each other and are connected through a left optical axis 14 and a right optical axis 14 (the optical axis in the invention refers to an axis with a smooth surface), the floating sliding table 9 is arranged between the upper base 5 and the lower base 10 and is arranged on the optical axis 14 in a penetrating mode through the linear bearing 15 and can move up and down along the optical axis 14, the spring 4 connects the floating sliding table 9 with the upper base 5 together, and a non-contact displacement sensor 6 is arranged on the lower surface of the upper base 5 and used for measuring the up-and-down displacement.
The mechanical system further comprises an adjusting plate A2, an adjusting plate B3 and an adjusting plate C8, wherein the adjusting plate A2, the adjusting plate B3 and the adjusting plate C8 are all vertically arranged, the gun clamping mechanism 7 is mounted on the side face of the floating sliding table 9 of the floating elastic mechanism through an adjusting plate C8, and the angle of the gun clamping mechanism 7 can be adjusted through rotating the adjusting plate C8; the floating elastic mechanism is arranged on the side surface of a feeding sliding table of the feeding mechanism 1 through an adjusting plate B3, the angle of the floating elastic mechanism can be adjusted by rotating an adjusting plate B3, the feeding mechanism 1 is arranged on the corresponding part of the electric spark deposition surfacing device through an adjusting plate A2, and the angle of the feeding mechanism 1 can be adjusted by rotating an adjusting plate A2; the welding gun 11 is fixed on the gun clamping mechanism 7, the electrode 12 is arranged on the welding gun 11, and the included angle between the welding gun 11 and the horizontally placed workpiece 13 can be adjusted by a specific angle, wherein the specific angle comprises: 0 °, 15 °, 30 °, 45 °, 60 °, 75 °, 90 °.
The axes and the installation plane of the feeding mechanism 1 and the welding gun 11 are vertical to the horizontal plane, when the included angle between the welding gun 11 and the workpiece 13 is changed, the adjustment is carried out by rotating the adjusting plate A2, the adjusting plate B3 and the adjusting plate C8, so that the axis of the feeding mechanism 1 and the axis of the welding gun 11 are always kept parallel, and the optical axis 14 of the floating elastic mechanism is always kept vertical.
The electric control system 16 mainly comprises a controller, an A/D module, a displacement sensor 6, a stepping motor 17 and a driver thereof, wherein the displacement sensor 6 is connected with the controller through the A/D module, the controller stores calibrated contact force-displacement table data, PID control software is arranged in the controller, an output interface of the controller is connected with the driver of the stepping motor 17, the stepping motor 17 is connected with the feeding mechanism 1 and drives a feeding screw to drive the feeding sliding table to move, and the controller is also in communication connection with an upper computer.
Fig. 2 is a force diagram of the floating elastic mechanism when the electrode 12 is not in contact with the workpiece 13 in the present invention, at time t0, the electrode 12 on the welding gun 11 is not in contact with the workpiece 13, the welding gun 11 and the floating slide 9 will move downward under the action of gravity, and when the elastic force of the spring 4, the friction force between the floating slide 9 and the two optical axes 14, and the gravity of the welding gun 11 and the floating slide 9, etc. reach equilibrium, the force equilibrium formula is as follows:
G＝Fp0+FfL0+FfR0＝kΔx0+FfL0+FfR0 (1)
in formula (1): g is the gravity of floating parts such as a welding gun and a floating slide table, Fp0Is the tension of the spring on the floating slide at time t0, FfL0Is the frictional resistance of the left optical axis to the floating slide table at time t0, FfR0The frictional resistance of the right optical axis to the floating slide table at the time t0, k is the elastic coefficient of the spring, and Δ x0 is the elongation of the spring at the time t 0.
The length of the spring when the spring is pulled is x0, and the displacement sensor detects that the displacement of the floating sliding table is z 0.
FIG. 3 is a force diagram of the floating member of the present invention during contact force-displacement calibration; at time ti, the electrode 12 on the welding gun 11 contacts the workpiece 13, the contact force between the electrode 12 and the workpiece 13 is the upward supporting force of the workpiece 13 on the electrode 12, and the formula for achieving the force balance at this time is as follows:
G＝FNi+Fpi+FfLi+FfRi＝FNi+kΔxi+FfLi+FfRi (2)
in formula (2): fNiIs the supporting force of the workpiece to the electrode at time ti, FpiSpring-to-floating slide at time tiTensile force, FfLiIs the frictional resistance of the left optical axis to the floating sliding table at time ti, FfRiIs the frictional resistance of the right optical axis to the floating sliding table at the time ti, and Δ xi is the elongation of the spring at the time ti.
The length of the spring when the spring is pulled is xi, and the displacement sensor detects that the displacement of the floating sliding table is zi.
Subtracting formula (2) from formula (1) gives:
FNi＝k(Δx0-Δxi)+(FfL0+FfR0)-(FfLi+FfRi) (3)
＝k(x0-xi)+(FfL0+FfR0)-(FfLi+FfRi)
＝k(z0-zi)+(FfL0+FfR0)-(FfLi+FfRi)
the floating elastic mechanism of the invention adopts a ball linear bearing between the floating sliding table 9 and the optical axis 14, and the friction coefficient between the ball linear bearing and the optical axis 14 is small and is about 0.002-0.003; in view of the assembly problem, the coefficient of friction of the two optical axes 14 against the floating slide table 9 is about 0.01; because the optical axis 14 of the floating elastic mechanism is vertically arranged, the positive pressure between the linear bearing 15 and the optical axis 14 is also very small (less than 10N), so the frictional resistance of the two optical axes 14 to the floating sliding table 9 is not more than 0.1N, which can be ignored, and then the formula (3) can be simplified as follows:
FNi＝k(z0-zi) (4)
i.e. the supporting force F of the workpiece 13 against the electrode 12NiDepending on the displacement zi of the floating slide 9, the contact force between the workpiece 13 and the electrode 12 corresponds one-to-one to the displacement of the floating slide 9.
As shown in fig. 3, in calibration, a load cell 18 is installed below the workpiece 13 at the position where the electrode 12 contacts the workpiece 13, and the supporting force of the workpiece 13 to the electrode 12, i.e., the contact force between the electrode 12 and the workpiece 13, is directly measured, and at the same time, the displacement sensor 6 measures the displacement of the floating slide 9, and the corresponding relationship between the contact force and the displacement of the floating slide 9 can be obtained, as shown in table 1 below.
TABLE 1 Displacement of the floating slide 9 corresponding to different contact forces
Figure BDA0002940731680000071
FIG. 4 is a schematic diagram of the contact force closed-loop control of the present invention, and the method for automatically controlling the contact force in the process of electric spark deposition overlaying welding by using the automatic control device of the present invention comprises: and storing the displacement table data of the floating sliding table corresponding to the calibrated contact force in a controller, and setting the contact force required to be automatically maintained in the electric spark deposition process. In the electric spark deposition process, a controller continuously and periodically detects the input of a displacement sensor, the displacement is converted into contact force according to contact force-displacement corresponding table data, then the contact force is compared with a set contact force value, the difference value generates an output signal through PID control software, a driver controls the rotation of a stepping motor, a feeding mechanism drives a welding gun and an electrode to move along the axis of the welding gun and the electrode, at the moment, a workpiece in contact with the electrode pushes an elastic sliding table to move correspondingly through the electrode, so that the contact force between the electrode and the workpiece changes correspondingly, and the automatic closed-loop control of the contact force is realized.
For example: the controller obtains the displacement of the floating sliding table in real time through the non-contact displacement sensor, and the contact force between the electrode and the workpiece can be obtained through the contact force-displacement corresponding relation. In the process of carrying out electric spark deposition overlaying welding, the floating sliding table moves downwards along with the loss of an electrode or the lowering of the surface of a workpiece and other reasons, so that when the contact force is reduced and is smaller than a set value, the controller generates an output signal and drives the feeding sliding table of the feeding mechanism, the floating elastic mechanism and the welding gun which are arranged on the feeding sliding table to move forwards along the axial lines of the feeding mechanism and the welding gun through the driver and the stepping motor, the floating sliding table moves upwards to reduce the displacement of the floating sliding table, namely the contact force between the electrode and the workpiece is increased to reach the set contact force value, and the automatic closed-loop control of the contact force.
Fig. 5 is a schematic diagram of a mechanical part of a specific embodiment of the present invention, wherein fig. 5(b) is a right side view of fig. 5(a), and the embodiment includes a three-dimensional numerical control device and an automatic control device for contact force rotation and displacement of electric spark deposition overlaying, wherein the three-dimensional numerical control device mainly includes an X-axis sliding table 21, a Y-axis sliding table 22, a Z-axis sliding table 23, an upright column 19, a base 20, and a numerical control system, etc., a workpiece 13 is installed on an XY-axis cross sliding table formed by the X-axis sliding table 21 and the Y-axis sliding table 22, and the automatic control device for contact force rotation and displacement of electric spark deposition overlaying of the present invention is installed on the Z-axis sliding table 23 of the three; the electric parameters of deposition are set on the electric spark deposition overlaying power supply, the three-dimensional numerical control device is responsible for controlling the starting and stopping of electric spark discharge and the motion track of the electrode 12 relative to the surface of the workpiece 13 in the automatic electric spark deposition overlaying process, and the automatic control device is responsible for controlling the contact force between the electrode 12 and the workpiece 13 in the automatic deposition process.
The displacement sensor 6 is an ohm dragon Z4W-V25 type laser displacement sensor, the measurement precision can reach 10 micrometers, the non-contact displacement sensor is installed on the upper base 5 of the floating elastic mechanism through a sensor support, and non-contact measurement can be achieved on the displacement of the elastic sliding table; and selecting the supporting force between the measuring electrode 12 of the electronic scale and the workpiece 13 with the precision of 0.001g, calibrating the corresponding relation between the contact force and the displacement of the floating sliding table 9, and obtaining the displacement table data of the floating sliding table 9 corresponding to different contact forces.
The feeding mechanism 1 selects a silver KK50 type lead screw sliding table module, the stepping motor 17 selects a Ralsay 42CM08 type stepping motor, and a driver thereof selects a Ralsay DM422S type driver; the controller selects a domestic LK-32MT type PLC which is provided with 10 paths of AD inputs and can be connected with the output of the displacement sensor 6 to obtain the displacement data of the floating sliding table 9; the PLC has 4 high-speed outputs, and can output pulse signals to be connected to the input of a driver of the stepping motor 17 so as to control the rotation of the stepping motor 17 of the feeding mechanism 1.
Under the control of a three-dimensional numerical control system, the Z-axis sliding table 23 controls the welding gun 11 to move downwards, so that the electrode 12 is in contact with the surface of the workpiece 13, electric spark discharge pulses are started, the XY-axis cross sliding table controls the workpiece 13 to do plane linear or curvilinear motion relative to the electrode 12, and deposition and surfacing is performed layer by layer point by point and line by line to form a deposition layer, so that automatic deposition and surfacing of electric sparks is realized. In the automatic electric spark deposition process, when the electrode 12 is consumed or the surface of the workpiece 13 is uneven to cause the change of the contact force, the device can control the automatic feeding of the electrode 12, and simultaneously, the contact force between the electrode 12 and the workpiece 13 is always kept at a set value, the specific control process is shown in fig. 4, and fig. 6 is a front view when the welding gun 11 is vertical to the workpiece 13, namely, the included angle between the welding gun 11 and the horizontally placed workpiece 13 is 90 degrees.
The automatic control device of the invention is a system which can work independently, and can be installed on other mechanical devices (such as a robot) besides a three-dimensional numerical control device in practical use.
The invention adopts the floating elastic mechanism, the change of the contact force between the electrode and the workpiece corresponds to the displacement change of the floating sliding table one by one, the contact force is indirectly measured by measuring the displacement of the floating sliding table, the contact force between the electrode and the workpiece is adjusted by controlling the movement of the floating elastic mechanism through the feeding mechanism, thereby realizing the closed-loop control of the contact force, realizing the accurate control of the micro contact force (0.5N-2N) between the electrode and the workpiece, simultaneously the floating elastic mechanism can play a role of damping and vibration reduction on the vibration of the electrode, the feeding mechanism compensates the change of the contact force after the electrode is consumed, and ensures the stable contact force and the unchanged deposition position, thereby ensuring the quality of the automatic deposition of the electric spark.
Although the present invention has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (5)

1. An automatic control device for contact force-to-displacement conversion of electric spark deposition surfacing welding comprises a mechanical system and an electric control system, and is characterized in that the mechanical system comprises a feeding mechanism, a floating elastic mechanism, a gun clamping mechanism and a welding gun; the feeding mechanism mainly comprises a feeding screw rod, a feeding sliding table and a feeding base; the floating elastic mechanism mainly comprises an upper base, an optical axis, a linear bearing, a lower base, a spring and a floating sliding table, wherein the upper base and the lower base are parallel to each other and are connected through the optical axis;
the mechanical system further comprises an adjusting plate A, an adjusting plate B and an adjusting plate C, the gun clamping mechanism is installed on the side face of a floating sliding table of the floating elastic mechanism through the adjusting plate C, the floating elastic mechanism is installed on the side face of a feeding sliding table of the feeding mechanism through the adjusting plate B, the feeding mechanism is installed on the corresponding position of the electric spark deposition surfacing welding device through the adjusting plate A, the welding gun is fixed on the gun clamping mechanism, and an electrode is installed on the welding gun; the axes and the installation plane of the feeding mechanism and the welding gun are vertical to the horizontal plane; when the included angle between the welding gun and the workpiece is changed, the axis of the feeding mechanism and the axis of the welding gun are always kept parallel by rotating the adjusting plate A, the adjusting plate B and the adjusting plate C for adjustment, and the axis of the floating elastic mechanism is always kept vertical;
the electric control system comprises a controller, an A/D module, a displacement sensor, a stepping motor and a driver, wherein the displacement sensor is connected with the controller through the A/D module, calibrated contact force-displacement table data are stored in the controller, PID control software is arranged in the controller, an output interface of the controller is connected with the driver of the stepping motor, and the stepping motor is connected with a feeding mechanism.
2. An automatic control device for contact force-to-displacement of electric spark deposition overlaying welding according to claim 1, wherein an included angle between a welding gun and a horizontally placed workpiece can be adjusted by a specific angle, and the specific angle comprises: 0 °, 15 °, 30 °, 45 °, 60 °, 75 °, 90 °.
3. Automatic control of contact force rotary displacement of electric spark deposition overlaying welding according to claim 1The device is characterized in that in the mechanical system, neglecting the frictional resistance of the optical axis to the floating slide table, the relationship between the contact force of the electrode and the workpiece and the displacement of the floating slide table is as follows:
Figure DEST_PATH_IMAGE002
wherein, in the step (A), z0 represents the displacement of the floating slide at time t0 when the electrode workpiece is not in contact,zi denotes the displacement of the floating ramp at time ti,F Niand k is the elastic coefficient of the spring, and represents the supporting force of the workpiece on the electrode at the moment ti, namely the contact force between the electrode and the workpiece.
4. An automatic control device for contact force-displacement conversion of electric spark deposition overlaying welding according to claim 1, wherein when calibrating the contact force-displacement relationship, the supporting force of the workpiece to the electrode, namely the contact force between the electrode and the workpiece, is directly measured by arranging a weighing sensor below the workpiece, and the displacement of the floating sliding table is obtained by measuring through a displacement sensor, so that the corresponding data of the contact force-displacement are obtained and stored in the controller.
5. The control method of the automatic control device for the contact force-to-displacement rotation of the electric spark deposition overlaying welding according to claim 1, characterized by comprising the following steps of: storing the displacement table data of the floating sliding table corresponding to the calibrated contact force in a controller of an electric control system, and setting the contact force required to be automatically maintained in the electric spark deposition process; in the electric spark deposition process, a controller continuously and periodically detects the input of a displacement sensor, the displacement data is converted into contact force according to contact force-displacement corresponding data, the contact force is compared with a set contact force value, the difference value of the contact force and the displacement is compared with an output signal generated by PID control software in the controller, a driver controls the rotation of a stepping motor, a feeding mechanism drives a welding gun and an electrode to move along the axis of the welding gun and the electrode, the electrode in contact with a workpiece pushes a floating sliding table to move correspondingly at the moment, so that the contact force between the electrode and the workpiece is changed correspondingly, and the automatic closed-loop control of the contact force is realized.
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