CN113814525A - Pulse welding method and system - Google Patents
Pulse welding method and system Download PDFInfo
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- CN113814525A CN113814525A CN202111275514.4A CN202111275514A CN113814525A CN 113814525 A CN113814525 A CN 113814525A CN 202111275514 A CN202111275514 A CN 202111275514A CN 113814525 A CN113814525 A CN 113814525A
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- 238000003466 welding Methods 0.000 title claims abstract description 71
- 238000000034 method Methods 0.000 title claims abstract description 40
- 238000002844 melting Methods 0.000 claims description 17
- 230000000737 periodic effect Effects 0.000 claims description 17
- 230000008018 melting Effects 0.000 claims description 14
- 238000004364 calculation method Methods 0.000 claims description 5
- 238000010891 electric arc Methods 0.000 claims description 4
- 230000020169 heat generation Effects 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 230000000694 effects Effects 0.000 abstract description 2
- 230000002265 prevention Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000004146 energy storage Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000010355 oscillation Effects 0.000 description 1
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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
- B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
- B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
- B23K9/092—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits characterised by the shape of the pulses produced
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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 a pulse welding method and a pulse welding system. The pulse welding method is used for a welding machine, the welding current in the welding process of the welding machine has a pulse waveform, the waveform comprises a pulse base value stage and a pulse peak value stage, and the method comprises the steps of judging whether the pulse base value stage of the current pulse period has an arc breaking trend or not; when the arc breaking trend is judged, increasing the preset base value current of the pulse base value stage of the current pulse period; judging whether the arc breaking trend of the current pulse period is relieved or not; and reducing the preset peak current of the pulse peak stage of the next pulse period after the arc breaking trend risk is judged to be relieved. The invention can prevent arc breaking during pulse welding, keep the arc length stable and improve the welding effect.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a pulse welding method and a pulse welding system.
Background
In the prior art, when the welding is carried out by small current pulse, the pulse period is usually longer, and the main time is distributed in the period of the basic value. The base current is generally low, usually below 20A, once the molten pool is unstable or the molten drop swings, the distance between the welding wire top end and the molten pool changes, if the distance becomes longer, because the energy storage of the reactor is limited, and the lifting speed of the output energy of the welding machine is also limited, the arc breaking condition is easy to occur. However, although the arc interruption can be prevented by increasing the base current as a whole, the pulse period is longer and the welding performance is deteriorated due to the increase of energy.
Disclosure of Invention
In view of the problems in the prior art, the present invention aims to provide a pulse welding method and system, which can prevent arc interruption and ensure the stability of arc length.
The invention provides a pulse welding method for a welding machine, wherein a welding current in the welding process of the welding machine has a pulse waveform, the waveform comprises a pulse base value stage and a pulse peak value stage, and the method comprises the following steps:
judging whether the pulse base value stage of the current pulse period has an arc breaking trend;
when the arc breaking trend is judged, increasing the preset base value current of the pulse base value stage of the current pulse period;
judging whether the risk of the arc breaking trend of the current pulse period is relieved or not;
and reducing the preset peak current of the pulse peak stage of the next pulse period after the arc breaking trend risk is judged to be relieved.
In some embodiments, the determining whether there is an arc breaking trend includes the following steps:
acquiring a first conduction angle PMW _1 and an average conduction angle PMW _0 of the pulse welded IGBT module, and acquiring a base value current threshold I of the pulse base value stage1；
When the predetermined base current is less than I1And when the real-time conduction angle of the IGBT module is larger than PMW _0+ PWM _1, judging that an arc breaking trend occurs.
In some embodiments, when the current pulse period is the (n +1) th pulse period, obtaining the average conduction angle PWM _0(n) of the pulse-welded IGBT module, includes the steps of:
acquiring the period conduction angle of n +1 pulse periods within a single pulse period time from PWM (0) to PWM (n);
replacing the periodic conduction angle of the single pulse period with the periodic conduction angle of the next pulse period in sequence, and keeping the periodic conduction angle of the (n +1) th pulse period unchanged;
the average value of the periodic conduction angles of n +1 pulse periods is calculated as the average conduction angle PWM _0(n) in n +1 pulse periods.
In some embodiments, when the arc breaking trend is judged to occur, the base value current of the current pulse period is increased to I2，I2The current is increased for a preset base value.
In some embodiments, determining whether the arc breakage risk of the current pulse period is removed includes the following steps:
acquiring a second conduction angle PWM _2 of the IGBT module;
judging whether the real-time conduction angle is smaller than PWM _0+ PWM _ 2;
if so, the arc interruption risk is relieved.
In some embodiments, when determining whether the arc breaking trend occurs in the nth pulse period, the method includes:
acquiring a second conduction angle PWM _2 of the IGBT module;
judging whether the real-time conduction angle of the current pulse period is larger than PWM _0(n-1) + PWM _2 or smaller than PWM _0(n-1) -PWM _ 2;
if yes, judging that the electric arc is unstable, and stopping accumulating calculation of the periodic conduction angle in a single pulse period to obtain the periodic conduction angle PWM (n) of the period;
the average conduction angle PWM _0(n) over n +1 pulse periods is obtained.
In some embodiments, when it is determined that the arc breakage risk is removed, reducing the predetermined peak current in the pulse peak phase of the next pulse period comprises the steps of:
restoring the base current to a predetermined base current set before the increase;
calculating the peak current variation according to the increased melting amount of the welding wire for pulse welding in the period of the basic value of the current pulse period;
the peak current for the next pulse period is calculated.
In some embodiments, the increased melting amount of the pulse-welded wire when the arc breaking tendency occurs is m1, satisfying the following formula:
in the formula, u is the equivalent voltage drop of anode heat generation, r is the equivalent resistance, IbPredetermined background current for pulse background phase, T1To determine the time from the occurrence of the arc breakage risk to the release of the arc breakage risk, k1Melting coefficient, k, for heat production by the anode2A thermal melting coefficient for generating heat at the cathode.
In some embodiments, calculating the peak current for the next pulse period comprises the steps of:
calculating the melting amount m to be reduced in the peak period of the next pulse period2And the formula is satisfied:
calculating a new pulse peak current IP2And the formula is satisfied:
m1＝m2；
wherein, IP2Corrected peak current for the next pulse period, IPFor the predetermined peak current before correction, T2The time for which the pulse peak current is maintained.
The invention provides a pulse welding system which realizes the pulse welding method.
The pulse welding method and the pulse welding system provided by the invention have the following advantages:
the invention provides a pulse welding method which can prejudge the arc risk and adjust the base value current of the current pulse period when the arc risk occurs, thereby achieving the purpose of preventing arc interruption; meanwhile, the pulse peak current of the next pulse period is adjusted, arc breakage is prevented, and the stability of the arc length is guaranteed.
Drawings
Other features, objects and advantages of the present invention will become more apparent upon reading of the following detailed description of non-limiting embodiments thereof, with reference to the accompanying drawings.
FIG. 1 is a schematic illustration of a pulse welding method with arc break prevention in accordance with an embodiment of the present invention;
FIG. 2 is a schematic illustration of a prior art non-preventive arc interruption;
FIG. 3 is a schematic diagram of an embodiment of the present invention implementing arc interruption;
fig. 4 is a schematic diagram of calculating the average conduction angle for the (n +1) th pulse period in the embodiment of the present invention.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and thus their repetitive description will be omitted. In the specification, "or" may mean "and" or ".
The invention provides a pulse welding method and a pulse welding system with arc breakage prevention measures. The pulse welding method in the embodiment is used for a welding machine, the welding current in the welding process of the welding machine has a pulse waveform, and the waveform comprises a pulse base value stage and a pulse peak value stage, and the method comprises the following steps:
s100: judging whether the pulse base value stage of the current pulse period has an arc breaking trend;
s200, increasing the preset base value current of the pulse base value stage of the current pulse period when the arc breaking trend is judged;
s300, judging whether the risk of the arc breaking trend of the current pulse period is relieved or not;
and S400, reducing the preset peak current of the pulse peak stage of the next pulse period after the risk of the arc breaking trend is judged to be relieved.
FIG. 2 is a schematic illustration of pulse welding without arc break prevention. As can be seen from FIG. 2, the puddle begins to destabilize beginning at point A, increasing the distance between the puddle and the wire tip. Because the current command of the basic value of the current pulse period is smaller, the energy provided by the power supply is small, and the energy storage of the reactor is less. As the weld puddle and wire tip increase, the rate of energy increase, and the reactor storing insufficient energy, causes point B to arc, at which time the current stops, with only no-load voltage.
FIG. 3 is a schematic illustration of pulse welding with arc break prevention provisions. As shown in fig. 3, the determining whether there is an arc breaking trend includes the following steps:
s110: acquiring a first conduction angle PMW _1 and an average conduction angle PMW _0 of the pulse welded IGBT module, and acquiring a base value current threshold I of the pulse base value stage1；
S120: when the predetermined base current is less than I1And when the real-time conduction angle of the IGBT module is larger than PMW _0+ PWM _1, judging that an arc breaking trend occurs.
The predetermined base current for the current pulse period in FIG. 3 is IbLess than the base current threshold I1When reaching the point A, the real-time conduction angle is smaller than PMW _0+ PWM _1, the current time is not judged to have the arc breaking risk, but when reaching the point C, the real-time conduction angle is larger than PMW _0+ PWM _1, the current time is judged to have the arc breaking trend, at the moment, the base value current of the current pulse period starts to increase, and the base value current is increased from Ib to I2，I2For a preset base current increase value, I2The arc breaking is difficult to occur, and the arc breaking of pulse welding in the current pulse period is ensured. Said I2Is an empirical parameter obtained by welding for a long time according to different materials, wire diameters and gases. The first conduction angle PWM _1 is an empirical parameter obtained from ordinary experimental experience of the inventor.
When the base current is from IbIs increased to I2And then, judging whether the arc breaking risk of the current pulse period is removed or not, wherein the method comprises the following steps:
s310: acquiring a second conduction angle PWM _2 of the IGBT module;
s320: judging whether the real-time conduction angle is smaller than PWM _0+ PWM _ 2;
s330: if so, the arc interruption risk is relieved.
After the arc breaking risk is judged to be relieved, reducing the preset peak current of the pulse peak stage of the next pulse period, wherein the method comprises the following steps:
s410: restoring the base current to a predetermined base current set before the increase;
s420: calculating the peak current variation according to the increased melting amount of the welding wire for pulse welding in the period of the basic value of the current pulse period;
s430: the peak current for the next pulse period is calculated.
The second conduction angle PWM _2 is empirically obtained by the inventors. At time D in FIG. 3, the real-time conduction angle is smaller than PWM _0+ PWM _2, the system of pulse welding considers that the molten pool oscillation is relieved, and the base current command is recovered to I at the beginning of point Db。
The base value current of the current pulse period is increased, although arc breakage is prevented, the energy of the current pulse period is larger than that of the normal pulse period, and if output is carried out in the next pulse period according to preset pulse parameters (peak current, peak time, period and the like), the formed and transitional solution drops are larger, so that the stability of the arc length is influenced. The added energy needs to be subtracted in the next pulse peak to keep droplet size and arc length stable. The melting amount required to be reduced for the peak value of the next pulse period is approximately equal to the melting amount increased when the current is increased in the base value stage of the current pulse period.
When the arc breaking trend occurs, the increased melting amount of the pulse welding wire is m1The following formula is satisfied:
in the formula, u is the equivalent voltage drop of anode heat generation, r is the cathode equivalent resistance, IbIs the pulse base valuePredetermined base current of phase, T1To determine the time from the occurrence of the arc breakage risk to the release of the arc breakage risk, k1Melting coefficient, k, for heat production by the anode2A thermal melting coefficient for generating heat at the cathode. These parameters can be calculated during the welding process, and the specific calculation method is not in the scope of the present invention.
Calculating the peak current for the next pulse period, comprising the steps of:
s510: calculating the melting amount m to be reduced in the peak period of the next pulse period2And the formula is satisfied:
s520: calculating a new pulse peak current IP2And the formula is satisfied:
m1＝m2；
wherein, IP2Corrected peak current for the next pulse period, IPFor the predetermined peak current before correction, T2The time for which the pulse peak current is maintained.
Fig. 4 is a diagram illustrating calculation of the average conduction angle PWM _ 0. When the current pulse period is the (n +1) th pulse period, obtaining the average conduction angle PWM _0(n) of the pulse-welded IGBT module, and the method comprises the following steps:
s610: acquiring the period conduction angle of n +1 pulse periods within a single pulse period time from PWM (0) to PWM (n); specifically, the period conduction angle of the 1 st pulse period is recorded as PWM (0), the period conduction angle of the 2 nd pulse period is recorded as PWM (1), the period conduction angle of the third pulse period is recorded as PWM (2), and so on;
s620: sequentially replacing the average conduction angle of a single pulse period with the cycle conduction angle of the next pulse period, and keeping the average conduction angle PWM _0(n) in the n +1 th pulse period, namely PWM (0) ═ PWM (1), PWM (1) ═ PWM (2), … …, PWM (n-1) ═ PWM (n), and PWM (n) ═ d;
s630: the average value of the periodic conduction angles of the n +1 pulse periods is calculated as the average conduction angle PWM _0(n) in the n +1 th pulse period, that is, PWM _0(n) ═ PWM (0) + PWM (1) + … … + PWM (n-1) + PWM (n))/(n + 1).
Where d is the cycle conduction angle value of the (n +1) th pulse cycle. The period conduction angle is calculated during each pulse base value after waiting for the base value to stabilizebAverage value of (d).
When judging whether the nth pulse period can generate an arc breaking trend, the method comprises the following steps:
s710: acquiring a second conduction angle PWM _2 of the IGBT module;
s720: judging whether the real-time conduction angle of the current pulse period is larger than PWM _0(n-1) + PWM _2 or smaller than PWM _0(n-1) -PWM _ 2;
s730: if yes, judging that the electric arc is unstable, and stopping accumulating calculation of the periodic conduction angle in a single pulse period to obtain the periodic conduction angle PWM (n) of the period;
s740: the average conduction angle PWM _0(n) over n +1 pulse periods is obtained.
In a period of time at the moment E, the real-time conduction angle is larger than PWM _0(n-1) + PWM _2 or PWM _0(n-1) -PWM _2, at the moment, the electric arc of pulse welding is considered to be unstable (the molten ball swings or the molten pool shakes), the process of calculating the periodic conduction angle in the pulse period is stopped, and the pulse base value of the current pulse period is stably Tb’The periodic conduction angle PWM (n) of the present period is obtained, and the average value PWM _0(n) of n +1 periods is calculated.
The pulse welding method and the system provided by the invention have the following advantages:
the invention provides a pulse welding method, which can prevent arc breakage during pulse welding, ensure stable arc length and improve welding effect.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several simple deductions or substitutions can be made without departing from the spirit of the invention, and all shall be considered as belonging to the protection scope of the invention.
Claims (10)
1. A pulse welding method for use with a welding machine, the welding current in the welding process of the welding machine having a pulse waveform, said waveform including a pulse base phase and a pulse peak phase, said method comprising:
judging whether the pulse base value stage of the current pulse period has an arc breaking trend;
when the arc breaking trend is judged, increasing the preset base value current of the pulse base value stage of the current pulse period;
judging whether the risk of the arc breaking trend of the current pulse period is relieved or not;
and reducing the preset peak current of the pulse peak stage of the next pulse period after the arc breaking trend risk is judged to be relieved.
2. A pulse welding method as defined in claim 1, wherein said determining whether there is an arc breaking tendency comprises the steps of:
acquiring a first conduction angle PMW _1 and an average conduction angle PMW _0 of the pulse welded IGBT module, and acquiring a base value current threshold I of the pulse base value stage1；
When the predetermined base current is less than I1And when the real-time conduction angle of the IGBT module is larger than PMW _0+ PWM _1, judging that an arc breaking trend occurs.
3. A pulse welding method according to claim 2, wherein when a current pulse period is an n +1 th pulse period, an average conduction angle PWM _0(n) of said pulse-welded IGBT module is obtained, comprising the steps of:
acquiring the period conduction angle of n +1 pulse periods within a single pulse period time from PWM (0) to PWM (n);
replacing the periodic conduction angle of each pulse period with the periodic conduction angle of the next pulse period in sequence, and keeping the periodic conduction angle of the (n +1) th pulse period unchanged;
the average value of the periodic conduction angles of the n +1 pulse periods is calculated as the average conduction angle PWM _0(n) in the n +1 th pulse period.
4. A pulse welding method as defined in claim 2, wherein when it is judged that the arc breakage tendency occurs, the base current for the present pulse period is increased to I2，I2The current is increased for a preset base value.
5. A pulse welding method as defined in claim 4, wherein said step of determining whether the risk of arc interruption is removed for the current pulse cycle comprises the steps of:
acquiring a second conduction angle PWM _2 of the IGBT module;
judging whether the real-time conduction angle is smaller than PWM _0+ PWM _ 2;
if so, the arc interruption risk is relieved.
6. A pulse welding method as defined in claim 3, wherein when judging whether the arc breakage tendency occurs in the nth pulse period, it comprises:
acquiring a second conduction angle PWM _2 of the IGBT module;
judging whether the real-time conduction angle of the current pulse period is larger than PWM _0(n-1) + PWM _2 or smaller than PWM _0(n-1) -PWM _ 2;
if yes, judging that the electric arc is unstable, and stopping accumulating calculation of the periodic conduction angle in a single pulse period to obtain the periodic conduction angle PWM (n) of the period;
the average conduction angle PWM _0(n) over n +1 pulse periods is obtained.
7. A pulse welding method as defined in claim 5, wherein, when it is judged that the risk of arc interruption is released, the predetermined peak current in the pulse peak stage of the next pulse cycle is lowered, comprising the steps of:
restoring the base current to a predetermined base current set before the increase;
calculating the peak current variation according to the increased melting amount of the welding wire for pulse welding in the period of the basic value of the current pulse period;
the peak current for the next pulse period is calculated.
8. A pulse welding method as defined in claim 7, wherein said pulse welding wire increases melting quantity m in occurrence of said arc interruption tendency1The following formula is satisfied:
in the formula, u is the equivalent voltage drop of anode heat generation, r is the equivalent resistance, IbPredetermined background current for pulse background phase, T1To determine the time from the occurrence of the arc breakage risk to the release of the arc breakage risk, k1Melting coefficient, k, for heat production by the anode2A thermal melting coefficient for generating heat at the cathode.
9. A pulse welding method as defined in claim 8, wherein calculating the peak current for the next pulse period comprises the steps of:
calculating the melting amount m to be reduced in the peak period of the next pulse period2And the formula is satisfied:
calculating a new pulse peak current IP2And the formula is satisfied:
m1＝m2；
wherein, IP2Corrected peak current for the next pulse period, IPFor the predetermined peak current before correction, T2The time for which the pulse peak current is maintained.
10. A pulse welding system, characterized in that said system implements a pulse welding method according to any one of claims 1-9.
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| CN1500586A (en) * | 2002-11-13 | 2004-06-02 | 株式会社大亨 | Electric current controlling method of pulse electric arc welding |
| JP2004237342A (en) * | 2003-02-07 | 2004-08-26 | Matsushita Electric Ind Co Ltd | Pulse output control method, and consumable electrode type pulse arc welding equipment |
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| CN202367329U (en) * | 2011-11-21 | 2012-08-08 | 无锡市南方电器制造有限公司 | Welding control circuit of digitized direct-current pulse MIG (metal-inert gas welding) welding machine |
| CN111037055A (en) * | 2019-12-31 | 2020-04-21 | 唐山松下产业机器有限公司 | Welding control method, welding machine control device and welding machine |
| CN111958094A (en) * | 2020-08-17 | 2020-11-20 | 深圳市佳士科技股份有限公司 | Cutting machine output control circuit and cutting machine |
-
2021
- 2021-10-29 CN CN202111275514.4A patent/CN113814525A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1500586A (en) * | 2002-11-13 | 2004-06-02 | 株式会社大亨 | Electric current controlling method of pulse electric arc welding |
| JP2004237342A (en) * | 2003-02-07 | 2004-08-26 | Matsushita Electric Ind Co Ltd | Pulse output control method, and consumable electrode type pulse arc welding equipment |
| JP2006205189A (en) * | 2005-01-26 | 2006-08-10 | Matsushita Electric Ind Co Ltd | Arc blow countermeasures control method, and consumable electrode type pulse arc welding equipment |
| CN202367329U (en) * | 2011-11-21 | 2012-08-08 | 无锡市南方电器制造有限公司 | Welding control circuit of digitized direct-current pulse MIG (metal-inert gas welding) welding machine |
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