CN114192954A - Flash butt welding electric control system based on hydraulic proportional valve - Google Patents
Flash butt welding electric control system based on hydraulic proportional valve Download PDFInfo
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- CN114192954A CN114192954A CN202111488647.XA CN202111488647A CN114192954A CN 114192954 A CN114192954 A CN 114192954A CN 202111488647 A CN202111488647 A CN 202111488647A CN 114192954 A CN114192954 A CN 114192954A
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- welding
- proportional valve
- flash butt
- control system
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- 238000003466 welding Methods 0.000 title claims abstract description 82
- 238000000034 method Methods 0.000 claims abstract description 19
- 238000005070 sampling Methods 0.000 claims abstract description 6
- 230000003321 amplification Effects 0.000 claims abstract description 3
- 238000003199 nucleic acid amplification method Methods 0.000 claims abstract description 3
- 238000013461 design Methods 0.000 abstract description 5
- 230000002457 bidirectional effect Effects 0.000 abstract 1
- 230000005540 biological transmission Effects 0.000 abstract 1
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000005065 mining Methods 0.000 description 3
- 230000003068 static effect Effects 0.000 description 3
- 238000011161 development Methods 0.000 description 2
- 230000004069 differentiation Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000011105 stabilization Methods 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000010720 hydraulic oil Substances 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Classifications
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/04—Flash butt welding
Abstract
The invention aims to provide an electric control system design based on flash butt welding of a hydraulic proportional valve. The electric control system consists of an industrial personal computer HMI, a PLC, a control assembly, a power assembly, a voltage and current sampling device, a welding transformer, a limit and switch, a proportional valve amplification board and other electrical appliance elements. The industrial personal computer HMI completes the functions of flash welding process parameter setting, welding voltage and current real-time tracking display, fault alarm and the like. The PLC completes the functions of PID adjustment of welding voltage and current, self-adaptive intelligent welding control, automatic control of flash butt welding equipment, bidirectional data transmission with HMI and the like. The electric control system is designed based on the principle of preheating flash butt welding, and the feeding speed of the movable clamp during flash is self-adaptive and intelligently controlled based on the burning current. The method is applied to the flash butt welding of chain links with phi 26 mm-phi 34mm, has high and stable welding quality, and can meet the requirements of welding processes.
Description
The technical field is as follows:
the invention relates to the field of welding of various metal chain flash butt welding, and is applied to the design of an electric control system of high-strength mining chain welding equipment with medium specification of phi 26-phi 34 mm.
Background art:
butt welding, which is frequently used in the industry, includes resistance butt welding and flash butt welding, which belongs to the category of pressure welding, and is one of the main welding methods, and the most used flash butt welding currently includes continuous flash butt welding and preheating flash butt welding. Flash butt welding is widely used in military industry, railway, ship, automobile, mining machinery, various industries, aviation and other fields because of its high heat efficiency, good welding quality and wide range of weldable metals and alloys, and can weld not only compact section materials but also welding materials with expanded sections.
Flash butt welding is in a development and increasingly perfect stage in China, so that the application research of flash butt welding and the development of flash butt welding equipment are particularly important. The flash butt welding equipment mainly comprises a mechanical part, a hydraulic part, an electric control system, an actuating mechanism and the like. The design of each part, particularly the electric control system and the movable clamp actuating mechanism, relates to the reasonable application of the welding technology, and whether higher welding quality can be obtained or not.
The invention content is as follows:
the invention aims to: in order to improve the welding quality of a chain ring (phi 26-phi 34 mm), enhance the welding mechanical property and increase the use stability of welding equipment, the invention provides a design of an electric control system based on hydraulic proportional valve flash butt welding.
The purpose of the invention is realized by the following technical scheme: the electric control system of the invention consists of an industrial personal computer HMI, a PLC, a welding control assembly, a power assembly, a voltage and current sampling device, a welding transformer, a limit and switch, a proportional valve amplifying plate, a hydraulic proportional valve and other matched electric appliance elements.
The invention relates to an electrical control system design based on a hydraulic proportional valve and based on the principle of preheating flash butt welding, which realizes high-quality welding of a high-strength mining round-link chain (phi 26-phi 34 mm).
In the welding process, except that the ring back preheating is in a constant current mode, the welding voltage in the flash butt welding process is a stable value, the stable value is subjected to PID (proportion integration differentiation) adjustment on the welding voltage by a PLC (programmable logic controller), the preheating and the continuous flashing are controlled on the basis of the welding current, particularly, the continuous flashing in the later period is subjected to exponential function calculation on the basis of the instantaneous burning current, and an electric signal of an amplification plate of a hydraulic proportional valve is given, so that the feeding control of the self-adaptive intelligent continuous flashing clamp is realized, the stability of equipment is improved, the welding quality of chain rings is also improved, and the mechanical property of the welded chain rings is also enhanced.
The invention has the advantages that the control of the link welding continuous flashing process mainly shows two aspects: the first welding quality is superior to a hard characteristic curve, such as a traditional cam curve or a specific moving clamp feeding curve controlled by a hydraulic reversing valve, and the welding quality is lower because the continuous flash process is not controlled by instantaneous burning current; and for the welding of the chain ring with the medium specification, the manufacturing cost of the hydraulic proportional valve is at least 20% lower than that of the hydraulic servo valve, so that the welding quality of the chain ring can be ensured, and the cost can be saved.
Description of the drawings:
the accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
fig. 1 is a diagram of the electric control system of the present invention.
FIG. 2 is a partial schematic view of the hydraulic system of the moving clamp cylinder of the present invention,
in the figure, 1 is a hydraulic oil cylinder of a movable clamp, 2 is a hydraulic proportional valve, and 3 is a hydraulic reversing valve.
FIG. 3 is a schematic view of the principle of preheating flash butt welding used in the present invention,
in the figure, a is a static clamp, b is a movable clamp, c is a welding transformer, d is a weldment, FfFor clamping force, FuFor upsetting force of movable clamps, VsThe feed speed of the gripper is moved.
The specific implementation scheme is as follows:
preheating flash butt welding principle (as shown in figure 3), assembling a weldment d into a butt joint form, clamping the weldment d by a static clamp a and a movable clamp b, electrifying a welding transformer c, preheating the ring back of the weldment for 1-3S after electrification, repeatedly preheating for a plurality of times, then moving the movable clamp b to make the end face joint of the weldment d gradually approach to local contact and have contact points, heating the contact points by using resistance heat to form a liquid lintel, exploding the liquid lintel to generate flash, melting metal at the end face and heating the end face until the end face reaches the required temperature within a certain depth range, suddenly accelerating the movable clamp b, the end faces of the weldment d are mutually extruded by great pressure, the voltage is cut off after 0.5 to 1S, and the pressure is maintained for 0.5 to 2S, so that the welding area is subjected to strong plastic deformation, the joint faces are alternately crystallized, and a firm joint is formed.
The preheating flash butt welding mainly comprises the welding processes of ring back preheating, continuous flashing, upsetting, pressure maintaining, burr removing and the like. Preheating, continuous flashing and upsetting are key steps of preheating flash butt welding, how to weld the flash butt welding is completely determined by controlling the three steps, and particularly whether the feeding speed of a movable clamp can be matched with the burning speed of a welding chain ring during continuous flashing is important. In order to achieve the self-adaptive intelligent control of the feeding speed and the burning speed, the purpose is realized by the following specific scheme:
the movable clamp oil cylinder 1 is driven by a hydraulic proportional valve 2 and a common hydraulic reversing valve 3. The movable fixture is driven by the hydraulic proportional valve to move during preheating and continuous flashing, and the movable fixture is driven by the hydraulic proportional valve and the hydraulic reversing valve together during upsetting.
During preheating, the feeding and returning speeds of the movable clamp are set based on the ring back measuring current of the chain ring, the contact time of the movable clamp during feeding, and the return current and time of the movable clamp. When the feeding contact time and the return current of the movable clamp are simultaneously reached, the movable clamp returns, when the return time of the movable clamp is reached, the movable clamp is fed again, and continuous flashing is immediately carried out when the temperature of the chain ring crater reaches the requirement of entering continuous flashing. The feeding and returning times of the movable clamp are set according to the temperature requirement before chain rings with different specifications can enter continuous flashing.
During continuous flashing, the sampling current of the preheated movable clamp during the last return is taken as the reference, the sampling current is compared with the instantaneous sampling current in the continuous flashing process, the absolute value, the logarithm, the exponent and the like are calculated, finally, an exponential function is used for obtaining a voltage signal for controlling the hydraulic proportional valve amplifying plate, the self-adaptive intelligent control of the burning speed of the movable clamp feeding speed tracking chain ring is realized, and the exponential function formula is as follows.
In the formula: i isbCurrent at the start of flash (burn-in)
IaInstantaneous current during flash (burn-in)
Beta-flash (burn-in) current density
Voltage conversion factor of m-0V to +/-10V
n- - -dead band factor
During upsetting, in order to achieve high-speed and high-pressure upsetting, the hydraulic reversing valve is opened simultaneously, namely the hydraulic proportional valve and the reversing valve jointly control feeding of the movable clamp, welding end faces of the chain rings are mutually extruded under high pressure, meanwhile, pressure maintaining is carried out for 0.5-2S, strong plastic deformation of a welding area is realized, and the joint faces are crystallized alternately to form a firm joint.
The deburring is to trim burrs left on the welded chain ring, so that the surface of the chain ring is smooth and tidy.
Other auxiliary controls are: the method comprises the following steps of welding transformer and thyristor temperature protection, chain conveying, clamping and loosening of a static clamp and a dynamic clamp, clamping and loosening of an electrode, control of pressure and oil temperature of a hydraulic system and the like.
The control method comprises the following steps: manual, inching, automatic. The automatic control method is also divided into a non-strip current control mode.
The industrial personal computer HMI program mainly comprises the following aspects: an expert parameter interface, a welding process parameter interface, a fault interface and the like.
The expert parameter interface comprises PID (proportion integration differentiation) adjusting parameters of welding voltage stabilization and constant current, the level adjustment setting of a welding transformer and the test of voltage stabilization and constant current.
The welding process parameter interface comprises chain welding process parameters and parameters needing to be displayed in real time.
The fault interface comprises fault information prompt when a fault occurs.
Claims (6)
1. The utility model provides a flash butt welding electrical system based on hydraulic pressure proportional valve which characterized in that: the welding device consists of an industrial personal computer HMI, a PLC, a welding control assembly, a power assembly, a voltage and current sampling device, a welding transformer, a limit and switch, a proportional valve amplification plate, a hydraulic proportional valve and other matched electrical elements.
2. The electric control system based on the hydraulic proportional valve flash butt welding according to claim 1, characterized in that: the hydraulic proportional valve drives the movable clamp oil cylinder so as to drive the movable clamp to move, and the hydraulic proportional valve and the reversing valve jointly drive the movable clamp oil cylinder to realize high-pressure and high-speed upsetting during upsetting.
3. The electric control system based on the hydraulic proportional valve flash butt welding according to claim 1, characterized in that: the electrical signal of the hydraulic proportional valve amplifying plate during continuous flashing is given by a PLC (programmable logic controller), and the electrical signal is adaptively and intelligently controlled by an exponential function based on the burning current during continuous flashing, wherein the formula is as follows:
in the formula: i isbCurrent at the start of flash (burn-in)
IaInstantaneous current during flash (burn-in)
Beta-flash (burn-in) current density
Voltage conversion factor of m-0V to +/-10V
n- - -a dead zone factor.
4. The electric control system based on the hydraulic proportional valve flash butt welding according to claim 1, characterized in that: the initial position, the upsetting position and the power-off position of the electric upsetting of the movable clamp are controlled by a proximity switch or a limit.
5. The hydraulic proportional valve-based flash butt welding electric control system according to claim 1, wherein: the preheating times in the early stage of continuous flashing can be set according to the requirements of the welding process of chain rings with different specifications.
6. The hydraulic proportional valve-based flash butt welding electric control system according to claim 1, wherein: in the welding process, except that the ring back preheating mode is a constant-current mode, other welding technological processes are all in a constant-voltage mode.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111488647.XA CN114192954A (en) | 2021-12-08 | 2021-12-08 | Flash butt welding electric control system based on hydraulic proportional valve |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111488647.XA CN114192954A (en) | 2021-12-08 | 2021-12-08 | Flash butt welding electric control system based on hydraulic proportional valve |
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| CN114192954A true CN114192954A (en) | 2022-03-18 |
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| CN202111488647.XA Pending CN114192954A (en) | 2021-12-08 | 2021-12-08 | Flash butt welding electric control system based on hydraulic proportional valve |
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1165068A (en) * | 1997-02-04 | 1997-11-19 | 宝山钢铁(集团)公司 | Parallel clearance precision resistance welder control executive system |
| US6294752B1 (en) * | 1999-12-16 | 2001-09-25 | Sergei I. Kuchuk-Yatsenko | Method of flash-butt welding |
| JP2004058134A (en) * | 2002-07-31 | 2004-02-26 | Jfe Engineering Kk | Method and apparatus for feeding member in flash welding |
| CN101059694A (en) * | 2007-06-05 | 2007-10-24 | 西北工业大学 | Friction welding machine closed loop control device |
| CN109676239A (en) * | 2019-01-28 | 2019-04-26 | 哈尔滨焊接研究院有限公司 | Welding force closed-loop control and the interactive friction welding apparatuses of opened loop control and its friction-welding technique |
-
2021
- 2021-12-08 CN CN202111488647.XA patent/CN114192954A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1165068A (en) * | 1997-02-04 | 1997-11-19 | 宝山钢铁(集团)公司 | Parallel clearance precision resistance welder control executive system |
| US6294752B1 (en) * | 1999-12-16 | 2001-09-25 | Sergei I. Kuchuk-Yatsenko | Method of flash-butt welding |
| JP2004058134A (en) * | 2002-07-31 | 2004-02-26 | Jfe Engineering Kk | Method and apparatus for feeding member in flash welding |
| CN101059694A (en) * | 2007-06-05 | 2007-10-24 | 西北工业大学 | Friction welding machine closed loop control device |
| CN109676239A (en) * | 2019-01-28 | 2019-04-26 | 哈尔滨焊接研究院有限公司 | Welding force closed-loop control and the interactive friction welding apparatuses of opened loop control and its friction-welding technique |
Non-Patent Citations (1)
| Title |
|---|
| 冯锦国: "基于液压比例阀与PLC的闪光对焊设备的应用研究", 《焊接技术》 * |
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Application publication date: 20220318 |
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