CN114951923A - AC-DC composite driving device for stud welding arc and utilization method - Google Patents
AC-DC composite driving device for stud welding arc and utilization method Download PDFInfo
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- CN114951923A CN114951923A CN202210658074.9A CN202210658074A CN114951923A CN 114951923 A CN114951923 A CN 114951923A CN 202210658074 A CN202210658074 A CN 202210658074A CN 114951923 A CN114951923 A CN 114951923A
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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
- B23K9/20—Stud 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
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
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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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- Physics & Mathematics (AREA)
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- Arc Welding Control (AREA)
Abstract
The invention discloses an alternating current-direct current composite driving device for stud welding electric arc and a using method. The external excitation coil is uniformly distributed on the same circumference by 6 magnetic poles, wherein a single magnetic pole is clockwise wound on an excitation iron core by the excitation coil and is connected with a three-phase voltage regulator, a three-phase frequency converter and external alternating current; the inner magnet exciting coil is clockwise wound on the red copper frame by the magnet exciting coil and is connected with the sliding rheostat and the external direct current. After the device is started, the arc of the stud welding is positioned in an alternating-direct current composite magnetic field formed under the interaction of the inner magnet exciting coil and the outer magnet exciting coil, wherein the arc uniformly moves around the end face of the stud by the outer coil, and the arc energy is concentrated and the molten pool is deepened by the inner coil. The device has the advantages of simple structure, convenient installation and easy use and adjustment, effectively uses the energy of the electric arc under the action of the composite magnetic field, maintains the movement of the electric arc at the end surface, reduces the arc deflection phenomenon of the electric arc, and finally realizes the aim of high-quality welding of the stud.
Description
Technical Field
The invention relates to an alternating current-direct current composite driving device of a stud welding arc and a utilization method thereof, in particular to a method for carrying out stud welding by adopting a device which compositely drives the arc by an external excitation coil powered by alternating current and an internal excitation coil powered by direct current, belonging to the technical field of welding.
Background
The welding of steel substrates and steel, aluminum and copper studs is widely applied to the fields of ship cabins, the interiors of weapon armored vehicle bodies, the inner and outer walls of various pressure containers, bridges and the like, and the field of stud welding is increasingly wide. Stud welding is a technique of welding a stud to a plate by melting a metal by passing a current or forming an arc between the stud and a workpiece. At present, the stud welding usually adopts the technologies of pure capacitance energy storage, arc stud welding technology, manual arc welding, rod plate submerged arc pressure welding, electroslag pressure welding and the like. With the rapid development of modern industry, the use rate of studs is higher and higher, and the number of studs needing to be welded is increased. The modern mechanical manufacturing technology requires that stud welding has the characteristics of rapidness, reliability, simplification, simple and convenient operation, cost reduction and the like.
The method is classified according to different energy supply modes of a welding machine in the arc stud welding process, and can be divided into two basic methods of common arc stud welding and capacitive energy storage arc stud welding. The arc stud welding is an efficient and stable welding method, the stud is quickly welded on the machine body through arc striking and melting, the method is simple in welding and quick in forming, and once the stud is melted with the base body, the welding performance is excellent. Stud welding is single-side welding, and does not need additional connection skills such as drilling, punching, tapping, riveting and the like, and does not need to reprocess a non-welding surface. Plays an irreplaceable role in industry, and is widely applied to industries such as automobile manufacturing, aerospace, medical appliances, boiler chemical equipment and the like.
The stud generally comprises a hollow stud and a solid stud, wherein the solid stud is easy to generate the magnetic blow phenomenon of electric arcs in the welding process, so that the welding seams around the stud are asymmetric, the electric arcs in all areas of the end face of the stud are unevenly combusted, partial electric arcs are obviously not fully combusted, the heat provided for the stud and steel plate metal in the areas is insufficient, the metal is not fully melted, the fusion depth is shallow, a welding boss is not formed, the electric arc energy concentration on the other side causes the excessive combustion of the end face of the stud in the areas, the notches are burnt out of the stud to damage the integrity of the stud, and the welding seams at the welding position of the stud are discontinuous. During the welding process of the hollow stud, molten metal liquid is found to be accumulated on the inner wall of the stud, and after the welding is finished, additional processing treatment needs to be carried out on the inner part of the stud; moreover, the position of the electric arc generated at the end face of the hollow stud has randomness and uncontrollable property, the penetration is shallow, the spreading of a molten pool is uneven, and the welding time is short and generally not more than 2s, so that the electric arc of the hollow stud can not spread to the whole annular end face easily, a complete welding seam is difficult to form, and the stud with poor welding joint quality is easy to break from the welding position. In stud welding, the arc beam is a plasma composed of free electrons and positively and negatively charged ions. Because the plasma has the characteristics of conductivity, electric neutrality, magnetic field interaction and the like, the welding arc can be moved to a specified position by applying the magnetic field externally, the welding arc can reach a desired shape, and the welding arc can move according to a preset speed and direction, so that the aim of improving the welding quality is fulfilled.
The invention content is as follows:
the invention aims to provide an electric arc AC-DC driving device which ensures that the fusion rate of a stud and a steel matrix is high and the bonding strength meets the use requirement, so as to solve the problem that the end face of the stud cannot be completely combusted due to local unfused in the current stud welding process.
The technical scheme adopted by the invention for solving the technical problems is as follows:
an AC-DC driving device for stud welding arc and a utilization method thereof.
The device comprises an external excitation coil, an internal excitation coil, an excitation iron core, a three-phase voltage regulator, a three-phase frequency converter, a coil air cooling system, a sliding rheostat, an external direct-current power supply and external three-phase alternating current.
The coil in the device is formed by clockwise winding an excitation coil on a red copper frame, and the number of turns of the coil is 500; the external coil is composed of 3 groups of magnetic poles (one group is corresponding to 2 magnetic poles), a single magnetic pole is clockwise wound on the excitation iron core by the excitation coil, the number of turns of the coil is 550 turns, and each magnetic pole is distributed in 60 degrees; external three-phase alternating current is introduced into the external excitation coils, and the three groups of symmetrical excitation coils form a circulating magnetic field so that the welding arc rotates along with the magnetic field; an external direct-current power supply is introduced into the internal magnet exciting coil to generate a magnetic field which is axially parallel to the welding arc, so that the diffusion of the arc is limited, and the energy of the arc becomes concentrated; the cooling system is designed in the inner coil and the outer coil, a cooling air inlet and a cooling air outlet are formed in the top of the device, and the exciting coil is circularly cooled after a door valve is opened; six magnetic poles in the external magnet exciting coil are tightly connected with the upper baffle plate through bolts, and the inner wall of the upper baffle plate is connected with the internal magnet exciting coil through internal threads; for an external excitation coil, the range of excitation current is 0-0.85A, and the range of excitation frequency is 0-80 Hz; for the internal exciting coil, the range of exciting current is 0-0.85A.
Aiming at connection between different studs and steel plates, the studs are arranged in a welding gun to be moved to a specified welding position at the beginning of welding, and the method comprises the following steps before an AC-DC composite magnetic field device drives the studs to be welded:
the method comprises the following steps: checking whether an external excitation coil, a three-phase voltage regulator, a three-phase frequency converter and an external three-phase alternating current power supply form a loop or not, checking whether an internal excitation coil can be normally started or not, and checking whether a coil device and a welding gun clamping jaw are tightly assembled in an interference manner or not;
step two: clamping the stud by using a welding gun clamping jaw and moving the stud to a specified substrate position;
step three: opening the coil air cooling system to enable the coil air cooling system to work normally;
step four: starting an external three-phase alternating current power supply, adjusting the rotation frequency of an external coil through a connected three-phase frequency converter, and adjusting a three-phase voltage regulator to control the size of a magnetic field generated by the external coil;
step five: starting the external direct-current power supply, and changing the exciting current of the internal exciting coil through the slide rheostat so as to adjust the size of the internal magnetic field;
step six: and (3) electrifying the stud for welding, wherein a molten pool is under the action of a composite magnetic field generated by the external coil and the internal coil during welding, the external alternating current power supply and the external direct current power supply are turned off after the stud is pressed down to extinguish the arc, and the welding is finished.
Compared with the existing stud welding technology, the invention has the following beneficial effects:
1. the arc AC-DC composite driving device is used for welding the stud, and the composite magnetic field environment formed in the welding process helps the arc to do uniform circular motion on the end face of the stud and concentrate the energy of the arc, so that molten metal is spread more uniformly, and the quality of a stud welding seam is improved.
2. Under the combined action of the internal coil and the external coil, the motion condition of the electric arc at the end face of the stud is optimized, and the problem of poor quality of a welding joint with shallow stud fusion depth when the electric arc is driven by a single external coil is solved; the problems of arc deflection and incomplete welding seams on the end face of the stud when the arc is driven by a single internal coil are also solved.
3. When the alternating current-direct current composite driving device of the stud welding electric arc is adopted, the cooling system is designed to cool the coil in the welding process, the service life of the device is prolonged, and the working efficiency is improved.
4. The device is simple and easy to operate, and can be suitable for automatic stud welding guns and manual stud welding guns.
Drawings
FIG. 1 is a schematic view of an external coil in an AC-DC hybrid drive for a stud welding arc of the present invention
FIG. 2 is a schematic view of an AC-DC hybrid drive welding apparatus for a stud welding arc of the present invention.
FIG. 3 is a connection block diagram of an AC-DC hybrid drive welding device for a stud welding arc according to the present invention.
FIG. 4 is a diagram showing the welding effect of the post-welding medium-and large-diameter hollow stud welding using the AC-DC hybrid drive device using the stud welding arc in example 1.
FIG. 5 is a graph showing the welding effect of the medium-and large-diameter hollow stud welding in comparative example 1 after the stud welding arc was driven using the rotating magnetic field device.
FIG. 6 is a graph showing the welding effect of the medium and large diameter solid stud welding in comparative example 2 after driving the stud welding arc using the longitudinal magnetic field device.
The device comprises an external magnet exciting coil 1, a coil air cooling system 2, an internal magnet exciting coil 3, a stud 4, a stud welding gun 5 three-phase voltage regulator 6, a three-phase frequency converter 7, three-phase alternating current 8, a slide rheostat 9 and direct current 10.
Detailed Description
The present invention is described in further detail below with reference to the attached drawing figures.
For the arc AC-DC composite driving device for stud welding, which is disclosed by the invention, the arc can realize complete arc motion on the bottom surface of a stud in the welding process, the arc deflection phenomenon is reduced, the arc energy is concentrated, the depth of a molten pool is increased, and the mechanical property of a stud welding joint is favorably improved.
With reference to fig. 1 and 2, the ac-dc hybrid driving device for stud welding arc according to the present invention includes an external excitation coil, an internal excitation coil, an excitation core, a three-phase voltage regulator, a three-phase inverter, a coil air cooling system, a sliding rheostat, an external constant current power supply, and an external three-phase ac power supply. In the structure of the device, an external excitation coil 1 is uniformly distributed on the same circumference through six magnetic poles and is fixed to an upper baffle through bolt connection, wherein a single magnetic pole is tightly arranged on an excitation iron core in a clockwise direction through an enameled wire wrapping an insulating layer, three magnetic poles in the external excitation coil are connected with the output end of a three-phase voltage regulator 6, the other three opposite magnetic poles are connected back to a zero line of the three-phase voltage regulator 6, the three-phase voltage regulator 6 is connected with a three-phase frequency converter 7, and the three-phase frequency converter 7 is connected with external three-phase alternating current 8. The inner magnet exciting coil 3 is formed by winding the magnet exciting coil on a red copper frame clockwise and uniformly, so that current is uniformly distributed along the cross section, and the direction of current density forms a right-hand spiral relation. The inner exciting coil 3 is connected to a sliding varistor 9 and a direct current 10, and the magnetic field of the inner exciting coil 3 is controlled by adjusting the sliding varistor 9. Inside excitation coil and outside excitation coil pass through screw thread zonulae occludens and welder is connected with inside coil for inside and outside coil uses with welder is supporting.
The specific use method of the AC-DC composite driving device for the stud welding arc provided by the invention is as follows: before the stud welding process, whether the external magnet exciting coil 1, the three-phase voltage regulator 6, the three-phase frequency converter 7 and the three-phase alternating current 8 are normally connected or not and whether the internal magnet exciting coil 3, the slide rheostat 9 and the direct current 10 form a loop or not are checked, then a steel plate is placed at a proper position, the stud 4 is clamped by the stud welding gun 5 and moved to a specified welding position, and a switch of the external direct current is turned on to enable the internal magnet exciting coil 3 to normally work. The size of the three-phase voltage regulator 6 and the three-phase frequency converter 7 is adjusted according to requirements, and the size and the frequency of the magnetic field of the external excitation coil 1 are controlled. The switch of the dc power supply 10 is turned on, and the size of the slide rheostat is adjusted as required, thereby controlling the magnetic field of the internal excitation coil 3. In order to prevent the exciting coil from heat radiation damage to the inner and outer coils in the exciting process, the coil air cooling system 2 is opened. After the AC-DC composite magnetic field generating device is started, the stud welding gun ignites electric arcs between the studs and the steel plate, the electric arcs do uniform circular motion with the central axis of the studs, local melting occurs between the end faces of the studs and the steel plate base body, local extrusion is performed between the studs and the steel plate, the electric arcs are extinguished, metallurgical bonding is achieved for welding joints, meanwhile, part of liquid metal is extruded, welding of the studs and the steel plate is achieved, and welding is finished. In the technical scheme, the electric arc is driven by a composite magnetic field generated by the external alternating current coil and the internal direct current coil, so that the electric arc can be ensured to perform uniform circular motion on the end face of the stud, the arc deflection phenomenon can be effectively reduced, the electric arc energy is concentrated, the depth of a molten pool is increased, and the mechanical property of a stud welding joint is favorably improved.
The method and apparatus for ac-dc hybrid driving of a stud welding arc according to the present invention will be described in detail with reference to the following examples.
Example 1
In combination with a welding flow chart of an AC-DC composite driving device using stud welding arcs, as shown in FIG. 3, a 45# steel plate made of Q235 steel and having dimensions of phi 16mm multiplied by 30mm, an inner diameter of phi 8mm, a length of 30mm and dimensions of 120mm multiplied by 12mm is taken as an example. Clamping a hollow stud with the diameter of 16mm and the length of 30mm on a welding gun and moving the hollow stud to a specified welding position, starting an alternating-direct current composite magnetic field generating device, turning on a three-phase alternating current switch to provide an alternating current power supply of 380V for an external excitation coil, immediately adjusting a three-phase frequency converter to control the rotation frequency of the external coil to be 60Hz, adjusting a three-phase voltage regulator to control the magnetic field size of the external coil, controlling the excitation current to be 0.65A, turning on a direct current switch to provide stable direct current for an internal excitation coil, controlling the excitation current to be 0.3A, turning on a coil air cooling system, then descending the stud welding gun to the specified position to ignite an electric arc with a steel plate base body, and welding with the welding current of 800A and the welding time of 1300 ms. After welding, the welding gun is lifted to a specified height, the constant direct current power supply and the three-phase alternating current power supply switch are closed, the coil air cooling system is closed, and the welding process is finished. The welding effect is as shown in figure 4, the welding seam is uniform and attractive, the bosses with complete and uniform height are arranged around the hollow stud, the molten pool is spread outwards and becomes deep in the welding process, and the hollow stud does not have the problem that molten metal is accumulated on the inner wall of the stud after welding.
Comparative example 1
The stud welding process is performed directly using a rotating magnetic field device. A45 # steel plate made of Q235 hollow studs is taken as an example, and the dimension of the steel plate is phi 16mm multiplied by 30mm, the diameter of the steel plate is phi 16mm, the length of the steel plate is 30mm, and the dimension of the steel plate is 120mm multiplied by 12 mm. Clamping a hollow stud with the diameter of 16mm and the length of 30mm on a welding gun, moving to a specified welding position, starting a rotating magnetic field generating device, turning on a three-phase alternating current switch, adjusting a three-phase frequency converter to control the rotating frequency of an external coil to be 30Hz, adjusting a three-phase voltage regulator to control the magnetic field of the external coil, controlling the exciting current to be 0.35A, descending the hollow stud welding gun to the specified position to ignite an electric arc with a steel plate, and welding, wherein the welding current is 800A, and the welding time is 1300 ms. After welding, the welding gun is lifted to a specified height, the rotating magnetic field device is closed, and the welding process is finished. The welding effect is as shown in fig. 5, a complete welding seam appears around the stud, but the penetration depth of the stud is shallow, and a large amount of molten metal is accumulated to the inside of the stud, so that the quality of a welding joint is poor.
Comparative example 2
The stud welding process is performed directly using a longitudinal magnetic field device. A45 # steel plate made of Q235 hollow studs is taken as an example, and the dimension of the steel plate is phi 16mm multiplied by 30mm, the diameter of the steel plate is phi 16mm, the length of the steel plate is 30mm, and the dimension of the steel plate is 120mm multiplied by 12 mm. Clamping a hollow stud with the diameter of 16mm and the length of 30mm on a welding gun, moving to a specified welding position, starting a longitudinal magnetic field generating device, turning on a direct current switch, controlling exciting current to be 0.4A, descending the hollow stud welding gun to the specified position to ignite electric arcs with a steel plate, and welding, wherein the welding current is 800A, and the welding time is 1300 ms. And after the welding is finished, lifting the welding gun to a specified height, closing the rotating magnetic field device, and finishing the welding process. The welding effect is as shown in fig. 6, because the stay time at a certain position after the arc is started is too long, the combustion at the end part of the stud is uneven, so that the local part is not fused, and meanwhile, part of molten metal in a molten pool enters the hollow part of the stud to destroy the internal thread structure.
Claims (7)
1. An AC-DC hybrid drive device for stud welding arc, characterized in that: the device includes: the excitation coil is clockwise wound on the excitation iron core to form a single magnetic pole, 6 magnetic poles are uniformly distributed on the same circumference to form an external excitation coil, an alternating current power supply is provided for the external excitation coil, and the external excitation coil is connected with a three-phase voltage regulator and a three-phase frequency converter device; the excitation coil is clockwise wound inside the frame by the inner excitation coil, power is supplied by being connected with a direct-current stabilized power supply, the movable sliding rheostat is arranged to change excitation current, and a welding environment of an alternating-direct-current composite magnetic field is formed under the interaction of the inner excitation coil and the outer excitation coil, so that an arc moves under the action of Lorentz force during welding, the arc uniformly moves around the end face of the stud under the action of the magnetic field of the outer coil, and arc energy is concentrated under the action of the inner coil.
2. An ac-dc hybrid drive for a stud welding arc according to claim 1, wherein: the inner coil is formed by winding an excitation coil on a red copper frame layer by layer clockwise, and the number of turns of the coil is 500; the external coil is composed of 3 groups of magnetic poles, 2 opposite magnetic poles are in a group, a single magnetic pole is formed by clockwise tightly winding an excitation coil on an excitation iron core, the number of turns of the coil is 550, and each magnetic pole is distributed in 60 degrees in order to enable the magnetic field to be uniformly distributed.
3. An ac-dc hybrid drive for a stud welding arc according to claim 1, wherein: external three-phase alternating current is introduced into the external excitation coils, and the three groups of symmetrical excitation coils are excited to form a circulating magnetic field so that the welding arc rotates along with the magnetic field; an external direct current power supply is connected to the internal excitation coil to generate a magnetic field parallel to the axial direction of the welding arc, so that the diffusion of the arc is limited, and the energy of the arc is concentrated.
4. An ac-dc hybrid drive for a stud welding arc according to claim 1, wherein: and cooling systems are arranged in the inner coil and the outer coil, a cooling air inlet and a cooling air outlet are formed in the top of the device, and the gate valve is opened to circularly cool the excitation coil.
5. An ac-dc hybrid drive for a stud welding arc according to claim 1, wherein: six magnetic poles in the outside excitation coil pass through bolt and last baffle close connection, and the internal excitation coil is connected to the interior wall car internal thread of overhead gage.
6. An ac-dc hybrid drive for a stud welding arc according to claim 1, wherein: for an external excitation coil, the range of excitation current is 0-0.85A, and the range of excitation frequency is 0-80 Hz; for the internal exciting coil, the range of exciting current is 0-0.85A.
7. A method of using an ac-dc hybrid drive for a stud welding arc according to any one of claims 1 to 6, comprising the steps of:
the method comprises the following steps: before welding an alternating current-direct current composite driving stud, checking whether an external excitation coil, a three-phase voltage regulator, a three-phase frequency converter and an external three-phase alternating current power supply form a loop, checking whether an internal excitation coil can be normally started, and checking whether a coil device and a welding gun clamping jaw are tightly assembled in an interference manner;
step two: clamping the stud by using a welding gun clamping jaw and moving the stud to a specified substrate position;
step three: opening the coil air cooling system to enable the coil air cooling system to work normally;
step four: starting an external three-phase alternating current power supply, adjusting the rotation frequency of an external coil through a connected three-phase frequency converter, and adjusting a three-phase voltage regulator to control the size of a magnetic field generated by the external coil;
step five: starting the external direct-current power supply, and changing the exciting current of the internal exciting coil through the slide rheostat so as to adjust the size of the internal magnetic field;
step six: and (3) electrifying the stud for welding, wherein a molten pool is under the action of a composite magnetic field generated by the external coil and the internal coil during welding, the external alternating current power supply and the external direct current power supply are turned off after the stud is pressed down to extinguish arc, and the arc welding of the stud is driven by alternating current-direct current combination to be finished.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210658074.9A CN114951923A (en) | 2022-06-12 | 2022-06-12 | AC-DC composite driving device for stud welding arc and utilization method |
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| CN202210658074.9A CN114951923A (en) | 2022-06-12 | 2022-06-12 | AC-DC composite driving device for stud welding arc and utilization method |
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2022
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| CN104959601A (en) * | 2015-07-03 | 2015-10-07 | 华中科技大学 | Electromagnetic flexible composite fused deposition direct preparation forming method for gradient part |
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