CN115194303B - Arc stud welding device and arc stud welding method - Google Patents
Arc stud welding device and arc stud welding method Download PDFInfo
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- CN115194303B CN115194303B CN202210211903.9A CN202210211903A CN115194303B CN 115194303 B CN115194303 B CN 115194303B CN 202210211903 A CN202210211903 A CN 202210211903A CN 115194303 B CN115194303 B CN 115194303B
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- 238000003466 welding Methods 0.000 title claims abstract description 218
- 238000000034 method Methods 0.000 title claims abstract description 19
- 239000000463 material Substances 0.000 claims abstract description 95
- 238000012937 correction Methods 0.000 claims abstract description 77
- 239000010953 base metal Substances 0.000 claims abstract description 7
- 238000003825 pressing Methods 0.000 claims abstract description 4
- 238000006073 displacement reaction Methods 0.000 claims description 108
- 238000012545 processing Methods 0.000 claims description 20
- 230000008859 change Effects 0.000 claims description 14
- 230000007704 transition Effects 0.000 claims description 11
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- 230000004048 modification Effects 0.000 description 7
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- 238000003754 machining Methods 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 230000006866 deterioration Effects 0.000 description 4
- 230000006870 function Effects 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 2
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- 230000015556 catabolic process Effects 0.000 description 2
- 238000004590 computer program Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000010891 electric arc Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 241000605447 Anemarrhena Species 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229930191283 anemarrhena Natural products 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
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- 239000007769 metal material Substances 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
- B23K9/00—Arc welding or cutting
- B23K9/20—Stud welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0953—Monitoring or automatic control of welding parameters using computing means
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Abstract
The present invention relates to an arc stud welding apparatus and an arc stud welding method. Provided is an arc stud welding device capable of improving welding quality. The arc stud welding device is provided with: a welding gun for pressing and pulling up the stud relative to the base material; a power supply device capable of supplying electric power to the welding gun; a voltage sensor for detecting a voltage applied to the welding gun; and a control device for controlling the power supply device and the welding gun during a pilot arc for generating the pilot arc and during a main arc for generating the main arc. When the voltage value obtained from the voltage sensor during the pilot arc is greater than a predetermined first threshold value, the control device performs a first correction for changing the welding conditions during the main arc and suppressing the heat generated in the base metal and the stud, and performs welding using the changed welding conditions by the first correction.
Description
Technical Field
The present disclosure relates to an arc stud welding apparatus and an arc stud welding method.
Background
A technique is known in which a welding current flowing to an arc stud welding gun is measured in an arc stud welding apparatus, and feedback control is performed to bring the welding current close to a target current value (for example, patent literature 1). In the conventional technique, the occurrence of a deviation at the time of the rise of the welding current and the surge of the welding current at the cut-in point are eliminated by the feedback control, thereby suppressing the deterioration of the welding quality.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 5-31581
Disclosure of Invention
Problems to be solved by the invention
In an arc stud welding apparatus, improvement in welding quality is being sought.
Means for solving the problems
The present disclosure can be implemented as follows.
(1) According to one aspect of the present disclosure, an arc stud welding apparatus is provided. The arc stud welding device comprises: a welding gun for pressing and pulling up the stud relative to the base material; a power supply device capable of supplying electric power to the welding gun; a voltage sensor for detecting a voltage applied to the welding gun; and a control device for controlling the power supply device and the welding gun during a pilot arc period and a main arc period, wherein the pilot arc period is a period for supplying pilot power generated by the base material and the stud to the welding gun during the pilot arc period, and the main arc period is a period for supplying main power generated by the base material and the stud to the welding gun during the main arc period and is a period for allowing a current larger than a current flowing to the welding gun during the pilot arc period to flow to the welding gun. The control device performs a first correction for changing a processing condition of welding during the main arc and suppressing heat generated in the base metal and the stud when the voltage value obtained from the voltage sensor during the pilot arc is larger than a predetermined first threshold value, and performs welding using the processing condition changed by the first correction.
According to the arc stud welding apparatus of this aspect, it is possible to suppress heat generated during welding of the base material and the stud by determining whether or not the voltage value obtained during the pilot arc is greater than the first threshold value, and changing the welding condition during the main arc by the first correction. Therefore, excessive heat is reduced or prevented from being supplied to the base material and the stud during welding, and the welding quality can be improved.
(2) In the arc stud welding apparatus according to the above aspect, the control device may perform the first correction of advancing a timing of transition to the main arc period.
According to the arc stud welding apparatus of this aspect, by advancing the transition timing to the main arc period, the period during which the excessive voltage is applied to the stud and the base material can be shortened during the pilot arc period. As a result, excessive heat is reduced or prevented from being supplied to the base material and the stud, and the welding quality can be improved.
(3) In the arc stud welding apparatus according to the above aspect, the control device may perform the first correction to reduce the target current value of the main power.
According to the arc stud welding apparatus of this aspect, the amount of heat corresponding to the excessive heat supplied to the stud and the base material by the voltage greater than the first threshold value applied at the time point when the voltage value is acquired by the control device can be reduced during the main arc, and the welding quality can be improved.
(4) In the arc stud welding apparatus according to the above aspect, the control device may further stop welding of the stud when the obtained voltage value during the pilot arc is equal to or greater than a second threshold value that is predetermined and greater than the first threshold value.
According to the arc stud welding apparatus of this embodiment, unnecessary machining can be reduced or prevented.
(5) The arc stud welding apparatus according to the above aspect may further include a displacement sensor that detects a displacement of the stud relative to the base material. The control device may perform a second correction for changing the processing condition of the welding during the main arc and adjusting the heat amount when the difference between the displacement amount and a predetermined reference value during the pilot arc is not included in a predetermined first range.
According to the arc stud welding apparatus of this aspect, by changing the processing conditions during the main arc using the distance between the stud and the base metal during the pilot arc, it is possible to reduce or prevent excessive or insufficient heat from being generated during welding.
(6) In the arc stud welding apparatus according to the above aspect, the control device may perform the second correction of changing the target current value of the main power to a current value smaller than the target current value of the main power when the difference between the displacement amount and the reference value is included in the first range when the displacement amount is not included in the first range, and may perform the second correction of changing the target current value of the main power to a current value larger than the target current value of the main power when the difference between the displacement amount and the reference value is included in the first range when the displacement amount is smaller than the reference value when the displacement amount is not included in the first range.
According to the arc stud welding apparatus of this aspect, it is possible to fill up an excessive or insufficient amount of heat generated during welding due to the displacement amount of the stud by changing the target current value.
(7) In the arc stud welding apparatus according to the above aspect, the control device may further stop welding of the stud when the difference between the displacement amount and the reference value is not included in a second range that is predetermined and wider than the first range.
According to the arc stud welding apparatus of this embodiment, it is possible to reduce or prevent unnecessary machining from being performed.
The present disclosure can also be implemented in various ways other than an arc stud welding apparatus. For example, the present invention can be realized by an arc stud welding method, a control method of an arc stud welding apparatus, a computer program for realizing the control method, a non-transitory recording medium on which the computer program is recorded, or the like.
Drawings
Fig. 1 is an explanatory diagram showing an arc stud welding apparatus as a first embodiment.
Fig. 2 is a flowchart showing a control routine executed by the control apparatus.
Fig. 3 is a flowchart showing a control routine of the second modification.
Fig. 4 is a graph schematically showing the target current value changed by the second correction.
Fig. 5 is a flowchart showing a control routine of the first modification.
Fig. 6 is a graph conceptually showing the target current value changed by the first correction and the shortened pilot arc period.
Fig. 7 is a graph showing a change in voltage at the time of welding in the conventional arc stud welding apparatus as a comparative example.
Fig. 8 is a graph showing a change in voltage at the time of welding in the arc stud welding apparatus of the present embodiment.
Fig. 9 is an explanatory diagram showing a state of a welded stud and base material of a conventional arc stud welding apparatus as a comparative example.
Fig. 10 is an explanatory diagram showing the state of the welded stud and base metal of the arc stud welding apparatus according to the present embodiment.
Description of the reference numerals
50 … welding machine, 52 … control device, 54 … power supply device, 56 … current sensor, 58 … voltage sensor, 60 … displacement sensor, 70 … welding gun, 80 … stud, 82 … fusion part, 90 … base metal, 100 … arc stud welding device, CA1, CA2 … power supply line, F1 … protrusion, im1, im2, im21, im22, im3, ip … target current value, la … displacement, lm … reference displacement, V1 … first threshold, V2 … second threshold, va1, VR … measured voltage, va … voltage value, vm … target voltage value, vp1, vp2 … target voltage value.
Detailed Description
A. First embodiment:
fig. 1 is an explanatory diagram showing an arc stud welding apparatus 100 as a first embodiment in the present disclosure. The arc stud welding apparatus 100 is, for example, a short-cycle welding apparatus. The arc stud welding apparatus 100 includes a welder 50 including a power supply device 54 and a control device 52, and a welding gun 70. The arc stud welding apparatus 100, for example, is configured to generate an arc between a base metal 90 such as a steel plate or a steel pipe and the stud 80 by assembling the stud 80 such as a bolt or a pin to the welding gun 70 and flowing a current. The contact portion between the stud 80 and the base material 90 is arc-melted, and the melted stud 80 and base material 90 are welded by being pressurized. As the base material 90, various metal materials such as mild steel, SUS, aluminum, and aluminum alloy can be used. The arc stud welding apparatus 100 may be a welding apparatus of a power arc type using a Ferrule (ferro).
The control device 52 is a microcomputer that integrally controls the arc stud welding device 100, and includes a memory such as RAM and ROM and a CPU. The control device 52 further includes a timer, not shown, for measuring the time. The control device 52 controls the operation of the welding gun 70, the magnitude of the current flowing to the welding gun 70, the energization time, and the like. Various programs for realizing the functions provided in the present embodiment, the processing conditions for welding, and the like are stored in the memory. The processing conditions of welding mean, for example, a target current value flowing to the welding gun 70, a target voltage value applied to the welding gun 70, a pilot arc, a current-carrying period of a main arc, and a first threshold value, a second threshold value, a first range, a second range, and the like, which will be described later. The CPU reads out various programs from the memory and expands them on the RAM to execute them. Some or all of the functions of the arc stud welding apparatus 100 may be implemented by hardware circuitry. The control device 52 may be provided separately from the welder 50.
The power supply device 54 includes a three-phase ac power supply, not shown, and a rectifier for converting ac to dc. The power supply device 54 and the welding gun 70 are connected by a power supply line CA1, and the power supply device 54 and the base material 90 are connected by a power supply line CA 2. The power supply device 54 supplies pilot power for generating pilot arc at the base material 90 and the stud 80 and main power for generating main arc at the base material 90 and the stud 80 to the welding gun 70 under the control of the control device 52.
The welding gun 70 performs press-fitting and pulling-up of the stud 80 with respect to the base material 90. The welding gun 70 includes a shaft body, not shown, of the fixing stud 80 and a driving mechanism, not shown, for driving the shaft body in a direction orthogonal to the base material 90. The welding gun 70 can pull the stud 80 away from the base material 90 as indicated by an arrow D1 in fig. 1, and press the stud 80 toward the base material 90 as indicated by an arrow D2 in fig. 1, by using a driving mechanism. The driving mechanism may be, for example, an electromagnetic solenoid type including a spring and an electromagnetic coil for biasing the shaft toward the base material 90, or a motor driving type in which the shaft is driven by a servo motor or a linear motor.
In the present embodiment, the arc stud welding apparatus 100 includes a current sensor 56, a voltage sensor 58, and a displacement sensor 60. The current sensor 56 is provided in the power supply line CA1. The voltage sensor 58 is provided between the power supply line CA1 and the power supply line CA 2. The current sensor 56 detects a current value flowing to the welding gun 70, and the voltage sensor 58 detects a voltage value applied to the welding gun 70. The displacement sensor 60 is provided in the welding gun 70, and detects the displacement of the stud 80. The displacement amount of the stud 80 corresponds to the separation distance of the stud 80 from the base material 90. In the present embodiment, the displacement sensor 60 uses a laser displacement meter, and detects the displacement of the stud 80 by laser light. The displacement sensor 60 is not limited to a laser displacement meter, and a magnetic sensor or the like may be used, or various linear encoders such as an optical type and a magnetic type may be used. The detection results of the various sensors of the current sensor 56, the voltage sensor 58, and the displacement sensor 60 are output to the control device 52.
Fig. 2 is a flowchart showing a control routine executed by the control device 52. The flow shown in fig. 2 is started, for example, by assembling the base material 90 and the stud 80 to the arc stud welding apparatus 100 and pulling a trigger provided to the welding gun 70 by an operator. The present flow is a flow for welding 1 stud 80 to the base material 90. For example, in the case where the stud 80 is welded to each of a plurality of positions of the base material 90, the flow Cheng Zhen is repeated for each position of the weld stud 80. The present flow may be started by pressing a start switch of the arc stud welding apparatus 100 in a state where the base material 90 and the stud 80 are assembled.
In step S10, the control device 52 reads out the set values corresponding to the types of the stud 80 and the base material 90. The set value is a welding process condition stored in advance in the memory. The processing conditions for welding include, for example, a current-carrying period in a period in which a pilot arc is generated (hereinafter, also referred to as a "pilot arc period"), a target current value of a current (hereinafter, also referred to as a "pilot current") flowing in the pilot arc period, a target voltage value of a voltage (hereinafter, also referred to as a "pilot voltage") applied in the pilot arc period, a current-carrying period in a period in which a main arc is generated (hereinafter, also referred to as a "main arc period"), a target current value of a current (hereinafter, also referred to as a "main current") flowing in the main arc period, and a target voltage value of a voltage (hereinafter, also referred to as a "main voltage") applied in the main arc period. The pilot current is a current of about 10 to 50A for causing the arc column to continue between the stud 80 and the base material 90. The main current is about 200 to 2000A for causing a main arc to occur between the stud 80 and the base material 90.
In step S20, the control device 52 controls the power supply device 54 to cause a pilot current to flow to the stud 80 and the base material 90. Specifically, the control device 52 controls the driving mechanism of the welding gun 70 to press the tip of the stud 80 attached to the welding gun 70 against the surface of the base material 90. When the stud 80 is pressed against the base material 90, the control device 52 controls the power supply device 54 to flow the pilot current to the stud 80 and the base material 90 according to the target current value of the pilot current. The control device 52 causes the drive mechanism of the welding gun 70 to drive and pull the stud 80 from the base material 90, thereby causing a pilot arc to be generated between the stud 80 and the base material 90.
In step S30, the control device 52 obtains the displacement La of the stud 80 from the displacement sensor 60. The displacement La of the stud 80 corresponds to the pulling distance of the stud 80 from the base material 90 in step S20.
In step S40, the control device 52 confirms the amount of deviation of the pull-up distance of the stud 80. Specifically, the control device 52 checks whether or not the difference between the acquired displacement amount La and the reference displacement Lm, which is a predetermined reference value, is included in the first range and the second range. The reference displacement Lm, the first range, and the second range are stored in advance in the memory of the control device 52. The reference displacement Lm is a target value of the displacement amount of the stud 80 at the time of welding, and corresponds to a target value of the pull-up distance of the stud 80 from the base material 90. The deviation of the pulling-up amount of the stud 80 may occur due to, for example, a mechanical error of the welding gun 70.
The first range can be set in a range of, for example, -L1 or more and L1 or less. The second range can be set in a range of, for example, -L2 or more and L2 or less. The second range is a wider range than the first range, L2> L1. The first and second ranges L1 and L2 are set values set in advance to obtain sufficient welding quality by the main arc after the second correction described later. L1 is a lower limit value of an absolute value of a deviation of the pulling-up amount of the stud 80 allowed to obtain a sufficient welding quality by the main arc after the second correction, and L2 is an upper limit value of the absolute value of the deviation. If the absolute value of the deviation of the pulling-up amount of the stud 80 is larger than L1 and equal to or smaller than L2, sufficient welding quality can be obtained by the main arc after the second correction, and if the absolute value exceeds L2, sufficient welding quality may not be obtained even by the main arc after the second correction. L1 and L2 can be experimentally obtained in advance by using the correspondence between the magnitude of the main current and the welding quality after the main arc for each displacement La. In the present embodiment, l1=0.5 mm and l2=1.0 mm are set. In the present embodiment, the upper limit value of the first range is L1, the lower limit value is-L1, and the absolute values thereof are L1 and are identical, and the absolute values of the upper limit value and the lower limit value of the second range are L2 and are identical, but the upper limit value and the lower limit value of the first range may be set to different values, and the upper limit value and the lower limit value of the second range may be set to different values.
When the difference between the acquired displacement amount La and the reference displacement Lm is within the first range, the control device 52 moves to step S60, and when the difference is not included in the first range but within the second range, the control device moves to step S50, and when the difference is not included in the second range, the control device moves to step S120. In step S120, the control device 52 determines that there is an abnormality, and controls the power supply device 54 to stop the output, thereby ending the welding. In step S130, the control device 52 reports the determination result of the presence of the abnormality to the operator or the like using, for example, a display device, a speaker, or the like included in the arc stud welding apparatus 100, and ends the present flow.
In step S50, control device 52 performs a second correction. In the second modification, as described later, the processing conditions of welding during the main arc are changed. In the present embodiment, the second correction changes the target current value of the main current and the target voltage value of the pilot voltage. After performing the second correction, the control device 52 moves to step S60.
In step S60, the control device 52 acquires a voltage value during the pilot arc from the voltage sensor 58. In the present embodiment, the control device 52 calculates an average value of the voltages per unit time, for example, 1 millisecond, using the voltage values obtained from the voltage sensor 58, and obtains the average value as the voltage value Va. The voltage sensor 58 may calculate an average value of the voltages per unit time and output the average value to the control device 52.
In step S70, the control device 52 confirms the amount of deviation of the execution voltage from the target voltage value. Specifically, the control device 52 determines whether or not the difference between the obtained voltage value Va and the target voltage value Vm of the pilot voltage during the pilot arc is equal to or smaller than the first threshold V1 and smaller than the second threshold V2. The second threshold V2 is a voltage value greater than the first threshold V1, V2> V1. The target voltage value Vm, the first threshold value V1, and the second threshold value V2 are stored in advance in the memory of the control device 52.
The first threshold V1 is a set value for sufficiently obtaining the welding quality of the main arc under normal processing conditions, and the second threshold V2 is a set value for sufficiently obtaining the welding quality of the main arc under first modified processing conditions described later. If the voltage Va is greater than the first threshold V1 and less than the second threshold V2, the first correction may be performed to obtain sufficient welding quality by the main arc, and if the voltage Va exceeds the second threshold V2, sufficient welding quality may not be obtained even by the main arc after the first correction. For example, if foreign matter such as oil is present on the surface of the base material 90, the electrical resistance between the base material 90 and the stud 80 may increase. The control device 52 increases the power supplied from the power supply device 54 in order to raise the pilot current to the target current value. As a result, the pilot voltage increases. In the present embodiment, the first threshold V1 and the second threshold V2 are set to function as thresholds for detecting foreign matter on the surface of the anemarrhena material 90 using the pilot voltage. The first threshold V1 and the second threshold V2 can be experimentally obtained in advance by obtaining a correspondence relationship between the pilot voltage and the welding quality after the main arc using, for example, the base material 90 having a foreign material on the surface. The first threshold V1 and the second threshold V2 may be obtained using the correspondence between the amount of foreign matter adhering to the surface of the base material 90 and the guide voltage. In the present embodiment, the first threshold v1=5v is set, and the second threshold v2=10v is set. The first threshold V1 is not limited to 5V, and may be set at 2.5V, 3V, 4V, or the like, or may be set at any voltage such as 6V, 7.5V, 10V, or 15V. The second threshold V2 is not limited to 10V, and may be set at 5V, 6V, 7.5V, 15V, 20V, or the like, or may be set at any voltage where V2> V1. When the difference between the obtained voltage value Va and the target voltage value Vm is equal to or smaller than the first threshold value V1, the control device 52 proceeds to step S100, and when the difference is greater than the first threshold value V1 and smaller than the second threshold value V2, proceeds to step S80, and when the difference is equal to or greater than the second threshold value V2, proceeds to step S120.
In step S100, the control device 52 starts the main arc on the condition that the energization period passes in the pilot arc period set in advance. Specifically, the control device 52 controls the power supply device 54 to start the main arc by flowing the main current to the stud 80 and the base material 90. When the second correction is performed in step S50 described above, the control device 52 starts the main arc by flowing the main current based on the target set value changed by the second correction. The tip of the stud 80 and the base material 90 that are being arc-discharged are thermally melted by the arc discharge. When a predetermined period of time has elapsed from the start of arc discharge, the control device 52 controls the driving mechanism of the welding gun 70 to press the stud 80 into the surface of the base material 90, thereby joining the stud 80 and the base material 90. In step S110, the control device 52 controls the power supply device 54 to stop the output and ends the welding in accordance with the passage of the energization period during the predetermined main arc period.
In step S80, the control device 52 confirms whether the amount of deviation of the pull-up distance of the stud 80 is within the first range. In the present embodiment, the control device 52 uses the determination result in step S40 to confirm whether or not the difference between the displacement amount La and the reference displacement Lm is included in the first range. If the difference between the displacement amount La and the reference displacement Lm is within the first range, that is, if the determination result in step S40 is |la-lm|l 1, the process proceeds to step S90.
If the difference between the displacement amount La and the reference displacement Lm in step S80 is not included in the first range, that is, if the determination result in step S40 is L1< |la-lm|l 2, the routine proceeds to step S120, where the welding is completed. Here, in step S80, the difference between the displacement amount La and the reference displacement Lm is not included in the first range, and the voltage value Va of the execution voltage exceeds the first threshold V1, and the displacement amount of the stud 80 is not included in the first range. In this embodiment, the process of ending the welding is performed in consideration of the possibility that the welding quality of the main arc cannot be sufficiently obtained. That is, in the present embodiment, both the second correction in step S50 and the first correction in step S90 described later are not performed. However, if the arc stud welding apparatus 100 can sufficiently obtain the welding quality of the first corrected main arc under this condition, the step S80 may be omitted, and the process may be shifted from the step S70 to the step S90.
In step S90, control device 52 performs a first correction. In the first correction, as described later, the target current value of the main current is changed and the energizing period in the pilot arc period is shortened. In step S102, the control device 52 controls the power supply device 54 to start the main arc based on the first corrected target current value. In the present embodiment, as described later, the control device 52 starts the main arc immediately after the process of step S90. When a predetermined energization period has elapsed from the start of the main arc, the control device 52 controls the drive mechanism of the welding gun 70 to join the stud 80 and the base material 90. In step S112, the power supply device 54 is controlled to stop the output and the welding is ended in accordance with the elapse of a predetermined energization period in the main arc period.
Details of the second modification will be described with reference to fig. 3 and 4. Fig. 3 is a flowchart showing a control routine of the second modification. In step S52, the control device 52 changes the target current value of the main current. In the present embodiment, the target current value Im2 after the second correction change is calculated using the following equation (1).
Im2=Im1 {1-k1 (La-Lm)/L1 } … (1)
Im1: target current value of main current at normal time
k1: coefficients of
The target current value Im1 corresponds to a current value flowing to the welding gun 70 when the difference between the displacement amount La and the reference displacement Lm is included in the first range. The coefficient k1 is a coefficient defining a correction amount of the target current value of the main current. The coefficient k1 can be experimentally obtained using, for example, a correspondence relationship between a current value of the main current per unit displacement of the stud 80 and the welding quality after the main arc. In the present embodiment, k1=0.05 is set. The coefficient k1 is not limited to 0.05, and may be set to any value such as 0.01, 0.025, 0.1, 0.15, or 0.2.
As shown in expression (1), in the present embodiment, the second correction value is calculated by multiplying the coefficient k1 by expression (La-Lm)/L1. The formula (La-Lm)/L1 is a coefficient based on the amount of deviation of the displacement La. When the displacement amount La is larger than the reference displacement Lm, the correction amount of the second correction value is set to be larger than when the displacement amount La is smaller. With this configuration, the target current value Im2 of the main current corresponding to the magnitude of the deviation of the detected displacement La of the stud 80 can be set, and the welding quality of the main arc can be further improved.
In step S54, the control device 52 changes the target voltage value at the time of arc starting. In the present embodiment, the target voltage value Vp2 after the second correction change is calculated using the following equation (2).
Vp2=Vp1+k2· (La-Lm) … (2)
Vp1: target voltage value of pilot voltage at normal time
k2: coefficients of
The target voltage value Vp1 corresponds to a voltage value applied when the difference between the displacement amount La and the reference displacement Lm is included in the first range. The coefficient k2 is a coefficient defining a correction amount of the target voltage value of the pilot voltage. The coefficient k2 can be experimentally obtained using, for example, a correspondence relationship between the displacement amount of the stud 80 and the voltage value of the pilot voltage. In the present embodiment, k2=3.8 is set. The coefficient k2 is not limited to 3.8, and may be set to any value such as 2.0, 3.0, 4.0, or 5.0.
When the stud 80 is away from the base material 90, the output power from the power supply 54 increases, and when the stud 80 is close to the base material 90, the output power from the power supply 54 decreases. Therefore, in the present embodiment, the target voltage value of the pilot voltage is changed according to the displacement amount of the stud 80, so that the output voltage after the change of the displacement amount based on the displacement amount of the stud 80 is suppressed from being detected as an abnormal value.
Details of the process of changing the target current value of the main current performed in step S52 will be described with reference to fig. 4. Fig. 4 is a graph schematically showing the target current value changed by the second correction. Fig. 4 shows a graph conceptually showing target current values during pilot arc and main arc. The horizontal axis of the graph of fig. 4 represents time (milliseconds), and the vertical axis represents the current value (a). The time axis of the horizontal axis is also common to fig. 6 to 8 described later. The current value Ip is a target current value of the pilot current during the pilot arc from time T1 to time T2. The period from time T2 to time T3 is a main arc period, and the current value Im1 is a target current value of the main current at normal times, that is, a target current value of the main current in the case where the second correction is not performed. The solid line G1 shows an example of a change in the target current value of the main current at the time of normal operation. The broken lines G2 and G3 each show an example of the target current value in the case where the second correction is performed. The current values Im21 and Im22 are examples of the target current value Im2 after the second correction. Specifically, the current value Im21 represents an example of the minimum value of the second corrected target current value Im2, and the current value Im22 represents an example of the maximum value of the second corrected target current value Im 2. The graphs of fig. 4 and 6 conceptually show changes in current values in order to facilitate understanding of the technique, and do not accurately show absolute values of the respective current values.
The broken line G2 conceptually represents an example of a change in the main current caused by the second correction performed when the difference between the displacement amount La of the stud 80 and the reference displacement Lm becomes positive. The case where the difference between the displacement amount La and the reference displacement Lm is positive corresponds to the case where the displacement amount La is larger than the reference displacement Lm, that is, the case where the position of the stud 80 is away from the base material 90 compared with the normal case. In the present embodiment, when the difference between the displacement amount La and the reference displacement Lm is positive, the target current value Im21 shown in fig. 4 is corrected by the above formula (1) so as to be smaller than the normal target current value Im 1. Here, when the stud 80 is separated from the base material 90 as compared with the normal time, the main current may be reduced as compared with the normal time. Accordingly, the output power from the power supply device 54 may be larger than usual in order to increase the current value to the target current value. As a result, the main voltage increases, and the heat generated during welding may become excessive as compared with normal welding. In the present embodiment, when the difference between the displacement amount La and the reference displacement Lm is positive, the second correction for reducing the target current value of the main current is performed to reduce or prevent the heat from becoming excessive during welding.
The broken line G3 conceptually shows an example of a change in the main current caused by the second correction performed when the difference between the displacement amount La of the stud 80 and the reference displacement Lm becomes negative. The case where the difference between the displacement amount La and the reference displacement Lm is negative corresponds to the case where the displacement amount La is smaller than the reference displacement Lm, that is, the case where the position of the stud 80 is closer to the base material 90 than in the normal state. In the present embodiment, when the difference between the displacement amount La and the reference displacement Lm is negative, the target current value Im22 shown in fig. 4 is corrected by the above formula (1) so as to be larger than the normal target current value Im 1. Here, when the stud 80 is closer to the base material 90 than the normal time, the main current may increase than the normal time. Accordingly, the output power from the power supply device 54 may be smaller than usual in order to reduce the current value to the target current value. As a result, the main voltage decreases, and the heat during welding may be reduced as compared with the normal welding. In the present embodiment, when the difference between the displacement amount La and the reference displacement Lm is negative, the second correction for increasing the target current value of the main current is performed to reduce or prevent the shortage of heat during welding.
Details of the first modification will be described with reference to fig. 5 to 8. Fig. 5 is a flowchart showing a control routine of the first modification. In step S92, control device 52 changes the target current value of the main current. In the present embodiment, the target current value Im3 after the first correction is calculated by using the following equation (3).
Im3=k3·im1 … type (3)
And k3: coefficients of
The coefficient k3 is a coefficient for adjusting the amount of heat supplied to the stud 80 and the base material 90. Here, if an excessive voltage exceeding the first threshold V1 is applied during the pilot arc, a larger amount of heat is supplied to the stud 80 and the base material 90 than in the normal case. In order to reduce the amount of heat corresponding to the excess amount of heat supplied to the base material 90 and the stud 80, the current value of the main current is reduced by using the coefficient k 3. The coefficient k3 can be obtained experimentally in advance by using, for example, a correspondence relationship between a current value of the main current and a welding quality after the main arc when an execution voltage larger than the first threshold V1 is applied to the base material 90 and the stud 80 during the pilot arc. In the present embodiment, k3=0.95 is set. The coefficient k3 is not limited to 0.95, and may be set to any value such as 0.975, 0.925, 0.90, 0.85, 0.80, or 0.70. Even when the measured voltage exceeds the first threshold V1 during the pilot arc, for example, when sufficient welding quality can be obtained by performing only the process of step S94 described later, step S92 can be omitted.
In step S94, the control device 52 shortens the pilot arc period as compared with the normal period, and advances the transition timing to the main arc period. The earlier the transition timing to the main arc period is, the better. In the present embodiment, after the control device 52 performs the process of changing the target current value in step S92, the control device immediately shifts to the main arc period regardless of the timing result of the pilot arc period. Even when the measured voltage exceeds the first threshold V1 during the pilot arc, the step S92 alone may be executed and the step S94 may be omitted if the sufficient welding quality can be obtained without shortening the pilot arc period.
Fig. 6 is a graph conceptually showing the target current value changed by the first correction and the pilot arc period shortened by the first correction. The horizontal axis of the graph of fig. 6 represents time (milliseconds), and the vertical axis represents the current value (a). The solid line G1 shows an example of the target current value at the time of normal operation, that is, the target current value in the case where the first correction is not performed. The broken line G4 shows an example of the target current value after the first correction. The current value Im1 is a target current value of the main current at normal times.
The current value Im3 represents a target current value of the first corrected main current. The target current value Im3 is set to be smaller than the normal target current value Im1 by the above equation (3). In the present embodiment, the target current value Im3 is 5% smaller than the target current value Im1 at normal times.
Time T4 represents the start timing of the first corrected main arc period, and time T2 represents the start timing of the main arc period at the time of normal operation. As shown in fig. 6, time T4 is closer to time T1, which is the start timing of the pilot arc period, than time T2, and the start timing of the main arc period is shorter than that in the normal state. The length of the main arc period before the first correction is substantially the same as the length of the main arc period after the first correction. Thus, the time T5, which is the end timing of the main arc period after the second correction, is advanced by the difference between the time T4 and the time T2 with respect to the time T3, which is the end timing of the main arc period during the normal operation.
Fig. 7 is a graph showing a change in voltage at the time of welding in the conventional arc stud welding apparatus as a comparative example. In fig. 7, an example of the target voltage value is shown by a solid line G5, and an example of the measured value of the voltage obtained by the voltage sensor 58 is shown by a broken line GR. More specifically, the broken line GR is an example of a case where the measured value of the voltage exceeds the first threshold V1 during the pilot arc. The broken line GR corresponds to an example of a voltage value in the case of processing the base material 90 having foreign matter attached to the surface. The displacement amount La of the stud 80 is included in the first range. As indicated by the dashed line GR, the measured voltage VR at time T7 exceeds the first threshold V1. As shown in fig. 7, in the conventional arc stud welding apparatus, the actual measurement voltage indicated by the broken line GR continues to be higher than the target voltage value Vm until the time T2 for transition to the main arc period. This is based on: the control device 52 performs constant current control during the pilot arc period, and does not change the target current value during the pilot arc period.
Fig. 8 is a graph showing a change in voltage at the time of welding in the arc stud welding apparatus 100 of the present embodiment. In fig. 8, an example of the target voltage value is indicated by a solid line G5, and an example of the measured value of the voltage obtained by the voltage sensor 58 is indicated by a broken line G6. More specifically, the broken line G6 is an example of a case where the measured value of the voltage exceeds the first threshold V1 during the pilot arc, and corresponds to an example of a case where the base material 90 having foreign matter attached to the surface is processed. The displacement amount La of the stud 80 is included in the first range.
As indicated by the broken line G6, the measured voltage Va1 at time T8 exceeds the first threshold V1. Accordingly, the control device 52 immediately shifts to the main arc period after performing the process of changing the target current value Im1 of the main current to the target current value Im 3. Thus, as shown in fig. 8, the transition timing to the main arc period, that is, the timing immediately after the time T4 becomes the time T8. In the arc stud welding apparatus 100 of the present embodiment, since the transition to the main arc period is made immediately, the period during which the state in which the execution voltage is higher than the target voltage value continues can be shortened as compared with the conventional example shown by the broken line GR in fig. 7.
Effects achieved by the arc stud welding apparatus 100 according to the present embodiment will be described with reference to fig. 9 and 10. Fig. 9 is an explanatory diagram showing a state of a post-welding stud 80 and a base material 90 in a conventional arc stud welding apparatus as a comparative example. Fig. 10 is an explanatory diagram showing the state of the welded stud 80 and base material 90 of the arc stud welding apparatus 100 according to the present embodiment.
According to the arc stud welding apparatus of the conventional example, for example, as shown by the broken line GR in fig. 7, during the pilot arc, the actual measurement voltage VR higher than the first threshold V1 is applied to the stud 80 and the base material 90. Thus, the heat supplied to the stud 80 and the base material 90 increases. As a result, as shown in fig. 9, the volume of the melted portion 82 melted during welding becomes larger than that during normal operation. As a result, as shown in the protruding portion F1 of fig. 9, the molten portion 82 penetrates the back surface of the base material 90, which is a problem of so-called breakdown.
According to the arc stud welding apparatus 100 of the present embodiment, for example, as shown by a broken line G6 in fig. 8, when the measured voltage Va1 higher than the first threshold V1 is detected during the pilot arc, the arc stud welding apparatus immediately shifts to the main arc period. As a result, the period during which a voltage higher than the first threshold V1 is applied to the stud 80 and the base material 90 is shortened. Therefore, for example, even when welding the stud 80 to the base material 90 having foreign matter on the surface, it is possible to reduce or suppress the excessive heat supply to the stud 80 and the base material 90 during the pilot arc. As a result, as shown in fig. 10, the volume of the molten portion 82 can be reduced as compared with the volume of the molten portion 82 generated in the conventional arc stud welding apparatus, and deterioration of welding quality can be reduced or prevented.
According to the arc stud welding apparatus 100 of the present embodiment, for example, as shown by a broken line G4 in fig. 6, the target current value Im3 during the main arc is changed to a current value smaller than the target current value Im1 at normal time by the first correction. As a result, the heat corresponding to the excessive heat supplied to the stud 80 and the base material 90 by the high measured voltage Va1 applied until the control device 52 acquires the measured voltage Va1 and shifts to the main arc period can be reduced in the main arc period. For example, by making the total heat amount at the time of welding after the first correction substantially equal to the total heat amount at the time of normal operation, the volume of the melted portion 82 can be made substantially equal to the total heat amount at the time of normal operation. As a result, as shown in fig. 10, the volume of the melted portion 82 is substantially equal to that in normal times, and the volume of the melted portion 82 is smaller than that in the conventional arc stud welding apparatus, so that the deterioration of the welding quality can be reduced or prevented.
As described above, according to the arc stud welding apparatus 100 of the present embodiment, the control device 52 acquires the voltage value Va of the pilot voltage from the voltage sensor 58 during the pilot arc, and suppresses the heat generated during welding of the base material 90 and the stud 80 by correcting the first correction of the machining condition during the main arc when the acquired voltage value Va of the pilot voltage is larger than the predetermined first threshold V1. By determining whether or not the base material 90 is abnormal before the transition to the main arc period based on whether or not the voltage Va during the pilot arc period is greater than the first threshold V1 and correcting the processing conditions during the main arc period, it is possible to reduce or prevent excessive heat from being supplied to the base material 90 and the stud 80 during welding. Therefore, occurrence of defects such as breakdown of the base material 90 can be reduced or prevented, and the welding quality can be improved.
According to the arc stud welding apparatus 100 of the present embodiment, when the voltage higher than the first threshold V1 is detected during the pilot arc, the control device 52 performs the first correction to advance the timing of transition to the main arc period. By advancing the timing of the transition to the main arc period, the period during which a voltage higher than the first threshold V1 is applied to the stud 80 and the base material 90 can be shortened, and by reducing or preventing the excessive heat from being supplied to the base material 90 and the stud 80, the welding quality can be improved.
According to the arc stud welding apparatus 100 of the present embodiment, when the control device 52 detects a voltage higher than the first threshold V1 during the pilot arc, the control device performs the first correction to reduce the target current value of the main current. The heat corresponding to the excessive heat supplied to the stud 80 and the base material 90 by the high measured voltage Va1 applied during the period until the control device 52 acquires the measured voltage Va1 and shifts to the main arc period can be reduced during the main arc period. Therefore, for example, by making the total heat amount at the time of welding substantially equal to that at the time of normal operation, it is possible to reduce or prevent deterioration of the welding quality.
According to arc stud welding apparatus 100 of the present embodiment, control device 52 further stops welding of stud 80 when voltage value Va of the pilot power is equal to or greater than second threshold V2, which is greater than first threshold V1. When it is determined during the pilot arc that the welding quality is not obtained even by the first correction on the surface of the base material 90, the welding can be stopped, and unnecessary processing can be reduced or prevented.
According to the arc stud welding apparatus 100 of the present embodiment, when the difference between the pilot arc period displacement La and the predetermined reference displacement Lm is not included in the predetermined first range, the control device 52 adjusts the amount of heat supplied to the stud 80 and the base material 90 by changing the second correction of the machining condition during the main arc. By estimating and changing the machining conditions during the main arc by using the displacement amount of the stud 80 with the excessive or insufficient heat amount during welding generated according to the distance between the stud 80 and the base material 90 during the pilot arc, it is possible to reduce or prevent the excessive or insufficient heat amount during welding from being generated.
According to the arc stud welding apparatus 100 of the present embodiment, when the difference between the pilot arc period displacement La and the predetermined reference displacement Lm is not included in the predetermined first range, the control device 52 performs the second correction of changing the target current value Im1 of the main power to the target current value Im21 smaller than the target current value Im1 of the main power in the normal state when the displacement La is larger than the reference displacement Lm. When the displacement La is smaller than the reference value, a second correction is performed to change the target current value Im1 of the main power to a target current value Im22 larger than the target current value Im1 in the normal state. Therefore, the excessive or insufficient heat generated during welding due to the displacement of the stud 80 can be filled by changing the target current value Im 1.
According to the arc stud welding apparatus 100 of the present embodiment, the control device 52 further stops welding of the stud 80 when the difference between the displacement amount La and the predetermined reference value is not included in the second range that is wider than the first range. When it is determined during the pilot arc that the welding quality is not obtained even by the second correction on the surface of the base material 90, the welding can be stopped, and unnecessary processing can be reduced or prevented.
B. Other embodiments:
(B1) In the first embodiment described above, the control device 52 executes both the first correction and the second correction. In contrast, for example, when the mechanical error of the stud 80 due to the driving mechanism of the welding gun 70 is sufficiently small and the influence of the distance between the stud 80 and the base material 90 on the welding quality is sufficiently small, for example, step S40 and step S50 may be omitted, and only the first correction may be performed without performing the second correction. In this case, the control device 52 may move to step S60 after step S30 is performed. In addition, the second correction may be omitted and step S80 may be further omitted.
(B2) In the first embodiment, when the difference between the displacement La obtained in step S40 and the reference displacement Lm is not included in the second range, the control device 52 stops welding the stud 80. In contrast, even when the difference between the displacement amount La and the reference displacement Lm is not included in the second range, for example, when the welding quality after the main arc can be sufficiently obtained by performing additional processing after the main arc, the welding of the stud 80 may not be stopped. The same applies to step S80.
The present disclosure is not limited to the above-described embodiments, and can be implemented in various configurations within a scope not departing from the gist thereof. For example, the technical features of the embodiments corresponding to the technical features of the embodiments described in the summary of the invention can be appropriately replaced or combined in order to solve part or all of the above-described problems or in order to achieve part or all of the above-described effects. Note that, this feature can be deleted appropriately as long as it is not described as an essential feature in the present specification.
Claims (5)
1. An arc stud welding apparatus, comprising:
a welding gun for pressing and pulling up the stud relative to the base material;
a power supply device capable of supplying electric power to the welding gun;
a voltage sensor for detecting a voltage applied to the welding gun; and
A control device for controlling the power supply device and the welding gun during a pilot arc period and a main arc period, wherein the pilot arc period is a period for supplying pilot power generated by the pilot arc at the base material and the stud to the welding gun, the main arc period is a period for supplying main power generated by the main arc at the base material and the stud to the welding gun, and a period for supplying current larger than current flowing to the welding gun during the pilot arc period to the welding gun,
The control means may be configured to, in a case where a voltage value obtained from the voltage sensor during the pilot arc is greater than a predetermined first threshold value,
a first correction for changing the welding conditions during the main arc and suppressing the heat generated in the base metal and the stud,
welding is performed using the processing conditions changed by the first correction,
the control device further stops welding of the stud when the obtained voltage value during the pilot arc is equal to or more than a second threshold value which is predetermined and greater than the first threshold value,
further comprising a displacement sensor for detecting the displacement of the stud relative to the base material,
the control means may be configured to, in a case where a difference between the displacement amount and a predetermined reference value during the pilot arc is not included in a predetermined first range,
a second correction is made to modify the processing conditions of the welding during the main arc and to adjust the heat,
when the displacement amount is not included in the first range, the control device performs the second correction of changing the target current value of the main power to a current value smaller than the target current value of the main power when the difference between the displacement amount and the reference value is included in the first range,
When the displacement amount is not included in the first range, the control device performs the second correction of changing the target current value of the main power to a current value larger than the target current value of the main power when the difference between the displacement amount and the reference value is included in the first range, when the displacement amount is smaller than the reference value.
2. The arc stud welding apparatus according to claim 1,
the control means performs the first correction of advancing a transition timing to the main arc period.
3. The arc stud welding apparatus according to claim 1 or 2,
the control device performs the first correction to reduce a target current value of the main power.
4. The arc stud welding apparatus according to claim 1,
the control device further stops welding of the stud when the difference between the displacement amount and the reference value is not included in a second range that is predetermined and wider than the first range.
5. An arc stud welding method, wherein,
during a pilot arc for supplying pilot power generated by the pilot arc at a base material and a stud to the base material and the stud, a voltage value of the pilot power supplied to the base material and the stud is obtained,
In case the obtained voltage value is larger than a predetermined first threshold value,
a first correction for changing a processing condition of welding in a main arc period in which main power generated by a main arc in the base material and the stud is supplied to the base material and the stud and in which a current larger than a current flowing to the base material and the stud in the pilot arc period is caused to flow to the base material and the stud, and for suppressing heat generated during welding of the base material and the stud,
welding is performed using the processing conditions changed by the first correction,
further, when the obtained voltage value during the pilot arc is equal to or greater than a second threshold value which is predetermined and greater than the first threshold value, the welding of the stud is stopped,
in the case where the difference between the displacement amount of the stud relative to the base material during the pilot arc and a predetermined reference value is not included in a predetermined first range,
a second correction is made to modify the processing conditions of the welding during the main arc and to adjust the heat,
when the displacement amount is not included in the first range, the second correction is performed to change the target current value of the main power to a current value smaller than the target current value of the main power when the difference between the displacement amount and the reference value is included in the first range,
When the displacement amount is not included in the first range, the second correction is performed to change the target current value of the main power to a current value larger than the target current value of the main power when the difference between the displacement amount and the reference value is included in the first range, when the displacement amount is smaller than the reference value.
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| JP2022157957A (en) | 2022-10-14 |
| CN115194303A (en) | 2022-10-18 |
| JP7548860B2 (en) | 2024-09-10 |
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