CN116174860A - Electromagnetic auxiliary K-TIG multi-position automatic welding system and control method - Google Patents
Electromagnetic auxiliary K-TIG multi-position automatic welding system and control method Download PDFInfo
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- CN116174860A CN116174860A CN202310147734.1A CN202310147734A CN116174860A CN 116174860 A CN116174860 A CN 116174860A CN 202310147734 A CN202310147734 A CN 202310147734A CN 116174860 A CN116174860 A CN 116174860A
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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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
- B23K9/02—Seam welding; Backing means; Inserts
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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
- B23K9/08—Arrangements or circuits for magnetic control of the arc
Abstract
The invention discloses an electromagnetic auxiliary K-TIG multi-position automatic welding system and a control method, comprising the following steps: the welding system comprises an industrial personal computer, a welding robot, a K-TIG welding machine, an excitation power supply, a visual detection camera, a K-TIG welding gun, an excitation device and a parent metal to be welded, wherein the system acquires an image of a welding area through the visual detection camera, and sends the image into the industrial personal computer to perform intelligent operation so as to acquire the position and the penetration state of the weld to be welded and predict the flowing trend of molten pool metal in advance, so that the motion track of the welding robot is regulated and controlled, the output current of the K-TIG welding machine and the output current and the direction of the excitation power supply are controlled, the excitation device is controlled to generate a magnetic field, lorentz force is formed to promote the arc deflection, molten pool metal downward flowing caused by the action of gravity is avoided under the condition of good penetration, the automatic operation of the welding process robot is realized, manual intervention is avoided, and the welding efficiency is greatly improved.
Description
Technical Field
The invention relates to the technical field of welding, in particular to an electromagnetic auxiliary K-TIG multi-position automatic welding system and a control method.
Background
With the rapid reduction of resources, the national demand for import and storage of clean energy is increasing, so that a great amount of large curved surface storage tanks (LNG) are urgently needed to be built for ocean transportation and storage. In order to ensure safety and make full use of storage space, natural gas is liquefied in a high-pressure mode, so that a base material of the storage tank is thicker, and the storage tank is larger in structure, and a mode of welding after splicing a plurality of steel plates on site is often adopted, so that a plurality of welding positions are included. If the conventional welding method is adopted, a large groove is needed to be formed, multi-layer and multi-channel welding is needed, a large amount of welding wires are wasted to be used as filling metal, and the cost and the working hour are high. The K-TIG welding is used as a novel welding mode, one-time penetration welding can be realized without grooving and filling welding wires, and the single-sided welding and double-sided forming have the advantages of high efficiency, energy saving, time saving and labor saving.
When in K-TIG welding, the arc pressure is required to penetrate through the base metal to form a penetrating lock hole, so that the purposes of once penetration welding and single-sided welding and double-sided molding are achieved, and the application range of the welding machine is limited to the flat welding position due to the characteristics. For welding with a large curved surface structure, the inclination angle of a welding line to be welded is changed continuously along with the change of a welding position, and often comprises inclined welding, transverse welding, vertical welding and the like, molten pool metal of the welding line is enabled to flow under the action of gravity, so that the welding line cannot be formed into a cutting shape, and therefore, a method for inhibiting the molten pool metal from flowing downwards during the welding of K-TIG multi-position (including but not limited to flat welding, transverse welding, climbing welding, vertical welding and the like) is urgently needed, thereby improving the welding line forming and widening the application range of K-TIG welding. The large-scale curved surface structure is large in size, long-time high-altitude welding operation is needed, manual welding is dangerous, consistency of welding quality cannot be guaranteed in long-time operation, and therefore automatic welding technology of a robot is needed.
Disclosure of Invention
In order to overcome the defects and shortcomings of the prior art, the invention aims to provide an electromagnetic auxiliary K-TIG multi-position automatic welding system and a control method. The multi-position welding device comprises, but is not limited to, flat welding, transverse welding, climbing welding, vertical welding and the like, is used for improving the welding efficiency of a large-scale curved surface structure, and realizes the robot automatic K-TIG welding of the large-scale curved surface structure, thereby reducing the production cost and improving the welding quality.
The aim of the invention is achieved by the following technical scheme:
an electromagnetic auxiliary K-TIG multi-position automatic welding system comprises an industrial personal computer, a welding robot, a K-TIG welding machine, an excitation power supply, a visual detection camera, a K-TIG welding gun, an excitation device and a parent metal to be welded;
the industrial personal computer is connected with the welding robot, the K-TIG welding machine, the exciting power supply and the visual detection camera;
the negative electrode of the K-TIG welding machine is connected with a K-TIG welding gun, and the positive electrode of the K-TIG welding machine is connected with a parent metal to be welded;
two ends of the excitation device are connected with an excitation power supply and sleeved on a K-TIG welding gun, and the excitation device is arranged on a cantilever beam at the front end of the welding robot;
the visual detection camera is arranged on a cantilever beam at the front end of the welding robot and is positioned at the front end of the welding gun, and the lens is focused on the molten pool area;
the welding robot carries a K-TIG welding gun, an excitation device and a visual detection camera to move along a weld joint to be welded.
Further, the excitation power supply comprises a full-bridge rectification filter module, a Buck direct-current conversion module and a polarity conversion module;
one end of the full-bridge rectifying and filtering module is connected with an alternating current input power grid, and the other end of the full-bridge rectifying and filtering module is connected with the Buck direct current conversion module;
one end of the polarity conversion module is connected with the Buck direct current conversion module, and the other end of the polarity conversion module is connected with the excitation device.
Further, the industrial personal computer outputs six PWM control signals to control the exciting power supply, specifically:
the control signal PWM1 and the control signal PWM2 are complementary and are used for controlling the Buck direct-current conversion module and controlling the output voltage amplitude of the excitation power supply;
the control signals PWM3, PWM4, PWM5 and PWM6 control the polarity conversion module to complete the output polarity of the exciting power supply.
Further, the exciting device includes a magnetic core and an exciting coil spirally wound around the magnetic core.
Furthermore, the magnetic cores are L-shaped, the two sets of L-shaped magnetic cores are placed in a mirror image mode, the generated magnetic field is led into a welding area through the lower portion of the L-shaped magnetic cores, and magnetic lines of force are parallel to a parent metal to be welded.
Further, the welding robot is an industrial robot or a trackless crawling robot, and is arranged on one side of the base metal to be welded if the welding robot is the industrial robot, and is adsorbed on the base metal to be welded if the welding robot is the crawling robot.
Further, the full-bridge rectifying and filtering module comprises a rectifying diode D 1 Rectifier diode D 2 Rectifier diode D 3 Rectifier diode D 4 Filter capacitor C 1 Converting the electric energy of the power grid into smooth direct current;
the Buck direct-current conversion module comprises a power switch tube Q 1 Power switch tube Q 2 Filter inductance L 1 And filter capacitor C 2 ；
The polarity conversion module comprises a power switch tube Q 3 Power switch tube Q 4 Power switch tube Q 5 Power switch tube Q 6 。
A control method of the electromagnetic auxiliary K-TIG multi-position automatic welding system comprises the following steps:
by setting the installation direction of the excitation device and the welding seam and the output current and polarity of the excitation power supply, the deflection angle and deflection direction of the welding arc are controlled, the heating area of the arc to the base metal is changed, and the flowing down of molten pool metal during multi-position welding is regulated.
Further:
when oblique welding or transverse welding is carried out, the excitation device is arranged in parallel to the welding line direction, and the generated magnetic field is parallel to the welding line direction;
at this time, when the exciting power supply outputs positive current, the positive current flows in from the P pole and the N pole of the exciting device, and a parallel magnetic field along the positive direction of the Y axis is generated at this time, and the magnetic field interacts with plasmatic fluid in the welding arc, so that the welding arc is promoted to deflect towards the negative direction of the X axis according to the law of electromagnetic induction;
when the exciting power supply outputs negative polarity current, the exciting power supply flows in from the N pole and flows out from the P pole of the exciting device, a parallel magnetic field along the negative direction of the Y axis is generated, the magnetic field interacts with plasmatic fluid in the welding arc, and the welding arc is caused to deflect towards the positive direction of the X axis according to the law of electromagnetic induction;
when vertical welding is carried out, the excitation device is arranged perpendicular to the welding line direction, and the generated magnetic field is perpendicular to the welding line direction;
when the exciting power supply outputs positive current, the positive current flows in from the P pole and flows out from the N pole of the exciting device, a parallel magnetic field along the negative direction of the X axis is generated, the magnetic field interacts with plasmatic fluid in the welding arc, and the welding arc is caused to deflect towards the negative direction of the Y axis according to the law of electromagnetic induction;
when the exciting power supply outputs negative polarity current, the exciting power supply flows in from the N pole and flows out from the P pole of the exciting device, generates a parallel magnetic field along the positive direction of the X axis, and the magnetic field interacts with plasmatic fluid in the welding arc to drive the welding arc to deflect towards the positive direction of the Y axis according to the law of electromagnetic induction.
Further, the exciting power supply adopts 'duty ratio feedforward+voltage ring' control, specifically:
obtaining a set output voltage of the excitation power supply, calculating an absolute value of the set output voltage, and simultaneously carrying out logic calculation according to signs of the set output voltage to obtain logic levels of a control signal PWM3, a control signal PWM4, a control signal PWM5 and a control signal PWM6 so as to control the output polarity of the excitation power supply;
collecting the input voltage of an excitation power supply, and obtaining an absolute value of the input voltage;
dividing the set output voltage of the exciting power supply by the input voltage of the exciting power supply, and multiplying the set output voltage by a gain coefficient Gv to obtain a feedforward duty ratio;
collecting the actual output voltage of the exciting power supply, calculating the absolute value of the actual output voltage, and then calculating the error between the actual output voltage and the set output voltage of the exciting power supply;
the error obtained in the previous step is sent to a PI controller for closed loop calculation, and an output compensation duty ratio is obtained;
and summing the feedforward duty cycle and the output compensation duty cycle to obtain a total output duty cycle, and then performing anti-saturation calculation to limit the maximum and minimum output duty cycles.
Comparing the total output duty ratio with the periodic triangular wave to obtain logic levels of a control signal PWM1 and a control signal PWM 2;
the total output duty ratio is output to the exciting power supply to obtain the actual output voltage.
Compared with the prior art, the invention has the following advantages and beneficial effects:
(1) When the large curved surface structure is used for multi-position welding, the system can detect the state of molten pool metal in real time, and predict and dynamically adjust the output current of the excitation power supply in advance so as to generate Lorentz force to inhibit the molten pool metal from flowing down, thereby ensuring good welding effect and realizing automatic welding of the whole-process robot;
(2) The invention can control the swing of the electric arc by utilizing the magnetic field generated by electric energy without adopting a mechanical swing mode, thereby improving the problem of unstable molten pool caused by mechanical vibration during welding;
(3) The system can be also used for a flat welding system, and electric arc oscillation is promoted by periodic alternating current, so that electric arc magnetic bias blowing caused by partial material remanence is prevented, and the effects of oscillating a molten pool and refining grains are achieved.
Drawings
FIG. 1 is a system block diagram of the present invention;
FIG. 2 is a schematic diagram of the excitation power supply of the present invention;
FIG. 3 is a diagram of an excitation power supply control system of the present invention;
FIG. 4 is a control signal diagram of the Buck DC conversion module of the present invention;
FIG. 5 is a diagram of a polarity inversion module control signal according to the present invention;
fig. 6 (a) is a structural view of the exciting device of the present invention;
FIG. 6 (b) is a schematic view of the exciter assembly of the present invention mounted on a YOZ plane;
FIG. 6 (c) is a schematic view of the field device of the present invention mounted on an XOZ plane;
FIG. 7 (a) is a schematic view of arc deflection when the excitation device is mounted on the YOZ plane and the excitation current is positive;
FIG. 7 (b) is a schematic view of arc deflection when the excitation device is mounted on the YOZ plane and the excitation current is negative;
FIG. 7 (c) is a schematic view of arc deflection when the excitation device is mounted in the XOZ plane and the excitation current is positive polarity;
FIG. 7 (d) is a schematic view of arc deflection when the excitation device is mounted in the XOZ plane and the excitation current is negative;
fig. 8 is a flow chart of a control method of the present invention.
Detailed Description
The present invention will be described in further detail with reference to examples, but embodiments of the present invention are not limited thereto.
Examples
As shown in fig. 1, an electromagnetic auxiliary K-TIG multi-position automatic welding system and a control method thereof include: the welding machine comprises an industrial personal computer 101, a welding robot 102, a K-TIG welding machine 103, an excitation power supply 104, a visual inspection camera 105, a K-TIG welding gun 106, an excitation device 107 and a base metal 108 to be welded;
the industrial personal computer 101 is connected with a welding robot 102, a K-TIG welding machine 103, an excitation power supply 104 and a visual inspection camera 105.
And the negative electrode of the K-TIG welding machine is connected with the K-TIG welding gun, and the positive electrode of the K-TIG welding machine is connected with the parent metal to be welded.
Two ends of the excitation device 107 are connected with an excitation power supply and sleeved on a K-TIG welding gun, and are arranged on a cantilever beam at the front end of the welding robot.
The visual inspection camera is arranged on a cantilever beam at the front end of the welding robot and is positioned at the front end of the welding gun, and the lens is focused on the molten pool area.
The welding robot is an industrial robot or a trackless crawling robot, is arranged beside a parent metal to be welded if the welding robot is the industrial robot, is adsorbed on the parent metal to be welded if the welding robot is the crawling robot, and carries a K-TIG welding gun, an excitation device and a visual detection camera to move along a welding seam to be welded.
As shown in fig. 2, the exciting power supply 104 includes a full-bridge rectifying and filtering module, a Buck dc conversion module and a polarity conversion module;
one end of the full-bridge rectifying and filtering module is connected with an alternating current input power grid, and the other end of the full-bridge rectifying and filtering module is connected with the Buck direct current conversion module;
one end of the polarity conversion module is connected with the Buck direct current conversion module, and the other end of the polarity conversion module is connected with the excitation device;
the full-bridge rectifying and filtering module comprises a rectifying diode D 1 Rectifier diode D 2 Rectifier diode D 3 Rectifier diode D 4 Filter capacitor C 1 Converting the electric energy of the power grid into smooth direct current;
the Buck direct-current conversion module comprises a power switch tube Q 1 Power switch tube Q 2 Filter inductance L 1 And filter capacitor C 2 ；
The polarity conversion module comprises a power switch tube Q 3 Power switch tube Q 4 Power switch tube Q 5 Power switch tube Q 6 。
Further, the full-bridge rectifying and filtering module comprises two working modes:
first working mode: alternating current is positioned in positive half cycle, rectifier diode D 1 And rectifier diode D 4 Conducting to charge the filter capacitor C 1 。
Second mode of operation: alternating current is positioned in the negative half cycle, rectifier diode D 2 And rectifier diode D 3 Conducting to charge the filter capacitor C 1 。
The input voltage of the full-bridge rectifying and filtering module is
The output voltage is
/>
Further, the Buck direct current conversion module is controlled by a control signal PWM1 and a control signal PWM2, as shown in fig. 3, the control signal PWM1 and the control signal PWM2 are complementary, so the Buck direct current conversion module includes two working modes.
First working mode: the control signal PWM1 is high level, the control signal PWM2 is low level, the power switch tube Q 1 On, power switch tube Q 2 Closing due to power switching tube Q 2 The drain electrode potential of the transistor is higher than that of the source electrode, so that the current passes through the full-bridge rectifying and filtering module and then passes through the power switch tube Q 1 Filter inductance L 1 Flows into the polarity conversion module, and at the moment, the filter capacitor C 2 And (5) charging.
Second mode of operation: the control signal PWM1 is low level, the control signal PWM2 is high level, the power switch tube Q 1 Closing, power switch tube Q 2 On, due to the filter inductance L 1 The current at two ends cannot be suddenly changed, so that the current flows through the polarity conversion module and the power switch tube Q 2 And a filtering point L 1 Form a closed loop, at this time, the filter capacitor C 2 Charging, filter capacitor C when current decreases to a certain value 2 And (5) discharging.
Assuming that the duty ratio of the control signal PWM1 is δ, the duty ratio of the control signal PWM2 is 1- δ, so that the output voltage of the Buck dc conversion module is
Further, the polarity conversion module is controlled by a control signal PWM3, a control signal PWM4, a control signal PWM5 and a control signal PWM6, as shown in fig. 4, wherein the control signal PWM3 is the same as the control signal PWM6, and the control signal PWM4 is the same as the control signal PWM5, so that the polarity conversion module comprises two working modes.
First working mode: the control signals PWM3 and PWM6 are high level, the control signals PWM4 and PWM5 are low level, and the power switch tube Q 3 And power switch tube Q 6 On, power switch tube Q 4 And power switch tube Q 5 Closing, at this time, the current output is positiveThe exciting device has P pole inflow and N pole outflow, and the exciting power source has output voltage of
Second mode of operation: the control signals PWM3 and PWM6 are low level, the control signals PWM4 and PWM5 are high level, and the power switch tube Q 4 And power switch tube Q 5 On, power switch tube Q 3 And power switch tube Q 6 Closing, wherein the current output is negative, the current flows in from the N pole and the P pole of the exciting device, and the output voltage of the exciting power supply is
The control signals PWM1 and PWM2 control the power switch tube Q 1 And power switch tube Q 2 The on and off time sequence of the power switch tube Q is controlled by the control signal PWM3, the control signal PWM4, the control signal PWM5 and the control signal PWM6 3 Power switch tube Q 4 Power switch tube Q 5 And power switch tube Q 6 The on and off time sequence of the exciting power supply is completed.
Further, as shown in fig. 5, the exciting power supply adopts a "duty ratio feedforward+voltage loop" control, and the control flow is as follows:
(1) Obtaining a set output voltage of the excitation power supply, calculating an absolute value of the set output voltage, and simultaneously carrying out logic calculation according to signs of the set output voltage to obtain logic levels of a control signal PWM3, a control signal PWM4, a control signal PWM5 and a control signal PWM6 so as to control the output polarity of the excitation power supply;
(2) Collecting the input voltage of an excitation power supply, and obtaining an absolute value of the input voltage;
(3) Dividing the set output voltage of the exciting power supply by the input voltage of the exciting power supply, and multiplying the set output voltage by a gain coefficient Gv to obtain a feedforward duty ratio;
(4) Collecting the actual output voltage of the exciting power supply, calculating the absolute value of the actual output voltage, and then calculating the error between the actual output voltage and the set output voltage of the exciting power supply;
(5) The error obtained in the previous step is sent to a PI controller for closed loop calculation, and an output compensation duty ratio is obtained;
(6) Summing the feedforward duty cycle and the output compensation duty cycle to obtain a total output duty cycle, then performing anti-saturation calculation, and limiting the maximum and minimum duty cycles of the output;
(7) Comparing the total output duty ratio with the periodic triangular wave to obtain logic levels of a control signal PWM1 and a control signal PWM 2;
(8) The total output duty ratio is output to the exciting power supply to obtain the actual output voltage.
Further, as shown in fig. 6 (a), the exciting device is composed of a magnetic core and an exciting coil, the magnetic core is made of silicon steel sheet with high magnetic permeability, the exciting coil is made of high-temperature resistant enameled wire, the exciting coil is spirally wound around the magnetic core, the magnetic core is L-shaped, the exciting device is formed by mirror-image placement of two sets of L-shaped magnetic cores, the generated magnetic field is led into a welding area through the lower part of the L-shaped magnetic core, and magnetic force lines are parallel to a parent metal to be welded;
the excitation device comprises two mounting modes:
mode one: as shown in fig. 6 (b), the excitation device is installed parallel to the weld direction (YOZ plane), and the magnetic field generated at this time is parallel to the weld direction:
as shown in fig. 7 (a), when the exciting power supply outputs a positive current, the positive current flows in from the P pole and the N pole of the exciting device, and a parallel magnetic field along the positive direction of the Y axis is generated, and the magnetic field interacts with plasmatic fluid in the welding arc, so that the welding arc is caused to deflect in the negative direction of the X axis according to the law of electromagnetic induction;
as shown in fig. 7 (b), when the exciting power supply outputs a negative current, the exciting power supply flows in from the N pole and flows out from the P pole of the exciting device, and generates a parallel magnetic field along the negative Y axis direction, which interacts with the plasmatic fluid in the welding arc and causes the welding arc to deflect in the positive X axis direction according to the law of electromagnetic induction;
mode two: as shown in fig. 6 (c), the excitation device is installed perpendicular to the weld direction (XOZ plane), and the magnetic field generated at this time is perpendicular to the weld direction:
as shown in fig. 7 (c), when the exciting power supply outputs a positive current, the positive current flows in from the P pole and flows out from the N pole of the exciting device, and a parallel magnetic field along the negative X axis direction is generated, and the magnetic field interacts with plasmatic fluid in the welding arc to cause the welding arc to deflect in the negative Y axis direction according to the law of electromagnetic induction;
as shown in fig. 7 (d), when the exciting power supply outputs a negative current, the exciting power supply flows in from the N pole and flows out from the P pole of the exciting device, and generates a parallel magnetic field along the positive direction of the X axis, and the magnetic field interacts with a plasmatic fluid in the welding arc to cause the welding arc to deflect in the positive direction of the Y axis according to the law of electromagnetic induction;
therefore, the purpose of controlling deflection of the welding arc can be achieved by controlling the output polarity of the excitation power supply, so that the heating area of the arc to the base metal is changed, and the mode is beneficial to regulating and controlling the flowing of molten pool metal during multi-position welding;
when the oblique welding or the transverse welding is carried out, the first installation mode can be adopted, and the magnetic field deflects the welding arc to be perpendicular to the welding line direction; when vertical welding is carried out, a second installation mode is adopted, and the magnetic field deflects the welding arc parallel to the welding line direction;
according to the magnetic induction intensity formula b=μ 0 nI/2 (wherein B is magnetic induction, mu 0 Vacuum magnetic permeability, n is the number of turns of the coil, I is exciting current), the magnetic induction intensity generated by the exciting device is in direct proportion to the magnitude of exciting coil current passing through the exciting device, and meanwhile, the magnetic field direction is related to the direction of exciting coil current passing through the exciting device; the output voltage of the exciting power supply is
Assuming that the internal resistance of the exciting coil is R, its output current is +.>
(wherein sign and control signal PWM3, control)The control signal PWM4, the control signal PWM5 and the control signal PWM6 are related, so that the deflection angle and the deflection direction of the welding arc can be adjusted by adjusting the output current and the polarity of the excitation power supply, and molten pool metal flowing during multi-position welding of a large curved surface structure can be adjusted; />
As shown in fig. 8, the whole control method of the invention comprises the following steps:
the visual detection camera shoots a welding pool area in real time, and sends the shot image to the industrial personal computer for processing to obtain the position of a weld joint to be welded, the flowing trend of molten pool metal and the penetration state;
the industrial personal computer calls an intelligent closed-loop control algorithm according to the information, plans the movement position of the welding robot to move along the position of the weld joint to be welded, sends a command to the welding robot, and adjusts the movement track of the welding robot; meanwhile, welding current parameters are adjusted according to the penetration state, and the welding parameters are sent to a K-TIG welding machine, so that stable penetration is ensured without burning-through defects; calculating required output parameters of the exciting power supply according to the predicted molten pool metal flow trend, and sending parameter instructions to the exciting power supply; the welding robot, the K-TIG welding machine and the exciting power supply are quickly adjusted after receiving the instruction of the industrial personal computer, and output parameters are changed so as to obtain good welding seams.
Meanwhile, the system can also be used for a flat welding position, and the alternating current is output by periodically adjusting the exciting power supply, so that the arc can generate a periodic swinging effect, and a swinging effect is generated on a welding pool.
According to the method, the welding area image is acquired through the visual detection camera, the welding area image is sent into the industrial personal computer to perform intelligent operation, so that the position and the penetration state of a welding seam to be welded are obtained, the flowing trend of molten pool metal is predicted in advance, the movement track of a welding robot is regulated and controlled, the output current of the K-TIG welding machine and the output current and the direction of an excitation power supply are controlled, the excitation device is controlled to generate a magnetic field, lorentz force is formed to promote arc deflection, molten pool metal flowing caused by the action of gravity is avoided under the condition of good penetration, automatic operation of the welding process robot is realized, manual intervention is avoided, and welding efficiency is greatly improved.
It should be noted that, in the present invention, the Buck dc conversion module of the exciting power supply should include all circuit topologies capable of performing dc conversion, such as phase-shifted full-bridge, LLC, flyback, half-bridge, etc.
The embodiments described above are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the embodiments described above, and any other changes, modifications, substitutions, combinations, and simplifications that do not depart from the spirit and principles of the present invention should be made in the equivalent manner, and are included in the scope of the present invention.
Claims (10)
1. An electromagnetic auxiliary K-TIG multi-position automatic welding system is characterized by comprising an industrial personal computer, a welding robot, a K-TIG welding machine, an excitation power supply, a visual detection camera, a K-TIG welding gun, an excitation device and a parent metal to be welded;
the industrial personal computer is connected with the welding robot, the K-TIG welding machine, the exciting power supply and the visual detection camera;
the negative electrode of the K-TIG welding machine is connected with a K-TIG welding gun, and the positive electrode of the K-TIG welding machine is connected with a parent metal to be welded;
two ends of the excitation device are connected with an excitation power supply and sleeved on a K-TIG welding gun, and the excitation device is arranged on a cantilever beam at the front end of the welding robot;
the visual detection camera is arranged on a cantilever beam at the front end of the welding robot and is positioned at the front end of the welding gun, and the lens is focused on the molten pool area;
the welding robot carries a K-TIG welding gun, an excitation device and a visual detection camera to move along a weld joint to be welded.
2. The electromagnetic auxiliary K-TIG multi-position automatic welding system of claim 1, wherein the excitation power source comprises a full-bridge rectifying and filtering module, a Buck dc conversion module, and a polarity conversion module;
one end of the full-bridge rectifying and filtering module is connected with an alternating current input power grid, and the other end of the full-bridge rectifying and filtering module is connected with the Buck direct current conversion module;
one end of the polarity conversion module is connected with the Buck direct current conversion module, and the other end of the polarity conversion module is connected with the excitation device.
3. The electromagnetic auxiliary K-TIG multi-position automatic welding system according to claim 2, wherein the industrial personal computer outputs six PWM control signals to control the exciting power supply, specifically:
the control signal PWM1 and the control signal PWM2 are complementary and are used for controlling the Buck direct-current conversion module and controlling the output voltage amplitude of the excitation power supply;
the control signals PWM3, PWM4, PWM5 and PWM6 control the polarity conversion module to complete the output polarity of the exciting power supply.
4. The electromagnetic assist K-TIG multi-location automatic welding system of any of claims 1-3, wherein the excitation device comprises a magnetic core and an excitation coil helically wound around the magnetic core.
5. The electromagnetic auxiliary K-TIG multi-position automatic welding system according to claim 4, wherein the magnetic cores are L-shaped, two sets of L-shaped magnetic cores are placed in mirror images, the generated magnetic field is led into the welding area through the lower portion of the L-shaped magnetic cores, and magnetic lines of force are distributed parallel to the parent metal to be welded.
6. The electromagnetic assist K-TIG multi-position automatic welding system according to claim 1, wherein the welding robot is an industrial robot or a trackless crawling robot, and is installed on a side of a base material to be welded if the welding robot is an industrial robot, and is adsorbed on the base material to be welded if the welding robot is a trackless crawling robot.
7. The electromagnetic assist K-TIG multi-location automatic welding system of claim 2, wherein the full bridge rectifier filter module comprises a rectifier diode D 1 Rectifier diode D 2 Rectifier diode D 3 Rectifier diode D 4 Filter capacitor C 1 Converting the electric energy of the power grid into smooth direct current;
the Buck direct-current conversion module comprises a power switch tube Q 1 Power switch tube Q 2 Filter inductance L 1 And filter capacitor C 2 ；
The polarity conversion module comprises a power switch tube Q 3 Power switch tube Q 4 Power switch tube Q 5 Power switch tube Q 6 。
8. A control method based on the electromagnetic auxiliary K-TIG multi-position automatic welding system of any of claims 1-7, comprising:
by setting the installation direction of the excitation device and the welding seam and the output current and polarity of the excitation power supply, the deflection angle and deflection direction of the welding arc are controlled, the heating area of the arc to the base metal is changed, and the flowing down of molten pool metal during multi-position welding is regulated.
9. The control method according to claim 8, wherein,
when oblique welding or transverse welding is carried out, the excitation device is arranged in parallel to the welding line direction, and the generated magnetic field is parallel to the welding line direction;
at this time, when the exciting power supply outputs positive current, the positive current flows in from the P pole and the N pole of the exciting device, and a parallel magnetic field along the positive direction of the Y axis is generated at this time, and the magnetic field interacts with plasmatic fluid in the welding arc, so that the welding arc is promoted to deflect towards the negative direction of the X axis according to the law of electromagnetic induction;
when the exciting power supply outputs negative polarity current, the exciting power supply flows in from the N pole and flows out from the P pole of the exciting device, a parallel magnetic field along the negative direction of the Y axis is generated, the magnetic field interacts with plasmatic fluid in the welding arc, and the welding arc is caused to deflect towards the positive direction of the X axis according to the law of electromagnetic induction;
when vertical welding is carried out, the excitation device is arranged perpendicular to the welding line direction, and the generated magnetic field is perpendicular to the welding line direction;
when the exciting power supply outputs positive current, the positive current flows in from the P pole and flows out from the N pole of the exciting device, a parallel magnetic field along the negative direction of the X axis is generated, the magnetic field interacts with plasmatic fluid in the welding arc, and the welding arc is caused to deflect towards the negative direction of the Y axis according to the law of electromagnetic induction;
when the exciting power supply outputs negative polarity current, the exciting power supply flows in from the N pole and flows out from the P pole of the exciting device, generates a parallel magnetic field along the positive direction of the X axis, and the magnetic field interacts with plasmatic fluid in the welding arc to drive the welding arc to deflect towards the positive direction of the Y axis according to the law of electromagnetic induction.
10. The control method according to claim 8, wherein the exciting power supply is controlled by a duty ratio feedforward+voltage ring, specifically:
obtaining a set output voltage of the excitation power supply, calculating an absolute value of the set output voltage, and simultaneously carrying out logic calculation according to signs of the set output voltage to obtain logic levels of a control signal PWM3, a control signal PWM4, a control signal PWM5 and a control signal PWM6 so as to control the output polarity of the excitation power supply;
collecting the input voltage of an excitation power supply, and obtaining an absolute value of the input voltage;
dividing the set output voltage of the exciting power supply by the input voltage of the exciting power supply, and multiplying the set output voltage by a gain coefficient Gv to obtain a feedforward duty ratio;
collecting the actual output voltage of the exciting power supply, calculating the absolute value of the actual output voltage, and then calculating the error between the actual output voltage and the set output voltage of the exciting power supply;
the error obtained in the previous step is sent to a PI controller for closed loop calculation, and an output compensation duty ratio is obtained;
summing the feedforward duty cycle and the output compensation duty cycle to obtain a total output duty cycle, then performing anti-saturation calculation, and limiting the maximum and minimum duty cycles of the output;
comparing the total output duty ratio with the periodic triangular wave to obtain logic levels of a control signal PWM1 and a control signal PWM 2;
the total output duty ratio is output to the exciting power supply to obtain the actual output voltage.
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| CN117001109A (en) * | 2023-08-22 | 2023-11-07 | 广东福维德焊接股份有限公司 | 9Ni steel deep-melting arc welding magnetic control power supply system and control method |
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| CN117001109A (en) * | 2023-08-22 | 2023-11-07 | 广东福维德焊接股份有限公司 | 9Ni steel deep-melting arc welding magnetic control power supply system and control method |
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