CN116174865A - Consumable electrode gas shielded welding system, control method thereof, controller and medium - Google Patents
Consumable electrode gas shielded welding system, control method thereof, controller and medium Download PDFInfo
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- CN116174865A CN116174865A CN202211743642.1A CN202211743642A CN116174865A CN 116174865 A CN116174865 A CN 116174865A CN 202211743642 A CN202211743642 A CN 202211743642A CN 116174865 A CN116174865 A CN 116174865A
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- 238000003466 welding Methods 0.000 title claims abstract description 261
- 238000000034 method Methods 0.000 title claims abstract description 40
- 230000003139 buffering effect Effects 0.000 claims abstract description 32
- 238000003860 storage Methods 0.000 claims abstract description 18
- 239000002184 metal Substances 0.000 claims abstract description 10
- 230000001276 controlling effect Effects 0.000 claims description 45
- 238000005070 sampling Methods 0.000 claims description 19
- 238000005086 pumping Methods 0.000 claims description 13
- 230000001105 regulatory effect Effects 0.000 claims description 6
- 230000007423 decrease Effects 0.000 claims description 4
- 230000009123 feedback regulation Effects 0.000 claims description 2
- 238000002844 melting Methods 0.000 abstract description 7
- 230000008018 melting Effects 0.000 abstract description 7
- 239000007789 gas Substances 0.000 description 40
- 238000010586 diagram Methods 0.000 description 11
- 230000008569 process Effects 0.000 description 8
- 239000000463 material Substances 0.000 description 6
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- 238000010168 coupling process Methods 0.000 description 3
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- 239000003570 air Substances 0.000 description 1
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- 239000010953 base metal Substances 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a 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
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
-
- 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
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
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Abstract
The application discloses a gas metal arc welding system of a melting electrode, a control method, a controller and a medium thereof. The gas shielded welding system for the consumable electrode comprises a welding gun and a wire feeding device, wherein the wire feeding device comprises a front-stage wire feeding device, a welding wire buffering device, a rear-stage wire feeding device and a welding wire storage device which are sequentially connected through a wire feeding pipe, and the front-stage wire feeding device is connected with the welding gun through the wire feeding pipe; the control method comprises the following steps: acquiring a current feedback value fed back by the welding wire buffer device; adjusting the wire feeding speed of a later stage wire feeding device according to the current feedback value so as to update the current feedback value and obtain an updated feedback value; and when the updated feedback value fed back by the welding wire buffer device reaches a preset target value, controlling the rear-stage wire feeding device to be closed. By the scheme, the initial state of the system can be ensured to meet the welding requirement when the next welding starts.
Description
Technical Field
The application relates to the technical field of welding, in particular to a gas shielded welding system for a melting electrode, a control method, a controller and a medium thereof.
Background
In order to expand the application range of gas shielded welding of a melting electrode, particularly reduce heat input and welding spatter, improve welding speed and welding forming, a scheme for promoting droplet transition by utilizing surface tension between a droplet and a molten pool through high-frequency reciprocating wire feeding is proposed. The proposal generally needs a servo motor to realize the reciprocating motion of wire feeding of the level not less than 70Hz, and sets different wire feeding speed amplitude values and directions in the short circuit and arcing stage, and when the selected wire feeding speed parameters are proper, the stable short circuit molten drop transition can be realized. In order to realize high-frequency reciprocating wire feeding of the level above 70Hz, a wire feeding system comprising a front-stage wire feeding motor, a welding wire buffer mechanism and a rear-stage wire feeding motor is provided, wherein the front-stage wire feeding motor realizes reciprocating motion characteristics and is controlled by a servo motor and a servo driver. However, because the motor is usually placed inside the welding gun, and the volume and power of the motor are limited, the motor cannot always maintain good steady moment while realizing the high-frequency reciprocating wire feeding function, and therefore an auxiliary wire feeding motor for continuously feeding welding wires, namely a rear wire feeding motor, must be added at the rear stage. Because the rear-stage motor does not need to consider limiting conditions such as volume and power, the steady moment and power are large enough, and the dynamic index is not a main assessment index, the high-power motor with large inertia and low cost can be selected.
In the steady-state working process, the front-stage motor reciprocates, and the rear-stage motor moves unidirectionally, so that welding wires are inevitably bent, and a wire feeding buffer device is added between the front-stage motor and the rear-stage motor and is used for releasing the energy of the welding wires. When the front-stage motor and the rear-stage motor are asynchronous, the buffer device can automatically adjust the internal structure of the buffer device, and meanwhile, the front-stage wire feeding and the rear-stage wire feeding are ensured to be stably fed. However, the regulation of the buffer device is usually limited, and after a certain limit is reached, the condition of saturation failure of regulation occurs; for example, during transient operation, particularly during the end of welding, the pre-feed motor is often stopped very rapidly, typically within 10 milliseconds, in order to achieve a good arc effect. Because the inertia of the rear wire feeding is large, the rear wire feeding is difficult to stop in a short time, so that the front motor and the rear motor are seriously unsynchronized, the effect of the unsynchronized is completely converted to a buffer, the regulator of the buffer is in a relatively limited modulation state when welding is finished, and saturation failure occurs when the regulator is seriously deformed. When the next welding starts, since the regulator of the buffer device is not in place, there is a high possibility that the buffer is saturated immediately after the welding starts, and then the wire feeding system is broken down.
Disclosure of Invention
The technical problem that this application mainly solves is to provide a melting electrode gas shielded welding system and control method, controller, medium thereof, can guarantee that the initial state of melting electrode gas shielded welding system accords with the welding requirement when the welding begins next time.
In order to solve the above problems, a first aspect of the present application provides a control method of a consumable electrode gas shielded welding system, the consumable electrode gas shielded welding system including a welding gun and a wire feeder, the wire feeder including a front stage wire feeder, a wire buffer, a rear stage wire feeder, and a wire storage device connected in sequence by a wire feed pipe, the front stage wire feeder being connected to the welding gun through the wire feed pipe; the control method comprises the following steps: acquiring a current feedback value fed back by the welding wire buffer device; adjusting the wire feeding speed of the rear stage wire feeding device according to the current feedback value to update the current feedback value to obtain an updated feedback value; and when the updated feedback value fed back by the welding wire buffer device reaches a preset target value, controlling the rear-stage wire feeding device to be closed.
Wherein the consumable electrode gas shielded welding system further comprises a welding power supply; before the step of obtaining the current feedback value fed back by the welding wire buffering device, the method further comprises the following steps: after receiving a welding end signal, controlling the front-stage wire feeder to execute a back-pumping instruction so as to separate a welding wire from a molten pool, and simultaneously controlling the welding power supply to be turned off; and after the back pumping instruction is executed by the front-stage wire feeding device, controlling the front-stage wire feeding device to be closed.
And in the time from the time when the welding end signal is received to the time when the rear-stage wire feeding device is controlled to be closed, the wire feeding direction of the rear-stage wire feeding device moves in a reciprocating mode, and the amplitude of the wire feeding speed of the rear-stage wire feeding device is gradually reduced to 0.
The step of adjusting the wire feeding speed of the subsequent wire feeding device according to the current feedback value to update the current feedback value to obtain an updated feedback value includes: when the current feedback value is larger than the preset target value, controlling the post-stage wire feeding device to forward feed wires so that the updated feedback value is smaller than the current feedback value; and when the current feedback value is smaller than the preset target value, controlling the rear-stage wire feeding device to draw back the welding wire so that the updated feedback value is larger than the current feedback value.
In order to solve the problems, a second aspect of the present application provides a controller applied to a consumable electrode gas shielded welding system including a welding gun and a wire feeder, the wire feeder including a front wire feeder, a wire buffer, a rear wire feeder and a wire storage device connected in sequence by a wire feed pipe, the front wire feeder being connected to the welding gun through the wire feed pipe; the controller includes: the welding logic control module, the front-stage wire feeding control module and the rear-stage wire feeding control module; the welding logic control module is connected with the welding gun and is used for sending a front-stage wire feeding closing signal to the front-stage wire feeding control module; the front-stage wire feeding control module is connected with the front-stage wire feeding device and is used for controlling the front-stage wire feeding device to be closed after receiving the front-stage wire feeding closing signal; the buffer regulator feedback sampling module is connected with the welding wire buffer device and used for acquiring a current feedback value fed back by the welding wire buffer device; the buffer regulator feedback regulation module is connected with the buffer regulator feedback sampling module and is used for regulating the wire feeding speed of the rear-stage wire feeding device according to the current feedback value so as to update the current feedback value; the buffer regulator feedback sampling module is also used for acquiring an updated feedback value fed back by the welding wire buffer device; the welding logic control module is further connected with the feedback sampling module of the buffer regulator, and is further used for sending a rear wire feeding closing signal to the rear wire feeding control module when the updated feedback value fed back by the welding wire buffer device reaches a preset target value; the rear wire feeding control module is respectively connected with the welding logic control module and the rear wire feeding device and is used for controlling the rear wire feeding device to be closed after receiving the rear wire feeding closing signal.
Wherein the consumable electrode gas shielded welding system further comprises a welding power supply; the controller also comprises a power supply control and driving module, wherein the welding logic control module is used for sending a back pumping instruction to the front wire feeding control module after receiving a welding end signal, and simultaneously sending the power supply closing signal to the power supply control and driving module; after receiving a back suction executed signal fed back by the front-stage wire feeding device, sending the front-stage wire feeding closing signal to the front-stage wire feeding control module; the power supply control and driving module is respectively connected with the welding logic control module and the welding power supply and is used for controlling the welding power supply to be turned off after receiving the power supply turning-off signal.
And the rear-stage wire feeding control module controls the wire feeding direction of the rear-stage wire feeding device to reciprocate and gradually reduces the amplitude of the wire feeding speed of the rear-stage wire feeding device to 0 in the time from receiving the rear-stage wire feeding closing signal to controlling the rear-stage wire feeding device to be closed.
The step of adjusting the wire feeding speed of the post-stage wire feeding device according to the current feedback value by the buffer regulator feedback adjustment module so as to update the current feedback value comprises the following steps: when the current feedback value is larger than the preset target value, controlling the post-stage wire feeding device to forward feed wires so that the updated feedback value is smaller than the current feedback value; and when the current feedback value is smaller than the preset target value, controlling the rear-stage wire feeding device to draw back the welding wire so that the updated feedback value is larger than the current feedback value.
To solve the above problems, a third aspect of the present application provides a controller, including a processor and a memory that are connected to each other; wherein the memory stores program instructions, and the processor retrieves the program instructions from the memory to execute the method for controlling the consumable electrode gas shielded welding system according to the first aspect.
In order to solve the above problems, a fourth aspect of the present application provides a consumable electrode gas shielded welding system, which includes a welding power source, a wire feeder, and a controller, the controller being connected to the welding power source and the wire feeder, respectively, and the controller being the controller of the second aspect or the third aspect.
To solve the above-described problems, a fifth aspect of the present application provides a computer-readable storage medium having stored thereon program instructions which, when executed by a processor, implement the control method of the consumable electrode gas shielded welding system of the first aspect described above.
The beneficial effects of the invention are as follows: in the control method of the consumable electrode gas shielded welding system, the consumable electrode gas shielded welding system comprises a welding gun and a wire feeding device, wherein the wire feeding device comprises a front-stage wire feeding device, a welding wire buffering device, a rear-stage wire feeding device and a welding wire storage device which are sequentially connected through a wire feeding pipe, the front-stage wire feeding device is connected with the welding gun through the wire feeding pipe, the current feedback value fed back by the welding wire buffering device is obtained, the wire feeding speed of the rear-stage wire feeding device is adjusted according to the current feedback value, the feedback value is updated, the updated feedback value is obtained, and when the updated feedback value fed back by the welding wire buffering device reaches a preset target value, the rear-stage wire feeding device is controlled to be closed. Because this application is when welding, the wire feed of later stage wire feed unit is not closed immediately, but continue to adjust the wire feed speed of later stage wire feed unit according to the current feedback value that welding wire buffer device fed back, with the current feedback value to the update, with the feedback value adjustment after guaranteeing that welding wire buffer device feeds back to preset target value in reasonable time, guarantee that welding wire buffer device adjusts to suitable, keep away from saturation adjustment's position promptly, at this moment, later stage wire feed unit just stops the action, just so make welding wire buffer device be in suitable adjustment position when welding is finished or welding speed change is great, the wire feed unit that has avoided follow-up welding process because welding wire buffer device is in unsuitable position collapses, then cause the unsuccessful problem of arcing, can guarantee that the initial state of melting electrode gas shielded arc welding system accords with the welding requirement when next welding begins.
Drawings
FIG. 1 is a flow chart of an embodiment of a method of controlling a consumable electrode gas arc welding system of the present application;
FIG. 2 is a schematic waveform diagram of the feedback values of the power supply, the front wire feed speed, the rear wire feed speed, and the wire buffering device according to the welding command in an application scenario of the present application;
FIG. 3 is a schematic diagram of a framework of an embodiment of the controller of the present application;
FIG. 4 is a schematic diagram of a frame structure of another embodiment of the controller of the present application;
FIG. 5 is a schematic diagram of a frame structure of a fusion electrode gas arc welding system of the present application;
FIG. 6 is a schematic diagram of a frame structure of the wire feeder and welding gun of FIG. 5;
FIG. 7 is a schematic diagram of an embodiment of a computer-readable storage medium of the present application.
Detailed Description
The following describes the embodiments of the present application in detail with reference to the drawings.
In the following description, for purposes of explanation and not limitation, specific details are set forth such as the particular system architecture, interfaces, techniques, etc., in order to provide a thorough understanding of the present application.
The terms "system" and "network" are often used interchangeably herein. The term "and/or" is herein merely an association relationship describing an associated object, meaning that there may be three relationships, e.g., a and/or B, may represent: a exists alone, A and B exist together, and B exists alone. In addition, the character "/" herein generally indicates that the front and rear associated objects are an "or" relationship. Further, "a plurality" herein means two or more than two.
Referring to fig. 5, fig. 5 is a schematic diagram of a frame structure of a consumable electrode gas metal arc welding system 60 of the present application, comprising: a welding power source 600, a welding wire 601, an arc 602, a base material 603, an air supply device 604 and a wire feeder 606, wherein the welding power source 600 provides energy to the welding wire 601, the arc 602 and the base material 603 for melting the welding wire 601, maintaining the arc 602 and heating the base material 603, respectively. When welding is needed, power is provided for each device through the welding power supply 600, various parameters of each welding component such as gas, welding wire material, welding voltage, welding current and the like are set by a user, then the user presses a switch of the welding gun 605, the welding power supply 600 enters an arc striking stage, an arc 602 melts a molten pool and a welding area formed by the welding wire 601 and the base metal 603 under the protection of inert gas or active gas, the harmful effect of ambient air can be effectively prevented, and then the welding is completed through the molten drop transition process. The droplet transition refers to the whole process that molten metal at the end of the welding wire 601 forms droplets under the thermal action of the arc 602, is separated from the end of the welding wire 601 by various forces and transits to a molten pool, has a direct relationship with the stability of the welding process, the formation of a weld bead, the size of spatter, and the like, and finally affects the welding quality and the production efficiency.
The consumable electrode gas shielded welding system 60 according to the embodiment of the present application further includes a controller 607, the controller 607 is respectively connected to the welding power source 600 and the wire feeder 606, referring to fig. 6, fig. 6 is a schematic diagram of a frame structure of the wire feeder and the welding gun in fig. 5, the wire feeder 606 includes a front stage wire feeder 6063, a wire buffer 6062, a rear stage wire feeder 6061 and a wire storage 6060 sequentially connected by a wire feed tube 6064, and the front stage wire feeder 6063 is connected to the welding gun 605 by the wire feed tube 6064; referring to fig. 1, fig. 1 is a schematic flow chart of an embodiment of a method for controlling a consumable electrode gas arc welding system according to the present invention, and specifically, the method for controlling a consumable electrode gas arc welding system according to the present invention includes the following steps:
step S11: and acquiring a current feedback value fed back by the welding wire buffering device.
It will be appreciated that the feedback value fed back by the wire buffering device may reflect the rigidity energy of the welding wire in the wire buffering device or the tension of the welding wire, during steady-state operation, the front wire feeding device 6063 controls the wire feeding speed to reciprocate, and the rear wire feeding device 6061 controls the wire feeding speed to move unidirectionally, so that the welding wire is inevitably bent, and therefore, the wire buffering device 6062 is added between the front wire feeding device 6063 and the rear wire feeding device 6061, the wire buffering device 6062 is used for releasing the rigidity energy of the welding wire, and when the front wire feeding device 6063 and the rear wire feeding device 6061 are out of synchronization, the wire buffering device 6062 automatically adjusts the internal structure thereof, and simultaneously ensures that the front wire feeding and the rear wire feeding are stably fed. However, the regulation of the wire buffer 6062 is usually limited, and a saturation failure occurs after a certain limit is reached. Therefore, the welding wire buffer device 6062 needs to transmit its state in the form of physical quantity or digital quantity, that is, the welding wire buffer device 6062 can feed back the current feedback value of the welding wire energy just inside, so that the front stage wire feeder 6063 or the rear stage wire feeder 6061 can adjust its motion state in real time according to the current feedback value, so as to avoid the saturation failure of the adjustment of the welding wire buffer device 6062.
Step S12: and adjusting the wire feeding speed of the rear stage wire feeding device according to the current feedback value so as to update the current feedback value and obtain an updated feedback value.
It will be appreciated that during transient operation, particularly during the end of welding, the pre-wire feeder 6063 is stopped very rapidly, typically within 10 milliseconds of each other, in order to achieve good arc initiation. However, because the rear wire feeder 6061 has a large inertia, it is difficult to stop in such a short time, and thus the front wire feeder 6063 and the rear wire feeder 6061 are severely unsynchronized, and the effect of the unsynchronized state is completely transferred to the wire buffer 6062, so that the regulator of the wire buffer 6062 is in a relatively limited modulation state at the end of welding, and saturation failure occurs severely (as shown by a broken line portion B in fig. 2). Thus, during the period when the front stage wire feeder 6063 is closed and the rear stage wire feeder 6061 is not closed, the wire feeding speed of the rear stage wire feeder 6061 may be adjusted according to the current feedback value of the wire stiffness energy fed back by the wire buffer 6062, so as to update the feedback value of the wire stiffness energy in the wire buffer 6062, and obtain an updated feedback value.
In an embodiment, the step S13 may specifically include: when the current feedback value is larger than the preset target value, controlling the post-stage wire feeding device to forward feed wires so that the updated feedback value is smaller than the current feedback value; and when the current feedback value is smaller than the preset target value, controlling the rear-stage wire feeding device to draw back the welding wire so that the updated feedback value is larger than the current feedback value.
Specifically, the wire buffering device 6062 may feed back the current feedback value of the energy of the welding wire just inside the wire buffering device 6062, so that the front stage wire feeding device 6063 or the rear stage wire feeding device 6061 may adjust its motion state in real time according to the current feedback value, when the current feedback value fed back by the wire buffering device 6062 is greater than a preset target value, the rear stage wire feeding device 6061 is controlled to feed forward so that the updated feedback value is smaller than the current feedback value, the tension of the welding wire in the wire buffering device 6062 is reduced, and when the current feedback value fed back by the wire buffering device 6062 is smaller than the preset target value, the rear stage wire feeding device 6061 is controlled to draw back the welding wire so that the updated feedback value is greater than the current feedback value, and the tension of the welding wire in the wire buffering device 6062 is increased so as to avoid the occurrence of saturation failure of adjustment of the wire buffering device 6062.
Step S13: and when the updated feedback value fed back by the welding wire buffer device reaches a preset target value, controlling the rear-stage wire feeding device to be closed.
With reference to fig. 2, when a welding end signal or a welding pause is received, unlike the prior art in which the wire feeding speed of the post-stage wire feeding device 6061 is slowly reduced to 0 (as shown by a dotted line portion a in fig. 2), the post-stage wire feeding device 6061 in the embodiment of the present application is not immediately turned off, but the wire feeding speed of the post-stage wire feeding device 6061 is continuously adjusted according to the current feedback value of the welding wire rigid energy fed back by the welding wire buffering device 6062, so as to update the current feedback value, when the updated feedback value of the welding wire rigid energy fed back by the welding wire buffering device 6062 is adjusted to a preset target value, it is indicated that the welding wire buffering device 6062 is adjusted to a suitable position far from saturation adjustment, and at this time, the post-stage wire feeding device 6061 is turned off, so that the problem that when the next welding starts, the arc starting is not successful due to the fact that the welding wire buffering device is in an unsuitable position, and the initial state of the welding system for protecting the welding electrode gas at the beginning of the next welding can be ensured to meet the welding requirements.
In an embodiment, before the step S11, the method for controlling a gas metal arc welding system for a molten electrode further includes the steps of:
step S10: and after receiving a welding end signal, controlling the front-stage wire feeding device and the welding power supply to be respectively closed.
Referring to fig. 5 and 6, at the end of welding, the pre-wire feeder 6063 is required to stop very rapidly, and the process from motion to stop can be typically performed within 10 milliseconds in order to achieve good arc striking. Specifically, a welding end signal may be sent through a switch of the welding gun 605, and then the pre-stage wire feeder 6063 and the welding power source 600 are controlled to be turned off, so that the droplet size may be ensured to be controllable.
In an embodiment, the step S10 may specifically include:
step S101: and after receiving a welding end signal, controlling the front-stage wire feeder to execute a back-pumping instruction so as to separate the welding wire from the molten pool, and simultaneously controlling the welding power supply to be turned off.
Step S102: and after the back pumping instruction is executed by the front-stage wire feeding device, controlling the front-stage wire feeding device to be closed.
Referring to fig. 2, fig. 2 is a schematic waveform diagram of power supply, front wire feeding speed, rear wire feeding speed and feedback value of a welding wire buffer device according to a welding command in an application scenario of the present application, when a welding end instruction is set, in order to ensure that the droplet size is close to the diameter of a welding wire after the end, first, the front wire feeding device 6063 is controlled to execute a back-pumping instruction so as to separate the welding wire from a molten pool, meanwhile, the power output of the welding power supply 600 is controlled to be closed, after the front wire feeding device 6063 executes the back-pumping instruction, the front wire feeding device 6063 is immediately controlled to be closed, and through quick back-pumping and quick stopping of the welding wire, the probability that the welding wire contacts with a base material again at the end of welding can be reduced, and when arc closing is finished each time, the distance between the end of the welding wire and the base material can be ensured within a certain range, thereby improving the arcing success rate and ensuring that the next welding start process is smooth.
Referring to fig. 2, it can be seen that, in a time period from when the welding end signal is received to when the post-stage wire feeder is controlled to be turned off, the wire feeding direction of the post-stage wire feeder 6061 reciprocates, and the amplitude of the wire feeding speed of the post-stage wire feeder 6061 gradually decreases to 0. By adjusting the wire feed speed of the rear stage wire feeder 6061 to a low frequency reciprocating motion, it is ensured that the regulator of the wire buffer 6062 is adjusted to a proper position away from saturation adjustment in a reasonable time.
In addition, it should be noted that, the scheme of adjusting the wire feeding speed of the post-stage wire feeding device 6061 to adjust the feedback value of the wire buffering device 6062 to a proper position in the present application can be applied not only at the end of welding, but also in the occasion of more transient wire feeding processes, such as double pulse welding, direct current, pulse system welding, etc., where the wire feeding speed has a drastic change, and when the wire feeding speed of the pre-stage wire feeding device 6063 has a drastic change, the wire feeding speed of the post-stage wire feeding device 6061 is adjusted to adjust the feedback value of the wire buffering device 6062 to a proper position, so as to avoid the saturation of the adjustment of the wire buffering device 6062.
Referring to fig. 3, fig. 3 is a schematic frame structure of an embodiment of the controller of the present application. The controller 40 in this embodiment is applied to a consumable electrode gas shielded welding system including a welding gun and a wire feeder including a front wire feeder, a wire buffer, a rear wire feeder, and a wire storage device connected in this order by a wire feed pipe, the front wire feeder being connected to the welding gun by the wire feed pipe; the controller 40 includes a welding logic control module 400, a pre-stage wire feed control module 401, a post-stage wire feed control module 403, a buffer regulator feedback sampling module 404, and a buffer regulator feedback adjustment module 405. The welding logic control module 400 is connected with the welding gun and is used for sending a front wire feeding closing signal to the front wire feeding control module 401; the pre-stage wire feeding control module 401 is respectively connected with the welding logic control module 400 and the pre-stage wire feeding device, and is used for controlling the pre-stage wire feeding device to be closed after receiving the pre-stage wire feeding closing signal; the buffer regulator feedback sampling module 404 is connected with the welding wire buffer device and is used for obtaining a current feedback value fed back by the welding wire buffer device; the buffer regulator feedback adjustment module 405 is connected to the buffer regulator feedback sampling module 404, and is configured to adjust a wire feeding speed of the post-stage wire feeding device according to the current feedback value, so as to update the current feedback value; the buffer regulator feedback sampling module 404 is further configured to obtain an updated feedback value fed back by the welding wire buffer device; the welding logic control module 400 is further connected to the feedback sampling module 404 of the buffer regulator, where the welding logic control module 400 is further configured to send a post-stage wire feeding closing signal to the post-stage wire feeding control module 403 when the updated feedback value fed back by the welding wire buffer device reaches a preset target value; the post wire feeding control module 403 is connected to the welding logic control module 400 and the post wire feeding device, respectively, and is configured to control the post wire feeding device to be turned off after receiving the post wire feeding off signal.
In one embodiment, the consumable electrode gas shielded welding system further comprises a welding power source; the controller 40 further includes a power control and driving module 402, and the welding logic control module 400 is configured to send a back pumping instruction to the pre-stage wire feeding control module 401 after receiving a welding end signal, and send the power shutdown signal to the power control and driving module 402; and after receiving a feedback pumping executed signal fed back by the pre-stage wire feeding device, sending the pre-stage wire feeding closing signal to the pre-stage wire feeding control module 401; the power control and driving module 402 is connected to the welding logic control module 400 and the welding power supply, respectively, and is configured to control the welding power supply to be turned off after receiving the power off signal.
In an embodiment, the post wire feeding control module 403 controls the wire feeding direction of the post wire feeding device to reciprocate and the amplitude of the wire feeding speed of the post wire feeding device to gradually decrease to 0 in a time from receiving the post wire feeding closing signal to controlling the post wire feeding device to close.
In one embodiment, the buffer regulator feedback adjustment module 405 performs the step of adjusting the wire feed speed of the subsequent stage wire feed apparatus according to the current feedback value to update the current feedback value, including: when the current feedback value is larger than the preset target value, controlling the post-stage wire feeding device to forward feed wires so that the updated feedback value is smaller than the current feedback value; and when the current feedback value is smaller than the preset target value, controlling the rear-stage wire feeding device to draw back the welding wire so that the updated feedback value is larger than the current feedback value.
In one application scenario, referring to FIG. 5, in a consumable electrode gas metal arc welding system 60, a welding power supply 600 provides power to an arc 602, and the welding power supply 600 should be capable of achieving a current output of at least 500 amps to accommodate most gas metal arc welding applications. Wire feeder 606 includes a wire feed loop comprising wire storage 6060, post wire feeder 6061, wire buffer 6062, and pre wire feeder 6063, where wire feeder 606 can achieve stable wire feed in the range of 0.8 meters/minute to 18 meters/minute to accommodate most gas shielded welding applications; the front wire feeder 6063 can realize the wire back-drawing of the level of 50-200 Hz. The shielding gas is supplied through a common gas supply device 604. The three physical quantities described above are collected at the welding gun 605 and arc 602 is formed through the contact tip inside the welding gun 605.
Referring to fig. 3 and 5, the controller 40 may include a Digital Signal Processor (DSP), where the DSP includes a welding logic control module 400, a front wire feeding control module 401, a power supply control and driving module 402, a rear wire feeding control module 403, a buffer regulator feedback sampling module 404, and a buffer regulator feedback regulating module 405, and the welding logic control module 400 is connected to the front wire feeding control module 401, the power supply control and driving module 402, and the rear wire feeding control module 403, respectively, so as to control the overall operation of the welding power supply 600, the front wire feeding device 6063, and the rear wire feeding device 6061. The front wire feeding control module 401 may specifically include a front wire feeding motor giving module 4011, a front motor speed sampling module 4012, a front wire feeding motor control module 4013 and a front wire feeding motor driving module 4014, and the rear wire feeding control module 403 may specifically include a rear wire feeding motor giving module 4031, a rear motor speed sampling module 4032, a rear wire feeding motor control module 4033 and a rear wire feeding motor driving module 4034; the current feedback value output by the welding wire buffering device 6062 is sampled by the buffering regulator feedback sampling module 404, and then the feedback value is regulated by the buffering regulator feedback regulating module 405, so that the speed given regulating quantity of the front-stage wire feeding device 6063 and the rear-stage wire feeding device 6061 is obtained. Thus, the given speed of the front wire feeder 6063 output by the front wire feeder giving module 4011 and the given speed adjustment of the front wire feeder 6063 can be combined, and the given speed of the front wire feeder 6063 is used as the input of the front wire feeder control module 4013, the actual wire feeding speed of the front wire feeder 6063 is sampled by the front motor speed sampling module 4012, the front wire feeder control module 4013 outputs a corresponding target speed output through a corresponding speed adjustment algorithm, and the front wire feeder 6063 is driven by the front wire feeder driving module 4014 to output a corresponding target speed output; similarly, the given speed of the post-stage wire feeder 6061 output by the post-stage wire feeder given module 4031 and the given speed adjustment of the post-stage wire feeder 6061 may be combined to serve as the input of the post-stage wire feeder control module 4033, the actual wire feeding speed of the post-stage wire feeder 6061 is sampled by the post-stage motor speed sampling module 4032, the post-stage wire feeder control module 4033 outputs a corresponding target speed output through a corresponding speed adjustment algorithm, and the post-stage wire feeder 6061 is driven by the post-stage wire feeder driving module 4034 to output a corresponding target speed output.
Referring to fig. 4, fig. 4 is a schematic frame structure of another embodiment of the controller of the present application. The controller 50 in this embodiment includes a processor 501 and a memory 502 connected to each other; the memory 502 stores program instructions, and the processor 501 retrieves the program instructions from the memory 502 to execute the steps of any of the embodiments of the control method of the consumable electrode gas arc welding system.
In particular, the processor 501 is configured to control itself and the memory 502 to implement the steps of any of the above described embodiments of the method of controlling a consumable electrode gas arc welding system. The processor 501 may also be referred to as a CPU (Central Processing Unit ). The processor 501 may be an integrated circuit chip having signal processing capabilities. The processor 501 may also be a general purpose processor, a digital signal processor (Digital Signal Processor, DSP), an application specific integrated circuit (Application Specific Integrated Circuit, ASIC), a Field programmable gate array (Field-Programmable Gate Array, FPGA) or other programmable logic device, discrete gate or transistor logic device, discrete hardware components. A general purpose processor may be a microprocessor or the processor may be any conventional processor or the like. In addition, the processor 501 may be commonly implemented by an integrated circuit chip.
For details of the method for implementing the gas metal arc welding system by the processor 501, please refer to the embodiment of the method for implementing the gas metal arc welding system, which is not described herein.
Referring to fig. 5, fig. 5 is a schematic diagram of a frame structure of a gas metal arc welding system for a consumable electrode of the present application. The consumable electrode gas shielded welding system 60 in this embodiment includes a welding power source 600, a wire feeder 606, and a controller 607, where the controller 607 is connected to the welding power source 600 and the wire feeder 606, and the controller 607 is the controller 40 or the controller 50 in any of the above embodiments.
Referring to fig. 7, fig. 7 is a schematic structural diagram of an embodiment of a computer readable storage medium of the present application. The present application is directed to a computer readable storage medium 80 having program instructions 800 stored thereon, which program instructions 800 when executed by a processor perform the steps of any of the above-described embodiments of a method of controlling a consumable electrode gas arc welding system.
The computer readable storage medium 80 may be a medium such as a usb disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, which may store the program instructions 800, or may be a server storing the program instructions 800, and the server may send the stored program instructions 800 to another device for execution, or may also self-execute the stored program instructions 800.
In the several embodiments provided in the present application, it should be understood that the disclosed methods, apparatuses, and devices may be implemented in other manners. For example, the above-described apparatus and device embodiments are merely illustrative, e.g., the division of modules or units is merely a logical functional division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another system, or some features may be omitted or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be an indirect coupling or communication connection via some interfaces, devices or units, which may be in electrical, mechanical or other form.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed over a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the embodiment.
In addition, each functional unit in each embodiment of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present application may be embodied essentially or in part or all or part of the technical solution contributing to the prior art or in the form of a software product stored in a storage medium, including several instructions to cause a computer device (which may be a personal computer, a server, or a network device, etc.) or a processor (processor) to perform all or part of the steps of the methods of the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
Claims (11)
1. The control method of the consumable electrode gas shielded welding system is characterized in that the consumable electrode gas shielded welding system comprises a welding gun and a wire feeding device, wherein the wire feeding device comprises a front-stage wire feeding device, a welding wire buffering device, a rear-stage wire feeding device and a welding wire storage device which are sequentially connected through a wire feeding pipe, and the front-stage wire feeding device is connected with the welding gun through the wire feeding pipe; the control method comprises the following steps:
acquiring a current feedback value fed back by the welding wire buffer device;
adjusting the wire feeding speed of the rear stage wire feeding device according to the current feedback value to update the current feedback value to obtain an updated feedback value;
and when the updated feedback value fed back by the welding wire buffer device reaches a preset target value, controlling the rear-stage wire feeding device to be closed.
2. The control method of claim 1, wherein the consumable electrode gas shielded welding system further comprises a welding power source; before the step of obtaining the current feedback value fed back by the welding wire buffering device, the method further comprises the following steps:
after receiving a welding end signal, controlling the front-stage wire feeder to execute a back-pumping instruction so as to separate a welding wire from a molten pool, and simultaneously controlling the welding power supply to be turned off;
and after the back pumping instruction is executed by the front-stage wire feeding device, controlling the front-stage wire feeding device to be closed.
3. The control method of claim 2, wherein the wire feed direction of the rear stage wire feed device reciprocates during the time from receiving the welding end signal to controlling the rear stage wire feed device to close, and the magnitude of the wire feed speed of the rear stage wire feed device gradually decreases to 0.
4. The control method according to claim 1, wherein the adjusting the wire feeding speed of the subsequent wire feeding device according to the current feedback value to update the current feedback value to obtain an updated feedback value includes:
when the current feedback value is larger than the preset target value, controlling the post-stage wire feeding device to forward feed wires so that the updated feedback value is smaller than the current feedback value; and when the current feedback value is smaller than the preset target value, controlling the rear-stage wire feeding device to draw back the welding wire so that the updated feedback value is larger than the current feedback value.
5. A controller, characterized in that the controller is applied to a consumable electrode gas shielded welding system comprising a welding gun and a wire feeding device, wherein the wire feeding device comprises a front-stage wire feeding device, a welding wire buffering device, a rear-stage wire feeding device and a welding wire storage device which are sequentially connected by a wire feeding pipe, and the front-stage wire feeding device is connected with the welding gun through the wire feeding pipe; the controller includes:
the welding logic control module, the front-stage wire feeding control module and the rear-stage wire feeding control module; the welding logic control module is connected with the welding gun and is used for sending a front-stage wire feeding closing signal to the front-stage wire feeding control module; the front-stage wire feeding control module is connected with the front-stage wire feeding device and is used for controlling the front-stage wire feeding device to be closed after receiving the front-stage wire feeding closing signal;
the buffer regulator feedback sampling module is connected with the welding wire buffer device and used for acquiring a current feedback value fed back by the welding wire buffer device;
the buffer regulator feedback regulation module is connected with the buffer regulator feedback sampling module and is used for regulating the wire feeding speed of the rear-stage wire feeding device according to the current feedback value so as to update the current feedback value;
the buffer regulator feedback sampling module is also used for acquiring an updated feedback value fed back by the welding wire buffer device;
the welding logic control module is further connected with the feedback sampling module of the buffer regulator, and is further used for sending a rear wire feeding closing signal to the rear wire feeding control module when the updated feedback value fed back by the welding wire buffer device reaches a preset target value;
the rear wire feeding control module is respectively connected with the welding logic control module and the rear wire feeding device and is used for controlling the rear wire feeding device to be closed after receiving the rear wire feeding closing signal.
6. The controller of claim 5, wherein the consumable electrode gas shielded welding system further comprises a welding power source; the controller also includes a power control and drive module,
the welding logic control module is used for sending back a pumping instruction to the front-stage wire feeding control module after receiving a welding end signal, and sending the power supply closing signal to the power supply control and driving module; after receiving a back suction executed signal fed back by the front-stage wire feeding device, sending the front-stage wire feeding closing signal to the front-stage wire feeding control module;
the power supply control and driving module is respectively connected with the welding logic control module and the welding power supply and is used for controlling the welding power supply to be turned off after receiving the power supply turning-off signal.
7. The controller of claim 5, wherein the post wire feed control module controls the wire feed direction of the post wire feed to reciprocate and the magnitude of the wire feed speed of the post wire feed to gradually decrease to 0 during the time from receiving the post wire feed off signal to controlling the post wire feed to close.
8. The controller of claim 5, wherein the buffer regulator feedback adjustment module performs the step of adjusting the wire feed speed of the post-stage wire feed in accordance with the current feedback value to update the current feedback value, comprising: when the current feedback value is larger than the preset target value, controlling the post-stage wire feeding device to forward feed wires so that the updated feedback value is smaller than the current feedback value; and when the current feedback value is smaller than the preset target value, controlling the rear-stage wire feeding device to draw back the welding wire so that the updated feedback value is larger than the current feedback value.
9. A controller comprising a processor and a memory connected to each other; wherein the memory stores program instructions, and the processor retrieves the program instructions from the memory to perform the method of controlling the consumable electrode gas metal arc welding system of any of claims 1-4.
10. A consumable electrode gas shielded welding system comprising a welding power source, a wire feeder, and a controller coupled to the welding power source and the wire feeder, respectively, the controller being the controller of any one of claims 5-8 or 9.
11. A computer-readable storage medium, characterized in that it has stored thereon program instructions, which when executed by a processor, implement a method of controlling a consumable electrode gas-shielded welding system according to any one of claims 1-4.
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