CN116352231A - Arc sensing-based adaptive control method for longitudinal filler wire position of filler wire GTAW - Google Patents
Arc sensing-based adaptive control method for longitudinal filler wire position of filler wire GTAW Download PDFInfo
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- CN116352231A CN116352231A CN202310375358.1A CN202310375358A CN116352231A CN 116352231 A CN116352231 A CN 116352231A CN 202310375358 A CN202310375358 A CN 202310375358A CN 116352231 A CN116352231 A CN 116352231A
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- 239000000945 filler Substances 0.000 title claims abstract description 104
- 238000000034 method Methods 0.000 title claims abstract description 56
- 230000003044 adaptive effect Effects 0.000 title claims abstract description 22
- 238000003466 welding Methods 0.000 claims abstract description 52
- 238000010891 electric arc Methods 0.000 claims abstract description 4
- 238000012544 monitoring process Methods 0.000 claims description 55
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 16
- 229910052721 tungsten Inorganic materials 0.000 claims description 16
- 239000010937 tungsten Substances 0.000 claims description 16
- 238000004364 calculation method Methods 0.000 claims description 7
- 230000002093 peripheral effect Effects 0.000 claims description 6
- 238000004891 communication Methods 0.000 claims description 3
- 238000010586 diagram Methods 0.000 description 6
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000012886 linear function Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000007704 transition 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
- B23K9/167—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
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
- B23K9/067—Starting the arc
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
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- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
Abstract
The invention relates to an arc sensing-based adaptive control method for a longitudinal filler wire position of a filler wire GTAW. Aiming at the difficult problem that the longitudinal filler wire position cannot be adaptively controlled in the GTAW process, the invention discloses an arc sensing-based filler wire GTAW longitudinal filler wire position adaptive control method. The arc starting state is identified by using a welding wire touch GTAW arc starting state sensing method, the longitudinal position of the welding wire in an electric arc is identified by using a welding wire longitudinal position sensing method, the wire filling position of the welding wire is self-adapted by using a self-adaptive wire filling device, and the self-adaptive control of the wire filling position of the wire filling GTAW is realized by using a wire filling GTAW longitudinal wire filling position self-adaptive control method.
Description
Technical Field
The invention relates to the field of self-adaptive control of a longitudinal filler wire position of a filler wire GTAW, in particular to a self-adaptive control method of the longitudinal filler wire position of the filler wire GTAW based on arc sensing.
Technical Field
GTAW (non-consumable electrode gas shielded welding) is widely applied to important fields such as aerospace, marine equipment, nuclear power construction and the like, and particularly in recent years, the rapid development of arc material-increasing technology brings higher requirements to the automation and intelligent degree of the filler wire GTAW. Both the stability of the arc and the accuracy of the filler wire position during the GTAW process have a very important impact on welding quality and efficiency. Too high and too low a filler wire position from the melt pool can affect the droplet transition mode, which in turn affects the welding quality and welding efficiency. However, no adaptive control method for the longitudinal filler wire position of the filler wire GTAW exists at present, and aiming at the difficult problem, the invention discloses an adaptive control method for the longitudinal filler wire position of the filler wire GTAW based on arc sensing.
Disclosure of Invention
An arc sensing-based longitudinal filler wire position adaptive control method for filler wires GTAW is used for longitudinal filler wire position adaptive control in the GTAW process, and the system schematic diagram is shown in figure 1, and is characterized in that: the arc sensing-based filler wire GTAW longitudinal filler wire position self-adaptive control method is realized by an arc sensing-based filler wire GTAW longitudinal filler wire position self-adaptive control system, and the arc sensing-based filler wire GTAW longitudinal filler wire position self-adaptive control system consists of a double-channel arc monitoring system, a self-adaptive filler wire device, an arc starting monitoring system and a filler wire GTAW longitudinal filler wire position self-adaptive controller. The arc starting state is identified by using a welding wire touch GTAW arc starting state sensing method, the longitudinal position of the welding wire in an electric arc is identified by using a welding wire longitudinal position sensing method, the wire filling position of the welding wire is self-adapted by using a self-adaptive wire filling device, and the self-adaptive control of the wire filling position of the wire filling GTAW is realized by using a wire filling GTAW longitudinal wire filling position self-adaptive control method. The longitudinal filler wire is positioned at a distance from the welding wire to the workpiece on the axis of the tungsten electrode.
The method for sensing the GTAW arcing state of the welding wire touch is realized by an arcing state monitoring system and is used for monitoring the GTAW arcing state and controlling a system power switch, so that the interference of high-frequency high voltage on a filling wire GTAW longitudinal filling wire position self-adaptive control system based on arc sensing in the GTAW arcing process is prevented, and a schematic diagram of the arcing monitoring system is shown in figure 2. The arcing state monitoring system consists of a peripheral monitoring circuit and an arcing monitoring system controller. The peripheral monitoring circuit is used for monitoring the arcing state signal and transmitting the signal to the arcing monitoring system controller. The controller of the arcing monitoring system sends out an instruction for starting arc monitoring through an output signal, and judges whether arcing is successful or not through an input signal. When starting the monitoring of the arc state, the arc monitoring system controller controls the peripheral monitoring circuit to enter the arc starting monitoring state through outputting high level, at this time, the wire filling mechanism starts to continuously fill wires, and the arc starting monitoring system controller at the input signal end monitors low level. When the welding wire touches a workpiece, the input signal end arcing monitoring system controller monitors a high level, the wire filling is stopped at the moment, the welding switch is opened for high-frequency high-voltage arcing, and when the input signal end arcing monitoring system controller monitors a low level again, GTAW arcing is successful.
The welding wire longitudinal position sensing method is realized by a double-channel arc monitoring system, a self-adaptive wire filling device and a wire filling GTAW longitudinal wire filling position self-adaptive controller. The double-channel arc monitoring system is provided with two arc monitoring channels which are respectively used for monitoring arc signals at the welding wire end and arc signals at the tungsten electrode end and transmitting the arc signals to the self-adaptive controller of the longitudinal filler wire position of the filler wire GTAW through a control bus. The tungsten electrode end arc signal is an arc voltage signal between a tungsten electrode and a workpiece. The welding wire end arc signal is an arc voltage signal between the welding wire and the workpiece.
The self-adaptive wire filling device consists of an insulating ring, a mounting mechanism, a servo motor, a clamping mechanism and a movable shaft. The insulating ring is used for isolating the welding wire end arc signal and the tungsten electrode end arc signal. The mounting mechanism is used for fastening and connecting the self-adaptive wire filling device and the GTAW welding gun. The servo motor is communicated with the self-adaptive controller of the longitudinal filler wire position of the filler wire GTAW through a control bus, and the driving of the movable shaft is realized. The clamping mechanism is used for fastening and connecting the self-adaptive wire filling device with the wire feeding pipe. The movable shaft is driven by the servo motor to control the longitudinal position adjustment of the welding wire. The self-adaptive controller for the longitudinal filler wire position of the filler wire GTAW receives tungsten electrode end arc signals and welding wire end arc signals acquired by the double-channel arc monitoring system through a communication bus, acquires the filler wire position by utilizing a GTAW longitudinal filler wire position calculation method, and controls the self-adaptive filler wire device to adjust the longitudinal filler wire position. The potential distribution in the whole arc is uneven, the slope of the potential distribution curve of the cathode region and the anode region is large, and the potential distribution of the arc column region is even, so in order to reduce the interference of the cathode region and the anode region in the arc length calculation process, the GTAW longitudinal wire filling position calculation method is as follows:
(1) When U is 1 -U 2 ≥U 2 When L 2 ＝f(U 1 )-f(U 1 -U 2 )；
(2) When U is 1 -U 2 ＜U 2 When L 2 ＝f(U 2 )；
Wherein U is 1 Arc voltage between tungsten electrode and workpiece; u (U) 2 Arc voltage between the welding wire and the workpiece; l (L) 2 Is the distance between the welding wire and the workpiece; f is a linear function between arc length and arc voltage.
The self-adaptive control method for the longitudinal filler wire position of the filler wire GTAW is realized by monitoring the variation and the variation rate of the longitudinal position of the welding wire, and the principle of the self-adaptive control method is shown in figure 5.
The invention has the beneficial effects that:
the invention relates to an arc sensing-based adaptive control method for a longitudinal filler wire position of a filler wire GTAW. Aiming at the difficult problem that the longitudinal filler wire position cannot be adaptively controlled in the GTAW process, the invention discloses an arc sensing-based filler wire GTAW longitudinal filler wire position adaptive control method. The arc starting state is identified by using a welding wire touch GTAW arc starting state sensing method, the longitudinal position of the welding wire in an electric arc is identified by using a welding wire longitudinal position sensing method, the wire filling position of the welding wire is self-adapted by using a self-adaptive wire filling device, and the self-adaptive control of the wire filling position of the wire filling GTAW is realized by using a wire filling GTAW longitudinal wire filling position self-adaptive control method. The invention solves the problem that the longitudinal wire filling position cannot be adaptively controlled in real time in the current wire filling GTAW process, and is hopeful to further improve the automation and intelligent level of the wire filling GTAW.
Drawings
FIG. 1 is a schematic diagram of an adaptive control system for the longitudinal filler wire position of a filler wire GTAW based on arc sensing.
Fig. 2 is a schematic diagram of an arcing condition monitoring system.
FIG. 3 is a model diagram of a filler wire position calculation method.
In the figure: l (L) 1 For tungsten electrode to workpiece distance, i.e. arc length, L 2 Is the distance between the wire and the workpiece on the tungsten axis.
Fig. 4 is a flowchart of a method for adaptive control of the longitudinal filler wire position of the filler wire GTAW based on arc sensing.
Fig. 5 is a schematic diagram of a method for controlling adaptive adjustment of the longitudinal filler wire position of the filler wire GTAW.
In the figure: q 0 、q 1 、q 2 Calculated by formula (1). k is the kth calculation period. e (k) is calculated by equation (2).
ec (k) is calculated by equation (3). K (K) p ，K i And K d Is a PID control parameter.
Wherein K is p Is a proportionality coefficient, T I Is an integral time constant, T D Is a differential time constant.
e(k)＝L 2 (k)-L 2P (2)
Wherein L is 2 (k) Calculating the distance between the welding wire and the workpiece for the kth calculation period, L 2P The longitudinal wire filling position is preset.
ec(k)＝e(k)-e(k-1) (3)
Detailed Description
In order to better express the technical scheme and beneficial effects of the whole invention, the invention is further described in detail below with reference to the accompanying drawings and the embodiment, and the whole working process is shown in fig. 4. Embodiments of the present invention are not limited thereto.
Step 1: arcing condition monitoring
In order to avoid the interference of high-frequency high voltage on an arc sensor-based filler wire GTAW longitudinal filler wire position self-adaptive control system in the GTAW arcing process, the invention monitors the GTAW arcing state by using an arcing state monitoring system shown in figure 2.
When starting to start arc state monitoring, the arc monitoring system controller controls the peripheral monitoring circuit to enter into the starting arc monitoring state through outputting high level, namely, the relay contact 1 and the contact 2 in fig. 2 are closed, the contact 3 and the contact 4 are closed, at the moment, the wire filling mechanism starts to continuously and slowly fill wires, and the arc monitoring system controller at the input signal end monitors low level. When the welding wire touches a workpiece, the input signal end arcing monitoring system controller monitors high level, at the moment, the wire filling is stopped, and the welding switch is opened to perform high-frequency high-voltage arcing. When the GTAW starts to arc smoothly, the welding wire is melted, the welding wire is not in contact with the workpiece, and the input signal monitors the low level again. When the input signal end arcing monitoring system controller monitors the low level again, the GTAW arcing is successful.
Step 2: adaptive control of GTAW longitudinal filler wire position in arc length adjusting process after arcing
After arcing, the arc length is lengthened, meanwhile, the dual-channel arc monitoring system in fig. 1 monitors arc data in real time and transmits the arc data to the filling wire GTAW longitudinal filling wire position adaptive controller through a communication bus, and the filling wire GTAW longitudinal filling wire position adaptive controller calculates L in real time by using a GTAW longitudinal filling wire position calculating method 1 And L 2 Up to L 1 ＝L 1P The arc length stops pulling up, wherein L 1P Is a preset arc length. When L 1 ＝L 1P When the self-adaptive control device is used, the self-adaptive control device for the longitudinal filler wire position of the filler wire GTAW sends a control command to the servo motor of the self-adaptive filler wire device through the control bus, and the longitudinal filler wire position of the filler wire GTAW is adjusted until L is reached 2 ＝L 2P Wherein L is 2P The longitudinal wire filling position is preset.
Step 3: adaptive control of longitudinal filler wire position of filler wire GTAW in welding process
In the GTAW process, when the arc length changes due to tungsten electrode burning or workpiece thermal deformation, the longitudinal wire filling position of the wire filling GTAW must be adaptively controlled in order to ensure good welding quality. When |L 2 -L 2P |≥L ST When the self-adaptive control method for the GTAW longitudinal filler wire position is used, wherein L is the same as that shown in fig. 5 ST Is a longitudinal filler wireA position change threshold.
Claims (4)
1. An arc sensing-based longitudinal filler wire position adaptive control method for filler wires GTAW is used for longitudinal filler wire position adaptive control in the GTAW process, and is characterized in that: the arc sensing-based filler wire GTAW longitudinal filler wire position self-adaptive control method is realized by an arc sensing-based filler wire GTAW longitudinal filler wire position self-adaptive control system, and the arc sensing-based filler wire GTAW longitudinal filler wire position self-adaptive control system consists of a double-channel arc monitoring system, a self-adaptive filler wire device, an arcing monitoring system and a filler wire GTAW longitudinal filler wire position self-adaptive controller; identifying an arcing state by using a welding wire touch GTAW arcing state sensing method, identifying the longitudinal position of a welding wire in an electric arc by using a welding wire longitudinal position sensing method, self-adapting a welding wire filling position by using a self-adapting wire filling device, and realizing self-adapting control of a filling wire GTAW longitudinal filling position by using a filling wire GTAW longitudinal filling position self-adapting control method; the longitudinal filler wire is positioned at a distance from the welding wire to the workpiece on the axis of the tungsten electrode.
2. The adaptive control method for the longitudinal filler wire position of the filler wire GTAW based on arc sensing as set forth in claim 1, wherein the method comprises the following steps: the method is realized by an arcing state monitoring system, and is used for monitoring the arcing state of the GTAW and controlling a power switch of the system, so that the interference of high-frequency high voltage on an arc sensing-based longitudinal filler wire position self-adaptive control system of the filler wire GTAW in the arcing process of the GTAW is prevented; the arcing state monitoring system consists of a peripheral monitoring circuit and an arcing monitoring system controller; the peripheral monitoring circuit is used for monitoring the arcing state signal and transmitting the signal to the arcing monitoring system controller; the controller of the arcing monitoring system sends out an instruction for starting arc monitoring through an output signal, and judges whether arcing is successful or not through an input signal.
3. The adaptive control method for the longitudinal filler wire position of the filler wire GTAW based on arc sensing as set forth in claim 1, wherein the method comprises the following steps: the welding wire longitudinal position sensing method is realized by a double-channel arc monitoring system, a self-adaptive wire filling device and a wire filling GTAW longitudinal wire filling position self-adaptive controller; the double-channel arc monitoring system is provided with two arc monitoring channels which are respectively used for monitoring arc signals at the welding wire end and arc signals at the tungsten electrode end and transmitting the arc signals to a self-adaptive controller of the longitudinal filler wire position of the filler wire GTAW through a control bus; the tungsten electrode end arc signal is an arc voltage signal between a tungsten electrode and a workpiece; the welding wire end arc signal is an arc voltage signal between a welding wire and a workpiece; the self-adaptive wire filling device consists of an insulating ring, a mounting mechanism, a servo motor, a clamping mechanism and a movable shaft; the insulating ring is used for isolating the welding wire end arc signal and the tungsten electrode end arc signal; the mounting mechanism is used for fastening and connecting the self-adaptive wire filling device with the GTAW welding gun; the servo motor is communicated with the self-adaptive controller of the longitudinal filler wire position of the filler wire GTAW through a control bus, and drives the movable shaft; the clamping mechanism is used for fastening and connecting the self-adaptive wire filling device with the wire feeding pipe; the movable shaft is driven by the servo motor to control the longitudinal position adjustment of the welding wire; the self-adaptive controller for the longitudinal filler wire position of the filler wire GTAW receives tungsten electrode end arc signals and welding wire end arc signals acquired by the double-channel arc monitoring system through a communication bus, acquires the filler wire position by utilizing a GTAW longitudinal filler wire position calculation method, and controls the self-adaptive filler wire device to adjust the longitudinal filler wire position.
4. The adaptive control method for the longitudinal filler wire position of the filler wire GTAW based on arc sensing as set forth in claim 1, wherein the method comprises the following steps: the self-adaptive control method for the longitudinal filler wire position of the filler wire GTAW is to realize the self-adaptive control of the longitudinal filler wire position of the filler wire GTAW by monitoring the variation quantity and the variation rate of the longitudinal position of the welding wire.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310375358.1A CN116352231A (en) | 2023-04-10 | 2023-04-10 | Arc sensing-based adaptive control method for longitudinal filler wire position of filler wire GTAW |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310375358.1A CN116352231A (en) | 2023-04-10 | 2023-04-10 | Arc sensing-based adaptive control method for longitudinal filler wire position of filler wire GTAW |
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| Publication Number | Publication Date |
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| CN116352231A true CN116352231A (en) | 2023-06-30 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310375358.1A Pending CN116352231A (en) | 2023-04-10 | 2023-04-10 | Arc sensing-based adaptive control method for longitudinal filler wire position of filler wire GTAW |
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| CN (1) | CN116352231A (en) |
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- 2023-04-10 CN CN202310375358.1A patent/CN116352231A/en active Pending
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