CN117428383A - Intelligent real-time control method for welding shielding gas under complex production state - Google Patents
Intelligent real-time control method for welding shielding gas under complex production state Download PDFInfo
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- CN117428383A CN117428383A CN202311754058.0A CN202311754058A CN117428383A CN 117428383 A CN117428383 A CN 117428383A CN 202311754058 A CN202311754058 A CN 202311754058A CN 117428383 A CN117428383 A CN 117428383A
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- 238000003466 welding Methods 0.000 title claims abstract description 101
- 238000000034 method Methods 0.000 title claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 230000001681 protective effect Effects 0.000 claims description 16
- 230000009471 action Effects 0.000 claims description 15
- 230000001105 regulatory effect Effects 0.000 claims description 7
- 230000005856 abnormality Effects 0.000 abstract description 3
- HSFWRNGVRCDJHI-UHFFFAOYSA-N Acetylene Chemical compound C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 4
- 230000008859 change Effects 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
Classifications
-
- 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
- B23K9/325—Devices for supplying or evacuating shielding gas
-
- 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)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Arc Welding In General (AREA)
Abstract
The invention discloses an intelligent real-time control method for welding shielding gas in a complex production state, which is used for respectively controlling the air flow speed of a pipeline in a welding state and a non-welding state; in a welding state, when the control mode cannot be quickly adjusted to a set flow rate or no obvious air flow exists in the pipeline, the controller enters a protection state, so that the gas flow rate reaches the maximum, and welding abnormality caused by insufficient gas flow rate is avoided; in a non-welding state, when no obvious air flow exists in the pipeline due to the fact that the opening and closing degree of the proportional valve is too small, the pipeline also enters a protection state and waits for entering a welding state; the method for switching the protection state and the control state can ensure that the controller can avoid the problem of welding quality caused by insufficient gas flow rate to the greatest extent no matter how the external welding working condition changes.
Description
Technical Field
The invention belongs to the technical field of air flow control, and particularly relates to an intelligent real-time control method for welding shielding gas in a complex production state.
Background
At present, along with popularization of large-scale robot welding in an industrial welding scene, pipeline gas supply is a mainstream trend of future development in welding operation, and compared with traditional bottled gas, pipeline gas supply has the advantages of stable gas supply and large quantity, but the problems that the protection gas flow is unstable, gas cannot be accurately controlled and the like exist, so that the cost of the protection gas is reduced for enterprises, and the welding quality is improved, so that the problems of non-negligible obstruction are caused.
Because the welding site working condition is complex, the pressure and the flow rate of gas in the pipeline can be changed continuously, and the insufficient flow rate of welding gas can be caused under the conditions of insufficient site pressure, insufficient flow rate of a preceding-stage pressure regulating valve or abrupt pressure change, so that the welding quality is influenced.
Disclosure of Invention
The invention aims to: aiming at the problems in the background art, the invention provides an intelligent real-time control method for welding shielding gas in a complex production state, corresponding control methods are provided according to different welding states, and meanwhile, under special abnormal conditions, a controller is adjusted to a protection mode, so that welding abnormality caused by too small opening and closing degree of the controller is avoided.
The technical scheme is as follows: an intelligent real-time control method for welding shielding gas in a complex production state comprises the following steps:
step S1, judging a welding state based on welding current data acquired in real time, and distinguishing an unwelded state from a welding state;
step S2, when entering a welding state, judging whether the current controller state is a control state or not; when the controller is in a control state, judging the air flow according to the current air flow speed; if the current gas flow rate is smaller than a preset threshold th1, judging that the current gas flow in the pipeline has no obvious gas flow, and at the moment, the controller enters a protection state, and the opening and closing degree of the proportional valve is adjusted to be maximum; otherwise, judging that normal air flow exists in the current pipeline, and performing air flow adjustment in a control state by the controller until the air flow rate reaches a target flow rate, and then keeping the control state by the controller; when the gas flow rate cannot reach the set flow rate value within n seconds, the controller enters a protection state;
step S3, when the welding state is not entered, firstly judging whether the controller is in a control state; when the controller is in a control state, judging the air flow according to the current air flow speed; if the current gas flow rate is smaller than a preset threshold th1, judging that the current gas flow in the pipeline has no normal gas flow; further judging whether the opening degree of the proportional valve can cause that the protective gas can not normally pass through the pipeline under the current input pressure; when the protective gas has no obvious air flow in the pipeline due to the fact that the opening and closing degree of the proportional valve is too small, the controller enters a protective state, the proportional valve is opened to the maximum, otherwise, the opening and closing degree of the proportional valve is considered to be large enough, but the protective gas is not conveyed by the front-end pipeline, and at the moment, the controller maintains the control state unchanged until the protective gas enters a welding state.
Further, the controller comprises a proportional valve arranged in the air path pipeline, and the proportional valve controls the opening and closing degree of the proportional valve through an external input current analog quantity, so that the pipeline flow speed adjusting function can be realized; the controller comprises a control state and a protection state; when the controller is in a control state, the gas flow rate is regulated according to the current actual welding working condition until the pipeline flow rate reaches a set target flow rate, and the opening and closing degree of the proportional valve is kept unchanged after the pipeline flow rate reaches the target flow rate; when the controller is in a protection state, the opening and closing degree of the proportional valve is adjusted to be maximum.
Further, under the control state, the protection air flow speed data are collected in real time, and when the fact that the air flow speed is not matched with the current actual welding state is detected, the controller enters the protection state; under the protection state, the gas flow rate is rapidly increased, the current gas flow rate is detected in real time, and when the actual flow rate in n continuous seconds is greater than the set target flow rate, the controller reenters the control mode and adjusts the gas flow rate to the preset target flow rate.
Further, the proportional valve is controlled by adopting a PID control method in a control state, and the gas flow rate in the pipeline is regulated in real time.
Further, the specific method for distinguishing the unwelded state from the welded state in the step S1 includes:
the method comprises the steps of adopting a sliding window mode to carry out real-time current data and judging, and finding out a first current point which is larger than or equal to a preset threshold value th1 in the sliding window, namely, a welding action starting point; when the last two current points in the sliding window are smaller than a preset threshold value th2, taking the first current point smaller than th2 as a welding action ending point; the welding state is between the starting point and the ending point of the welding action, and the non-welding state is between the ending point of the current welding action and the starting point of the next welding action.
Further, in the step S2, when the controller starts the air flow adjustment, the proportional valve controls the air flow speed in real time through PID in the control mode; when the proportional valve is opened to the maximum opening and closing degree through PID control and still cannot reach the set flow rate within n seconds, the controller enters a protection state, and the maximum opening and closing degree is always kept.
Compared with the prior art, the technical scheme adopted by the invention has the following beneficial effects:
the invention provides a detailed air flow control method aiming at different welding states, and when the control mode can not be quickly adjusted to a set flow rate or no obvious air flow exists in a pipeline in the welding state, the controller enters a protection state, so that the gas flow rate reaches the maximum, and welding abnormality caused by insufficient gas flow rate is avoided. In a non-welding state, when no obvious air flow exists in the pipeline due to the fact that the opening and closing degree of the proportional valve is too small, the pipeline also enters a protection state and waits for entering a welding state. The method for switching the protection state and the control state can ensure that the controller can avoid the problem of welding quality caused by insufficient gas flow rate to the greatest extent no matter how the external welding working condition changes.
Drawings
Fig. 1 is a schematic diagram of an intelligent real-time control method for welding shielding gas in a complex production state.
Description of the embodiments
Aiming at the problems that the welding gas flow rate is insufficient and the welding quality is affected due to the fact that the pressure of a welding protection gas pipeline is insufficient, the flow rate of a preceding pipeline is insufficient or the pressure is suddenly changed in the field, the invention designs an intelligent real-time control method for the welding protection gas under multiple states, and the intelligent real-time control method for the welding protection gas is used for carrying out real-time judgment by combining acquired welding protection gas flow rate data and welding current data, controlling an external controller in real time, ensuring that the gas flow rate is sufficient and meeting the welding quality requirement.
The invention adopts an external controller to perform feedback control on the gas supply of the welding pipeline. The external controller comprises a proportional valve arranged on the air path, and the opening and closing degree of the proportional valve is controlled by externally inputting current analog quantity, so that the flow speed adjusting function of the pipeline can be realized. The external controller adopted by the invention comprises two states: a control state and a protection state; when the external controller is in a control state, the gas flow rate is regulated according to the current actual welding working condition until the pipeline flow rate reaches the set target flow rate, and the opening and closing degree of the proportional valve is kept unchanged after the pipeline flow rate reaches the target flow rate. In this embodiment, PID control is used to regulate the gas flow rate in real time. When the external controller is in a protection state, the opening and closing degree of the proportional valve is directly adjusted to the maximum value, so that the flow rate is ensured to be adjusted to the maximum value.
Under the control state, the protection air flow speed data are collected in real time, and when the fact that the air flow speed is not matched with the current actual welding state is detected, the controller enters the protection state; under the protection state, the gas flow rate is rapidly increased, the current gas flow rate is detected in real time, and when the actual flow rate in n continuous seconds is greater than the set target flow rate, the controller reenters the control mode and adjusts the gas flow rate to the preset target flow rate.
The following control methods of the external controller are given based on different welding states, specifically as shown in fig. 1:
step S1, judging a welding state based on welding current data acquired in real time, and distinguishing an unwelded state from a welding state;
the method comprises the steps of adopting a sliding window mode to carry out real-time current data and judging, and finding out a first current point which is larger than or equal to a preset threshold value th1 in the sliding window, namely, a welding action starting point; when the last two current points in the sliding window are smaller than a preset threshold value th2, taking the first current point smaller than th2 as a welding action ending point; the welding state is between the starting point and the ending point of the welding action, and the non-welding state is between the ending point of the current welding action and the starting point of the next welding action.
S2, when the welding state is entered, judging whether the current controller state is a control state or not; when the controller is in a control state, judging the air flow according to the current air flow speed; if the current gas flow rate is smaller than a preset threshold th1, judging that the current gas flow in the pipeline has no obvious gas flow, and at the moment, the controller enters a protection state, and the opening and closing degree of the proportional valve is adjusted to be maximum; otherwise, judging that the current pipeline has normal air flow, and regulating the air flow by the controller in a control state until the air flow rate reaches the target flow rate. The controller then maintains the control state.
When the controller starts air flow regulation, the proportional valve can not adjust the air flow rate to the target flow rate in a short time due to the change of the front end input pressure of the proportional valve or the reduction of the front-stage flow rate, at the moment, the proportional valve controls the air flow rate in real time through the PID in a control mode, when the proportional valve is opened to the maximum opening and closing degree through PID control, the controller enters a protection state and always maintains the maximum opening and closing degree when the set flow rate still cannot be reached within n seconds. The gas flow rate is maintained at a maximum value to ensure that no weld quality problems occur.
In this embodiment, when the controller is in the protection state, the protection gas flow rate data is collected in real time, and when the gas flow rate is greater than the set flow rate in 3 seconds, the welding gas flow is recovered to be normal, the controller is turned to the control state, and the welding gas flow rate is gradually adjusted to the set flow rate.
And step S3, when the welding state is not entered, judging whether the controller is in a control state or not. When the controller is in a control state, judging the air flow according to the current air flow speed; if the current gas flow rate is smaller than the preset threshold th1, judging that the current gas flow in the pipeline has no normal gas flow. And in a non-welding state, detecting whether the opening and closing degree of the proportional valve can cause that the shielding gas cannot normally pass through the pipeline under the current input pressure. When the protective gas has no obvious air flow in the pipeline due to the fact that the opening and closing degree of the proportional valve is too small, the controller enters a protective state, the proportional valve is opened to the maximum, otherwise, the opening and closing degree of the proportional valve is considered to be large enough, but the protective gas is not conveyed by the front-end pipeline, and at the moment, the controller maintains the control state unchanged until the protective gas enters a welding state.
In the non-welding state, although there is no significant air flow in the pipe, it cannot be confirmed whether there is no significant air flow due to the small opening and closing degree of the proportional valve at the current input pressure or whether there is no significant air flow in the pipe due to the non-delivery of the shielding gas. When no gas flow is caused by no protective gas in the pipeline, the gas outlet hole at the welding gun end is closed, and the gas outlet hole at the welding gun end is opened during the next welding, so that the protective gas flows out normally and the next welding quality is not affected. And because the opening and closing degree of the proportional valve is very small under the current input pressure, no obvious air flow exists, and the problem of welding quality is caused by insufficient opening of the proportional valve even if the air outlet hole at the welding gun end is opened in the next welding, specific judgment and control instruction sending are needed.
Similarly, when the controller is in a protection state, the data of the protection air flow rate is collected in real time, and when the air flow rate is larger than the set flow rate in 3 continuous seconds, the welding air flow is represented to be recovered to be normal, the controller is turned to a control state, and the welding air flow rate is gradually adjusted to the set flow rate.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (6)
1. An intelligent real-time control method for welding shielding gas in a complex production state is characterized by comprising the following steps of:
step S1, judging a welding state based on welding current data acquired in real time, and distinguishing an unwelded state from a welding state;
step S2, when entering a welding state, judging whether the current controller state is a control state or not; when the controller is in a control state, judging the air flow according to the current air flow speed; if the current gas flow rate is smaller than a preset threshold th1, judging that the current gas flow in the pipeline has no obvious gas flow, and at the moment, the controller enters a protection state, and the opening and closing degree of the proportional valve is adjusted to be maximum; otherwise, judging that normal air flow exists in the current pipeline, and performing air flow adjustment in a control state by the controller until the air flow rate reaches a target flow rate, and then keeping the control state by the controller; when the gas flow rate cannot reach the set flow rate value within n seconds, the controller enters a protection state;
step S3, when the welding state is not entered, firstly judging whether the controller is in a control state; when the controller is in a control state, judging the air flow according to the current air flow speed; if the current gas flow rate is smaller than a preset threshold th1, judging that the current gas flow in the pipeline has no normal gas flow; further judging whether the opening degree of the proportional valve can cause that the protective gas can not normally pass through the pipeline under the current input pressure; when the protective gas has no obvious air flow in the pipeline due to the fact that the opening and closing degree of the proportional valve is too small, the controller enters a protective state, the proportional valve is opened to the maximum, otherwise, the opening and closing degree of the proportional valve is considered to be large enough, but the protective gas is not conveyed by the front-end pipeline, and at the moment, the controller maintains the control state unchanged until the protective gas enters a welding state.
2. The intelligent real-time control method for welding shielding gas under a complex production state according to claim 1, wherein the controller comprises a proportional valve arranged in a gas path pipeline, and the proportional valve controls the opening and closing degree of the proportional valve through an externally input current analog quantity so as to realize a pipeline flow speed adjusting function; the controller comprises a control state and a protection state; when the controller is in a control state, the gas flow rate is regulated according to the current actual welding working condition until the pipeline flow rate reaches a set target flow rate, and the opening and closing degree of the proportional valve is kept unchanged after the pipeline flow rate reaches the target flow rate; when the controller is in a protection state, the opening and closing degree of the proportional valve is adjusted to be maximum.
3. The intelligent real-time control method for welding shielding gas under a complex production state according to claim 2, wherein the method is characterized in that shielding gas flow rate data are collected in real time under the control state, and when the fact that the gas flow rate does not match with the current actual welding state is detected, the controller enters the shielding state; under the protection state, the gas flow rate is rapidly increased, the current gas flow rate is detected in real time, and when the actual flow rate in n continuous seconds is greater than the set target flow rate, the controller reenters the control mode and adjusts the gas flow rate to the preset target flow rate.
4. The intelligent real-time control method for welding shielding gas under a complex production state according to claim 2, wherein the proportional valve is controlled by adopting a PID control method under the control state, and the gas flow rate in the pipeline is regulated in real time.
5. The intelligent real-time control method for welding shielding gas under a complex production state according to claim 1, wherein the specific method for distinguishing the unwelded state from the welded state in step S1 comprises the following steps:
the method comprises the steps of adopting a sliding window mode to carry out real-time current data and judging, and finding out a first current point which is larger than or equal to a preset threshold value th1 in the sliding window, namely, a welding action starting point; when the last two current points in the sliding window are smaller than a preset threshold value th2, taking the first current point smaller than th2 as a welding action ending point; the welding state is between the starting point and the ending point of the welding action, and the non-welding state is between the ending point of the current welding action and the starting point of the next welding action.
6. The intelligent real-time control method for welding shielding gas under a complex production state according to claim 1, wherein in the step S2, when the controller starts air flow adjustment, the proportional valve controls the air flow speed in real time through PID under a control mode; when the proportional valve is opened to the maximum opening and closing degree through PID control and still cannot reach the set flow rate within n seconds, the controller enters a protection state, and the maximum opening and closing degree is always kept.
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