CN205008717U - Lockhole effect TIG deep penetration welding welding machine control system - Google Patents
Lockhole effect TIG deep penetration welding welding machine control system Download PDFInfo
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Abstract
The embodiment of the utility model discloses lockhole effect TIG deep penetration welding welding machine control system, including main control circuit module, man -machine interface, welding source control module, control switch module, high frequency scratch start module, current balance module, double - circuit drive module and double - circuit IGBT module. Adopt the utility model discloses, drive control patent special design's welder can realize that the lockhole effect melts argon arc deeply and welds, makes welding efficiency improve greatly, and simultaneously, the thick plate welding does not need the grooving, does not need the filler wire or only needs a small amount of filler wire, has consequently practiced thrift the welding cost greatly, has very high industrial applications.
Description
Technical field
The utility model relates to welding jig field, particularly relates to a kind of controlling system of welder producing lockhole effect TIG deep penetration welding.
Background technology
TIG welds (TungstenInertGasarcWelding), and be also called inert gas tungsten electrode protection weldering, it is a kind of welding method of maturation, is widely used at the welding field of carbon steel, stainless steel, aluminium alloy and nonferrous materials.Common TIG welding arc stablility, welding quality is good, but its fusion penetration is more shallow, and speed of welding is comparatively slow, and efficiency is lower.As for stainless steel or titanium alloy, a general welding penetration is maximum can only reach about 4mm.Therefore, TIG weldering is generally used for the bottom penetration bead backing welding of plate sheet welding or heavy wall important component.
For middle thickness (>4mm) sheet metal; traditional way needs the groove opening respective angles in junction according to actual plate thickness; and carry out multi-layer multi-pass welding and just can complete; such mode not only causes welding efficiency greatly to reduce; and welding deformation and heat affected area can be caused to increase, usually can have influence on the quality of welding point.Such as, concerning titanium alloy, heat affected area increase means growing up of crystal grain, causes its toughness sharply to decline.As square groove, once welding just can whole through weldings, thus greatly improve welding efficiency, significantly reduce the man-hour of steel plate bevel and welding, and can or with little filling wlding, greatly will reduce welding cost.Therefore, the efficient TIG welding method developing large fusion penetration has very large benefit for raising welding efficiency, minimizing welding material expenditure.
The current technology that can form the welding of " lockhole " effect mainly realizes in the weldering of Laser Welding, electron-bombardment welding and plasma.Laser Welding and vacuum electron beam soldering equipment very expensive, require harsh to welding surroundings and weldment, plasma weldering needs compression arc, welding energy density is very high, welding gun design is complicated, need often to safeguard, the change of welding parameters is very sensitive, and plasma welding technology is to thickness of slab more than 8 to 10 millimeters stainless steels at present, and more than 10 to 12 millimeters titanium alloys cannot realize the disposable welding of one side welding with back formation, and welding cost is high.
Summary of the invention
The utility model embodiment technical problem to be solved is, provides a kind of lockhole effect TIG deep penetration welding controlling system of welder.Welding gun can be driven to realize the deep penetration welding of lockhole effect, welding efficiency is improved greatly, the disposable welding without the need to bevel, one side welding with back formation is realized to the titanium alloy weldment of the stainless steel of 13 millimeters thick, 15 millimeters thick.
In order to solve the problems of the technologies described above, the utility model embodiment provides a kind of lockhole effect TIG deep penetration welding controlling system of welder, comprises main control circuit module, man-machine interface, source of welding current control module, gauge tap module, high frequency starting the arc module, current balance module, two-way driver module and two-way IGBT module;
Described man-machine interface produces control instruction and inputs described main control circuit module;
Described main control circuit module generates welding Control timing sequence data according to the technological parameter that described control instruction comprises, and described welding Control timing sequence data are conveyed into described source of welding current control module;
Described source of welding current control module gauge tap module according to described welding Control timing sequence Data Control produces ON/OFF action to described high frequency starting the arc module, and make described current balance module output drive control signal, and make the difference of described two-way driver module output current in limited range by described current balance module;
Described two-way driver module makes described two-way IGBT module export the highest 1000A DC current according to described excitation control signal, and superposes with the high-frequency impulse high-voltage signal that described high frequency starting the arc module produces and input welding gun.
Further, also comprise operating state signal feedback processing modules, for by source of welding current control module and current balance module described in the running status feed back input of described welding gun.
Further, described operating state signal feedback processing modules comprises the welding current feedback module, weldingvoltage feedback module, temperature signal feedback module, cooling-water machine running status feedback module and the two-way IGBT output feedack module that are respectively used to detect welding gun welding current, voltage, power device temperature, cooling-water machine running status and two-way IGBT module output state.
Further; described gauge tap module comprises welding gun protection gas air valve switch, cooling-water machine power switch and arc welding gun switch; be respectively used to switch welding gun protection gas air valve, switch cooling-water machine power supply and completed the starting the arc of described welding gun by the described high frequency starting the arc module work of control.
Further, described man-machine interface comprises LCD MODULE, film key input module, line traffic control input module switch, ENET Network Interface Module and alarm unit module;
Described LCD MODULE is for showing the current state information of configuration information, welding condition data, welding operating mode, user operation director information and welding machine;
Described film key input module is used for converting user input instruction to specific coding data, and described coded data is sent to described main control circuit module;
The key-press input of user is carried out code conversion and sends described main control circuit module to by described line traffic control input module switch;
Described ENET network interface processing module provides network interface, and the welding condition script file that the input for the long-range user of acceptance weaves downloads to welding machine, or reads welding machine current use welding condition data;
Described alarm unit module, for when welding machine generation unusual condition, receives the control signal of described main control circuit module, sends warning alarm signal to user.
Further, described two-way IGBT module controls arc current along I=β t
2+ I α quick and smooth rises to molten bath penetrating current Ip, and keep the output Tp time to penetrate weldment penetrating current Ip, reduce rapidly electric current after producing lockhole effect and export welding current Iw to, maintain stable welding current to having welded, and receive arc by I=-kt+Iw, wherein β is the coefficient determined with welding material and thickness, and I α is striking current, t is time variable, and k is constant coefficient.
Implement the utility model embodiment, there is following beneficial effect: the utility model can realize the deep penetration welding of lockhole effect, welding efficiency is improved greatly, the stainless steel of 13 millimeters thick, the titanium alloy weldment of 15 millimeters thick is welded, can realize without the need to bevel without the need to filler wire, disposable through welding, one side welding with back formation, thus greatly promote welding efficiency, reduce energy resource consumption, save welding cost, there is huge industrial application value.
Accompanying drawing explanation
Fig. 1 is overall structure schematic block diagram of the present utility model;
Fig. 2 is welding current change schematic diagram.
Detailed description of the invention
For making the purpose of this utility model, technical scheme and advantage clearly, below in conjunction with accompanying drawing, the utility model is described in further detail.
With reference to the structural schematic block diagram of the present embodiment shown in Fig. 1.
In the present embodiment, a kind of lockhole effect TIG deep penetration welding controlling system of welder, utility model patent to for the applicant: (patent No.: the control system 201420318497.7) designed comprises main control circuit module 1, man-machine interface 2, source of welding current control module 3, gauge tap module 4, high frequency starting the arc module 5, current balance module 6, two-way driver module 7, two-way IGBT module 8, operating state signal feedback processing modules 9 to lockhole effect TIG deep penetration welding welding gun.
Main control circuit module 1 comprises 32 high speed ARM microprocessor memory cell and peripheral interface circuit unit, technological parameter data reduction for user being selected generates accurate welding Control timing sequence data, and data are sent to source of welding current control module 3, source of welding current control module 3 realizes the welding job having controlled preflow, the starting the arc, pilot arc, receipts arc and delayed getter according to welding process requirement.
Man-machine interface 2 comprises LCD MODULE 21, film key input module 22, line traffic control input module switch 23, ENET Network Interface Module 24 and alarm unit module 25, for receiving control data, and show, export the system set-up information of welding machine, the information of welding operating mode and user-friendly native system, film key input module 22 is for converting user input instruction to specific coding data, and coded data is sent to main control circuit module 1, the key-press input of user is carried out code conversion and sends main control circuit module 1 to by line traffic control input module switch 23, ENET network interface processing module 24 provides network interface, the welding condition script file woven for the input of the long-range user of acceptance downloads to welding machine, or read welding machine current use welding condition data, alarm unit module, for when welding machine generation unusual condition, receives the control signal of main control circuit module 1, sends warning alarm signal to user.
Source of welding current control module 3 comprises the accurate welding Control timing sequence data transmitted for receiving main control circuit module 1, respective switch is opened or closed by controlling gauge tap module 4, the welding current fed back in conjunction with operating state signal feedback processing modules 9 and weldingvoltage signal, generate the current excitation signal exported to current balance module 6 through D/A switch
Gauge tap module 4, comprises the unit 43 such as welding gun protection gas air valve switch 41, cooling-water machine power switch 42 and arc welding gun switch, for switch welding gun protection gas air valve, and the starting the arc of switch cooling-water machine power supply and the welding gun that worked by control high frequency starting the arc module 5.
Operating state signal feedback processing modules 9, comprise welding current feedback module 91, weldingvoltage feedback module 92, temperature signal feedback module 93, cooling-water machine running status feedback module 94 and two-way IGBT output feedack module, the signals such as the temperature of welding current when running for monitoring system, weldingvoltage, power device and the operation conditions of cooling-water machine, and feed back to source of welding current control module 3 after these signals being done necessary electrical isolation.
Current balance module 6, for receiving the control signal and pumping signal that source of welding current control module 3 sends, connected with master-slave mode by inside, the two-way electric current frequency pwm pulse generator circuit surely of parallel running, export the pwm pulse signal of two-way balance to described two-way driver module 8, the two-way IGBT that current balance module 6 meeting simultaneously monitors two-way IGBT module 8 by operating state signal feedback processing modules 9 exports, once the difference that this two-way IGBT electric current exports reaches restriction degree, then current balance module 6 can automatically shut down pwm pulse output, to protect subordinate's power amplifier.
High frequency starting the arc module 5, for generation of the high voltage pulse signal of high frequency, and by the negative pole that high voltage pulse signal loading exports to the source of welding current, makes to produce electric arc between the tip of welding gun tungsten bar and weldment; Two-way driver module 7, for isolating the two-way pwm pulse signal inputted from current balance module 6 respectively, and is converted to the signal 8 being applicable to drive two-way IGBT module; Two-way IGBT module 8, comprises the IGBT circuit unit of two-way parallel operation, two-way IGBT exports merge cells, rectification unit and filter cell, and for welding gun stable output, the maximum DC current reaching 1000 amperes, completes the welding job of butt-welding fitting.
The utility model coordinates utility model patent: the lockhole effect TIG deep penetration welding welding gun (patent No.: 201420318497.7) can realize lockhole effect TIG deep penetration welding.
During welding, welding gun tungsten bar is by conducting rod connecting welding power cathode, workpiece connecting welding positive source to be welded, user is by human-computer interface module 2 startup optimization and select technological parameter, the technological parameter data that user selectes by main control circuit module 1 generate accurate welding Control timing sequence data by computing, and data are sent to source of welding current control module 3, controlled successively to open cold water electromechanical source switch according to accurate welding Control timing sequence data by source of welding current control module 3, welding gun protection air valve, welding gun recirculated cooling water operates, protective gas continues to flow out from torch head, after certain hour, space between tungsten pin and weldment to be welded is filled with protective gas, source of welding current control module 3 exports striking exciting current to current balance module 6, the pwm pulse producing two-way balance by it drives two-way driver module 7 and two-way IGBT module 8 to work, galvanic current pressure is formed with surface of the work at welding gun tungsten electrode tip, source of welding current control module 3 controls gauge tap module 4 and opens arc welding gun switch, control high frequency starting the arc module 5 exports high-frequency high-voltage signal and is loaded into source of welding current negative pole and excites electric arc, conducting between the positive pole of welding machine electric power and negative pole, after electric arc produces, high frequency starting the arc module 5 quits work immediately, background current pilot arc is exported by two-way IGBT module 8, source of welding current control module 3 controls to export according to accurate welding Control timing sequence data the exciting current increased gradually to current balance module 6, by current balance module 6, the work of two-way driver module 7 and two-way IGBT module 8, arc current is increased gradually, molten bath on weldment is deepened gradually, final molten bath penetration weldment also forms lockhole effect, source of welding current control module 3 also accurately controls arc current by the feedback information monitoring of operating state signal feedback processing modules 9 and keeps stable, fitting device drives between welding gun and weldment and does at the uniform velocity displacement, weldment constantly moves forward along weld seam in molten bath under the effect of electric arc, welding process is made to continue to carry out, when molten bath arrives weld seam end, user sends stopping welding instruction by human-computer interface module 2 to main control circuit module 1, main control circuit 1 module sends to source of welding current control module 3 immediately and receives arc instruction, source of welding current control module 3 reduces exciting current gradually according to accurate weldment Control timing sequence data, finally make arc extinction complete and receive arc work, when electric arc just extinguishes, the temperature of weldment and welding gun is still very high, source of welding current control module 3 maintains welding gun protection air valve switch according to accurate weldment Control timing sequence data and cooling-water machine power switch is in opening, until weldment, welding gun temperature is reduced to suitable degree and just closes protection air valve switch and cooling-water machine power switch.The welding current that lockhole effect TIG deep penetration welding control system described in the utility model produces is maximum reaches 1000A, can the sheet metal such as the carbon steel of through welding 3 ~ 18mm thickness, stainless steel, titanium and titanium alloys, zirconium and alloy thereof, it is a kind of Novel welding system that can realize the welding of lockhole effect, its lockhole formed is that " nature " is formed, because its electric arc is without compression, the main arc force by big current formation and liquid metals static pressure, surface tension balance are formed.This lockhole is that the energy of high concentration and pressure are formed, and in molten bath, liquid metal stream can not cause metal loss round " lockhole " flowing.The existence of " lockhole " makes welding penetration to increase widely, is the Perfected process of welding slab, particulate metal.
Lockhole effect TIG deep penetration welding control system of the present utility model is that the place by forming hole bottom molten bath increases arc pressure wittingly, these aspect on, the lower surface of workpiece has been worn out in the bottom of electric arc, just can be formed " lockhole " when heat inputs enough penetration workpiece, arc-plasma can gush.Act on arc-plasma by the arc pressure of long-range navigation magnetically-actuated, up hill and dale electromagnetization.The energy density of TIG weldering is not enough to produce suitable kickback pressure, therefore, different with electron beam welding lockhole from Laser Welding, and it is long-range navigation magnetically-actuated that TIG welds lockhole, is integrated with kickback pressure and stagnation pressure.
During welding, lockhole must keep open, and arcing gas is through workpiece, and therefore lockhole TIG is that single-run welding completes.Because arcing gas is discharged by back of work, therefore weld and seldom occur molten bath disturbance and pore.Compared with welding with big current general T IG, often there is the defects such as molten bath disturbance, weld seam cavity, vermicular porosity in big current TIG, main cause is the incomplete excretion of arcing gas.
Two-way IGBT module controls arc circuit along I=β t
2+ I α quick and smooth rises to molten bath penetrating current Ip, and keep the output Tp time to penetrate weldment penetrating current Ip, reduce rapidly electric current after producing lockhole effect and export welding current Iw to, maintain stable welding current to having welded receipts, and receive arc by I=-kt+Iw.
Wherein β is the coefficient determined with welding material and thickness, can experimentally data determine, I α is striking current, and t is time variable, and k is constant coefficient.
Below be illustrated:
With reference to schematic diagram shown in Fig. 2.
Use the utility model when the titanium alloy of welding 14 millimeters thick, welding condition is set as: front gas time=4s, welding current Iw=510A, slow rise time Ta=5s, delay and fall time Td=7s, prolong gas time=8s, control system will arrange β=21.54, Tp=0.2ms, Ia=150A, Is=60A, k=64.29, user weldment and welding machine ready after, press " startup " button, control system enters welding process: open welding gun protection air valve, protective gas is transported to welding gun, through 4 second time, air between welding gun tungsten electrode and solder joint to be welded is drained, driver module driving IGBT module exports striking current Ia, because now electric arc is not formed, open-circuit condition is between the positive and negative electrode of welding machine, there is no current flowing, only maintain certain electrical potential difference, system starts high frequency starting the arc module, high-frequency and high-voltage is exported to welding gun tungsten electrode, the breakdown formation electric arc of gas between tungsten electrode and solder joint, under arcing, path is formed between both positive and negative polarity, two-way IGBT module output current Ia makes electric arc be maintained, high frequency starting the arc module is closed, control system continues to increase excitation to two-way driver module, two-way IGBT module output current is driven to rise along curve I=21.54t2+150, Ip=688.5A is reached second through Ta=5, maintain the Tp=0.2 millisecond time, molten bath penetrates weldment and forms aperture, control the decorum and reduce the excitation exported to two-way driver module, that welding current Iw=510A is fallen back in IGBT module output, maintain stable lockhole effect, under frock drives, welding gun is along weld seam, relative disPlacement motion is done with weldment, molten bath constantly moves forward, control system detects two-way IGBT module by operating state signal feedback processing modules and exports, preset range is exceeded in the two-way brachium pontis outlet chamber difference of two-way IGBT module, or when the difference merged between the electric current of output and welding current Iw=510A exceeds preset range, control system is finely tuned IGBT module output by current balance module and two-way driver module, make it export to meet the demands, welding process continues, until molten bath arrives weld seam end, user presses " stopping " button, enter and receive the arc stage, Systematical control driver module exports and reduces gradually, IGBT module is exported also reduce gradually, output current linearly I=-64.29t+510 drops to blow-out below electric current 60A through Td=7 time second, arc extinction, in receipts arc process, molten bath arc crater backfills gradually, the bubble that bath may exist is overflowed molten bath completely, then molten bath cooled and solidified gradually, when electric arc just extinguishes, the temperature of weldment and welding gun is still very high, therefore protect gas still to maintain to supply gas, terminate until prolong 8 seconds gas time, control system closes protection air valve, the welding process of control system terminates.
Certain above-described embodiment, only for technical conceive of the present utility model and feature are described, its object is to person skilled in the art can be understood content of the present utility model and implement according to this, can not limit protection domain of the present utility model with this.All modifications done according to the Spirit Essence of the utility model main technical schemes, all should be encompassed within protection domain of the present utility model.
Claims (5)
1. a lockhole effect TIG deep penetration welding controlling system of welder, it is characterized in that, comprise main control circuit module, man-machine interface, source of welding current control module, gauge tap module, high frequency starting the arc module, current balance module, two-way driver module and two-way IGBT module;
Described man-machine interface produces control instruction and inputs described main control circuit module;
Described main control circuit module generates welding Control timing sequence data according to the technological parameter that described control instruction comprises, and described welding Control timing sequence data are conveyed into described source of welding current control module;
Described source of welding current control module gauge tap module according to described welding Control timing sequence Data Control produces ON/OFF action to described high frequency starting the arc module, and make described current balance module output drive control signal, and make the difference of described two-way driver module output current in limited range by described current balance module;
Described two-way driver module makes described two-way IGBT module export the highest 1000A DC current according to described excitation control signal, and superposes with the high-frequency impulse high-voltage signal that described high frequency starting the arc module produces and input welding gun;
Described two-way IGBT module controls arc current along I=β t
2+ I α quick and smooth rises to molten bath penetrating current Ip, and keep the output Tp time to penetrate weldment penetrating current Ip, reduce rapidly electric current after producing lockhole effect and export welding current Iw to, maintain stable welding current to having welded, and receive arc by I=-kt+Iw, wherein β is the coefficient determined with welding material and thickness, and I α is striking current, t is time variable, and k is constant coefficient.
2. lockhole effect TIG deep penetration welding controlling system of welder according to claim 1, it is characterized in that, also comprise operating state signal feedback processing modules, for by source of welding current control module and current balance module described in the running status feed back input of described welding gun.
3. lockhole effect TIG deep penetration welding controlling system of welder according to claim 2, it is characterized in that, described operating state signal feedback processing modules comprises the welding current feedback module, weldingvoltage feedback module, temperature signal feedback module, cooling-water machine running status feedback module and the two-way IGBT output feedack module that are respectively used to detect welding gun welding current, voltage, power device temperature, cooling-water machine running status and two-way IGBT module output state.
4. lockhole effect TIG deep penetration welding controlling system of welder according to claim 3; it is characterized in that; described gauge tap module comprises welding gun protection gas air valve switch, cooling-water machine power switch and arc welding gun switch; be respectively used to switch welding gun protection gas air valve, switch cooling-water machine power supply and completed the starting the arc of described welding gun by the described high frequency starting the arc module work of control.
5. lockhole effect TIG deep penetration welding controlling system of welder according to claim 1, it is characterized in that, described man-machine interface comprises LCD MODULE, film key input module, line traffic control input module switch, ENET Network Interface Module and alarm unit module;
Described LCD MODULE is for showing the current state information of configuration information, welding condition data, welding operating mode, user operation director information and welding machine;
Described film key input module is used for converting user input instruction to specific coding data, and described coded data is sent to described main control circuit module;
The key-press input of user is carried out code conversion and sends described main control circuit module to by described line traffic control input module switch;
Described ENET network interface processing module provides network interface, and the welding condition script file that the input for the long-range user of acceptance weaves downloads to welding machine, or reads welding machine current use welding condition data;
Described alarm unit module, for when welding machine generation unusual condition, receives the control signal of described main control circuit module, sends warning alarm signal to user.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105127553A (en) * | 2015-07-08 | 2015-12-09 | 广东福维德焊接股份有限公司 | Control system for lockhole effect TIG deep penetration welding welder and control method |
| CN108161180A (en) * | 2017-12-31 | 2018-06-15 | 上海自动化仪表有限公司 | Robot welding control device based on digital output modul |
| CN113290303A (en) * | 2021-05-06 | 2021-08-24 | 华南理工大学 | Arc pressure measuring device and method for lockhole effect deep melting TIG welding |
| CN117428297A (en) * | 2023-09-01 | 2024-01-23 | 广东福维德焊接技术研究院有限公司 | K-TIG welding gun short circuit, full-automatic real-time detection device for welding seam and control system |
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2015
- 2015-07-08 CN CN201520487037.1U patent/CN205008717U/en active Active
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105127553A (en) * | 2015-07-08 | 2015-12-09 | 广东福维德焊接股份有限公司 | Control system for lockhole effect TIG deep penetration welding welder and control method |
| CN105127553B (en) * | 2015-07-08 | 2016-10-19 | 广东福维德焊接股份有限公司 | A kind of lockhole effect TIG deep penetration welding controlling system of welder and control method |
| CN108161180A (en) * | 2017-12-31 | 2018-06-15 | 上海自动化仪表有限公司 | Robot welding control device based on digital output modul |
| CN108161180B (en) * | 2017-12-31 | 2024-02-02 | 上海自动化仪表有限公司 | Robot welding control device based on switching value control |
| CN113290303A (en) * | 2021-05-06 | 2021-08-24 | 华南理工大学 | Arc pressure measuring device and method for lockhole effect deep melting TIG welding |
| CN113290303B (en) * | 2021-05-06 | 2022-05-24 | 华南理工大学 | Arc pressure measuring device and method for lockhole effect deep melting TIG welding |
| CN117428297A (en) * | 2023-09-01 | 2024-01-23 | 广东福维德焊接技术研究院有限公司 | K-TIG welding gun short circuit, full-automatic real-time detection device for welding seam and control system |
| CN117428297B (en) * | 2023-09-01 | 2024-04-16 | 广东福维德焊接技术研究院有限公司 | K-TIG welding gun short circuit, full-automatic real-time detection device for welding seam and control system |
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