JP2004148371A - Welding system and welding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a double wire welding system that can be structured easily at a low cost from an existing single wire system welding equipment without requiring special remodeling and also to provide the welding method of the double wire system. <P>SOLUTION: In welding equipment having a consumable electrode wire feeding device, a welding power source for supplying power to a consumable electrode wire 4 and its feeding device, and control device 12 for controlling a consumable electrode wire feeding speed, power supply to the consumable electrode wire 4, etc.; there are installed a filler wire feeding device 19, a filler power source 21, a setting device 26 for setting a power supply to the filler wire 18 as well as the feeding speed and feeding starting time of the filler wire, a filler power source control device 25 for controlling a power supply by the filler power source 21 as well as the feeding speed and feeding start of the filler wire, and a connecting cable 28 for connecting by terminals between the control device 12 and the filler power source control device 25. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a consumable electrode type arc welding system for generating an arc between a base material and a consumable electrode wire, and more particularly to a so-called double wire type welding system and a welding system for feeding a filler wire to a molten pool generated by arc heat. It is about the method.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a so-called double-wire type arc welding facility using both a consumable electrode wire that generates an arc between itself and a base material and a filler wire that follows the consumable electrode wire in a welding direction has been proposed (eg, And Patent Document 1). In this double-wire type arc welding equipment, an arc is generated between the consumable electrode wire and the base material, and the arc heat causes the consumable electrode wire and the base material to be melted and further fed to the molten pool. The filler wires in the rows are melted by utilizing the heat of the molten pool in addition to the heating by energization. As described above, by using the heat of the molten pool to melt the filler wire, in a double-wire welding equipment, an arc welding equipment using only consumable electrode wires (hereinafter referred to as a single-wire welding equipment). In contrast, there is an advantage that the melting rate of the wire can be increased with the same amount of power supply, and high working efficiency can be secured.
[0003]
Here, in this type of double-wire welding equipment, conventionally, a part of the welding current flowing to the base material via the consumable electrode wire is diverted to the filler wire to supply power to the consumable electrode wire and the filler wire. Sharing power has been done. However, when the power supply is shared, the current flowing through the filler wire flows through, for example, a path of “power supply → consumable electrode wire → base metal → filler wire → power supply”, and the value varies depending on the resistance of each part in the path. Therefore, when a shared power supply is used, the value of the current flowing through the filler wire changes depending on, for example, the welding location, and as a result, the repulsive force of the magnetic field generated between the two wires changes irregularly. In some cases, there was a problem in terms of quality and work efficiency, such as the wire swaying (consequently the welded portion was shaken).
[0004]
On the other hand, in the welding equipment described in Patent Document 1 and the like, a filler power supply for supplying a filler wire is provided separately from a welding power supply for supplying a consumable electrode wire, and both power supplies are intentionally made separate power supplies. The above problem is solved by stabilizing the value of the current flowing through the wire.
[0005]
[Patent Document 1]
Japanese Patent No. 3185071
[Problems to be solved by the invention]
Here, the above-described single-wire type welding equipment generally includes a welding torch for holding at least a consumable electrode wire, and a consumable electrode wire feeding device for sequentially feeding the consumable electrode wire to a welding point via the welding torch. And a welding power supply for supplying power to the consumable electrode wire and the consumable electrode wire feeding device, and a control device for controlling the amount of power supplied to the consumable electrode wire. In addition, in the case of a fully automatic welding facility, a welding robot that includes the welding torch at the end of the arm and moves the welding torch on a movement path according to a command from the control device is additionally provided. Many factories often have such single-wire welding equipment, so if a new double-wire welding equipment is to be adopted, the existing single-wire welding equipment must be modified and replaced with a double-wire welding equipment. There are many cases where it is desired to shift to welding equipment.
[0007]
Therefore, when upgrading from a single-wire welding facility to a double-wire welding facility, it is necessary to add a filler power supply in addition to the existing welding power supply, considering the welding quality and work efficiency as described above. . In addition, in order to construct a semi-automatic or fully automatic double-wire welding equipment, it is necessary to supply power to the filler wire and supply the filler wire in contrast to the power supply to the existing consumable electrode wire and the supply of the consumable electrode wire. Must work together. Therefore, it is conceivable to add a dedicated control panel for controlling the power supply for the filler to the above-described control device. In this case, with the addition of the dedicated control panel, it is necessary to add a power supply for the filler. A communication terminal, a dedicated communication circuit, and the like must be added, which complicates the structure of the welding equipment itself, and also increases the cost for repair.
[0008]
The present invention has been made in view of the above-mentioned circumstances, and an object thereof is to provide a double-wire welding method that can be easily and inexpensively constructed from an existing single-wire welding equipment without special modification. It is to provide a system and a welding method.
[0009]
[Means for Solving the Problems]
(1) In order to achieve the above object, the present invention provides a welding system for feeding a filler wire to a molten pool while generating an arc between a base material and a consumable electrode wire to melt the base material and the consumable electrode wire. , A welding torch for holding the inserted consumable electrode wire, a consumable electrode wire feeding device for feeding the consumable electrode wire to a welding point via the welding torch, and a consumable electrode wire and a consumable electrode wire feeding device A welding power source for supplying power to the consumable electrode wire, a control device having at least one external signal output terminal, and the filler wire connected to the molten pool via the welding torch. A filler wire feeding device for feeding, a filler power source for feeding the filler wire and the filler wire feeding device, and a seal for the filler wire. A setting device for setting a current value to be supplied, the filler wire feeding speed, and a start time of feeding the filler wire to the molten pool; and applying an output signal from the control device and a setting value from the setting device to the filler wire. A power supply control device for a filler having at least one external signal input terminal, and controlling the current value to be supplied, the filler wire feeding speed, and the start of feed of the filler wire to the molten pool; and an external signal output terminal of the control device. And a connection cable for connecting the filler power control device to an external signal input terminal.
[0010]
In the present invention, for example, a welding torch, a consumable electrode wire feeding device, a welding power source, for a single-wire type welding equipment having a control device, the filler wire feeding device, a filler power source, a setting device, A filler power control device is additionally provided, and an external signal output terminal of the control device and an external signal input terminal of the filler power control device are connected via a connection cable. As a result, the equipment on the side of the consumable electrode wire is normally controlled by the control device, and further, by inputting an output signal from the control device, a device operated by a command from the control device 12 and a filler power control device 25 And a device that operates in response to a command from the device can be operated with appropriate timing.
[0011]
As described above, according to the present invention, when a single-wire type welding facility is owned as an existing facility, the control device is modified by using an external output terminal of the control device to provide a control panel dedicated to additional equipment. Even if it is not specially provided, by connecting the power supply control device for the filler prepared separately to the existing control device by terminals, both control devices can control the entire double-wire welding equipment. This makes it possible to provide a double-wire welding system that is easily and inexpensively constructed from existing single-wire welding equipment without special modification.
[0012]
(2) In the above (1), preferably, there is provided a welding robot that attaches the welding torch to a tip of an arm and moves the welding torch in response to a command signal from the control device.
[0013]
(3) In the above (1) or (2), more preferably, the welding power supply supplies a current from the consumable electrode wire to the base material side, and the filler power supply supplies a current from the base material side to the filler wire. Apply.
[0014]
(4) In order to achieve the above object, according to the welding method of the present invention, an arc is generated between a consumable electrode wire fed to a welding location via a welding torch and a base material in response to a command from a control device. A filler wire feeding device for feeding a filler wire via the welding torch to a welding facility for melting a consumable electrode wire and a base material; a filler power supply for feeding the filler wire and the filler wire feeding device; and a filler wire. A setting device for setting a current value to be applied, a filler wire feeding speed, and a start time for feeding the filler wire to the molten pool; and a connection device connected to the control device via a connection cable, and an output signal from the control device and the setting. A current value to be applied to the filler wire, a feed rate of the filler wire, and a start of feed of the filler wire to the molten pool according to a set value from an apparatus. A power supply control device for a filler to be controlled is additionally provided, and the arc is generated by applying a current to the consumable electrode wire, and a current is applied to the filler wire in a direction opposite to the consumable electrode wire to generate heat by the heat of the arc. The filler wire is fed to the resulting molten pool.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the welding system of the present invention will be described with reference to the drawings.
FIG. 1 is a schematic diagram in which a portion functioning as a single-wire type welding facility is extracted and represented in the entire configuration of an embodiment of the welding system of the present invention. In FIG. 1, reference numeral 1 denotes a welding robot (manipulator) having an articulated arm 1a that can operate three-dimensionally, reference numeral 2 denotes a welding torch provided at the tip of the arm 1a of the welding robot 1, and reference numeral 3 denotes this welding. It is a consumable electrode wire supply tube provided in the torch. Reference numeral 4 denotes a welding wire (consumable electrode wire) inserted and held in the consumable electrode wire supply tube 3 of the welding torch 2, and 5 denotes a consumable electrode wire 4 wound on a reel 6 sequentially fed and welded via the welding torch 2. It is a consumable electrode wire feeding device (feeding motor) for feeding to a location. Although not shown, the welding torch 2 is provided with a gas nozzle for injecting a shielding gas.
[0016]
Reference numeral 7 denotes a welding power source for supplying a current and a voltage to be applied to the consumable electrode wire 4. The plus terminal 7a of the welding power source 7 is connected to the consumable electrode wire 4 (strictly, the consumable electrode wire supply tube 3), and the minus terminal 7b is welded. The target base material 8 is connected via electric wires 9 and 10, respectively. An output terminal (not shown) of the welding power source 7 is connected to the consumable electrode wire feeding device 5 via a cable 11.
[0017]
Reference numeral 12 denotes a control device (robot control panel), which is not particularly shown for the purpose of preventing complexity, but has various control setting values (for example, current / voltage values applied to the consumable electrode wire 4, consumable electrode wire). An input unit for inputting the feed speed (welding speed) of the arm 4a, the position control unit for controlling the position and posture of the arm 1a, and the welding speed (moving speed of the welding torch 2). And a speed control unit for controlling the speed. A cable 13 connects the control device 12 and the welding robot 1. Further, the control device 12 has a plurality of external signal output terminals (not shown), and is connected to the welding power source 7 by cables 14 to 16 via at least one (three in this example) of them. .
[0018]
FIG. 2 shows an extracted portion of the entire configuration of the embodiment of the welding system of the present invention, which is added to the single-wire welding equipment of FIG. 1 in order to construct a double-wire welding system. In the schematic diagram, the welding system of the present embodiment is configured as a whole by adding the respective devices shown in FIG. 2 to the respective devices shown in FIG. 1 to form a double-wire welding system. 2, reference numeral 17 denotes a filler wire supply tube further provided on the welding torch 2, reference numeral 18 denotes a welding wire (filler wire) inserted and held in the filler wire supply tube 17, and reference numeral 19 denotes a filler wire 18 wound around a reel 20 in order. This is a filler wire feeding device (feeding motor) for feeding to a welding location via a feed welding torch 2.
[0019]
Reference numeral 21 denotes a filler power supply for supplying electric power to be applied to the filler wire 18. The plus terminal 21a of the filler power supply 21 is connected to the base material 8 to be welded, and the minus terminal 21b is connected to the filler wire 18 (strictly, the filler wire supply tube 17). Are connected via electric wires 22 and 23, respectively. An output terminal (not shown) of the filler power supply 21 is connected to the filler wire feeding device 19 via a cable 24.
[0020]
Reference numeral 25 denotes a power supply control device for a filler with a built-in timer, and reference numeral 26 denotes a setting device connected to the power supply control device for a filler 25 via a cable 27. The setting device 26 is for setting a current value, a feeding speed, a feeding start time, and the like of the filler wire 18 and inputting them to the filler power controller 25. The filler power supply control device 25 is connected to an external signal output terminal (not shown) of the control device 12 (see FIG. 1) via a signal input terminal (not shown) via a connection cable 28. The external signal from the control device 12 can be input to the input unit. Thereby, the power supply control device for filler 25 calculates the command signal to the power supply for filler 21 based on the set value from the setting device 26, and outputs the external signal from the control device 12 from the time of input from the setting device 26. When the timer time corresponding to the above-mentioned feeding start time has elapsed, the calculated command signal is output to the power supply 21 for the filler. Reference numerals 29 to 31 denote cables connecting the filler power supply control device 25 and the filler power supply 21.
[0021]
Next, the operation of the above-described welding system of the present embodiment will be described.
When a welding operation is performed by the welding system having the above configuration, first, before starting welding, a current value and a voltage value to be applied to the consumable electrode wire 4, a moving path of the welding torch 2, and a moving speed (welding speed) of the welding torch 2. , Various welding conditions such as a current value applied to the filler wire 18, a feed speed of the filler wire 18, and a feed start time of the filler wire 18 are set. Among these, conditions from the current value / voltage value applied to the consumable electrode wire 4 to the welding speed are set by a teaching box (not shown) or the like, and are respectively input to an input unit (not shown) of the control device 12. On the other hand, the power to be applied to the filler wire 18, the feed speed of the filler wire 18, and the feed start time of the filler wire 18 are separately set by the setting device 26 and input to the filler power supply control device 25.
[0022]
When welding is started after setting the above conditions, an arc start signal is output from the control device 12 to the welding power source 7, and the welding power source 7 applies the set voltage and current to the consumable electrode wire 4. As a result, an arc 32 is generated between the consumable electrode wire 4 and the welded portion of the base material 8, and the arc heat causes the distal end of the consumable electrode wire 4 and the welded portion of the base material 8 to be melted to form a molten pool 33. Is formed. At this time, since the consumable electrode wire 4 is consumed (melted) from the tip, the control device 12 outputs the set feeding speed of the consumable electrode wire to the welding power source 7 and feeds the wire of a size corresponding to the setting. By outputting a signal (voltage) from the welding power source 7, the driving speed of the consumable electrode wire feeding device 5 is controlled, and the consumable electrode wire 4 is sequentially fed to the welding location.
The current applied to the consumable electrode wire 4 flows in the order of “welding power supply plus terminal 7a → wire 9 → consumable electrode wire 4 → base metal 8 → wire 10 → welding power supply minus terminal 7b”.
[0023]
At the same time, the arm 1a of the welding robot 1 is drive-controlled by the position control unit and the speed control unit (both not shown) of the control device 12 to move the set welding path at the set welding speed. At this time, the posture of the arm 1a of the welding robot 1 is controlled so as to always hold the welding torch 2 in a direction in which the consumable electrode wire 4 precedes the filler wire 18 in the welding direction (see the arrow A in FIG. 2). .
[0024]
On the other hand, simultaneously with the output of the arc start signal, the control device 12 turns on the external signal output to the filler power supply control device 25 via the external signal output terminal. When an external signal (ON signal) is input from the control device 12, the filler power supply control device 25 turns on the filler after a predetermined time (after a set filler wire feeding start time, for example, 2 to 5 seconds) by a built-in timer. (Start of filler wire feeding), and instruct the filler power supply 21 on the control value of the current of the filler wire 18 and the set feeding speed of the filler wire 18.
[0025]
Upon receiving a command from the filler power supply control device 25, the filler power supply 21 applies a voltage and current of a set magnitude to the filler wire 18 and transmits a filler feed signal (voltage) to the filler wire. Output to the device 19. As a result, the filler wire 18 is fed (inserted) into the molten pool 33 at a set feed rate, and the filler wire 18 is heated by the applied current (or voltage) from the filler power supply 21 and the heat of the molten pool 33, thereby forming the filler wire 18. Is melted.
The current applied to the filler wire 18 is in the opposite direction to that of the consumable electrode wire 4, that is, “filler power supply plus terminal 21a → wire 22 → base material 8 → filler wire 18 → wire 23 → filler power supply negative terminal 21b”. Flow in the order of However, the current applied to the filler wire 18 is limited to a range where no arc is generated from the filler wire 18.
[0026]
As described above, in the present embodiment, each device is timing-controlled according to various setting conditions by the control device 12 and the filler power supply control device 25 connected thereto, and after the welding torch 2 moves on a predetermined route. A weld bead 34 is formed by the molten base material 8, the consumable electrode wire 4, and the filler wire 18.
[0027]
In the present embodiment, the single-wire type welding equipment shown in FIG. 1 including a welding robot 1, a welding torch 2, a consumable electrode wire feeding device 5, a welding power source 7, a control device 12, and the like is shown in FIG. A filler wire feeder 19, a filler power supply 21, a setting device 26, and a filler power controller 25 are additionally provided, and an external signal output terminal of the controller 12 and an external signal input of the filler power controller 25 are provided. By connecting the terminals to each other via the connection cable 28, the device that operates according to a command from the control device 12 and the device that operates according to a command from the filler power control device 25 are operated at appropriate timing. (Timing control is possible).
[0028]
Therefore, according to the present embodiment, when a single-wire welding facility is owned as an existing facility, the control apparatus is modified by using an external output terminal of the control apparatus to provide a control panel dedicated to additional equipment. Even if it is not specially provided, by connecting a separately prepared filler power supply control device to an existing control device, both control devices can control the entire welding system of the double wire system. As a result, it is possible to provide a double-wire welding system that can be constructed extremely easily and at low cost without special modification from existing single-wire welding equipment. By constructing the welding system of the double wire system, the melting speed (melting amount) of the wire can be increased with the same amount of power supply as the welding equipment of the single wire system, and high work efficiency can be secured.
[0029]
Also, by applying currents in opposite directions to the consumable electrode wire 4 and the filler wire 18, the magnetic fluxes generated in the consumable electrode wire 4 and the filler wire 18 repel each other. A force acts in a direction away from 18. Therefore, even if the filler wire 18 is disposed close to the worn electrode wire 4, the filler wire 18 is prevented from being blown off by the arc 32, and the filler wire 18 can be reliably and stably supplied to the molten pool 33. Accordingly, for example, even when carbon steel, alloy steel, aluminum, or the like is to be welded, high-speed and high-efficiency work can be performed. Further, by inserting the filler wire 18 into the molten pool 33, the temperature of the molten pool 33 is kept low, so-called puckering phenomenon in which the weld bead 34 is disturbed, black powder adhesion (oxide adhesion), solidification cracking, etc. Is also suppressed.
[0030]
As described above, in the present embodiment, the currents applied to the consumable electrode wire 4 and the filler wire 18 are set in opposite directions. It is not always necessary to reverse the currents of the wires 4 and 18 as long as the object of the present invention to provide the welding system of the present invention is achieved. Further, in the present embodiment, a so-called fully automatic welding system for automatically moving and controlling the speed of the welding torch 2 has been exemplified. The present invention is also applicable to a so-called semi-automatic welding system in which only the current / voltage and the feeding of both wires 4 and 18 are automatically performed. 1 and 2, an example in which a so-called push-type wire feeding device in which both wire feeding devices 5 and 19 are provided on a reel side has been described, but a so-called pull-type wire feeding device provided on a torch side. It may be a feeding device or a wire feeding device of a type combining these. In these cases, a similar effect is obtained.
[0031]
Further, the control device 12 and the filler power supply control device 25 are configured to output a command simply based on the set welding conditions. For example, the rotation speeds of the two wire feeding devices 5 and 19, the arm 1a of the welding robot 1 are set. The present invention is also applicable to a welding system of the type having a function of performing feedback control based on detection signals from sensors for detecting the angles of the joints, the current values and the voltage values of the wires 4 and 18, and the like. In addition, as the welding robot, a type having an articulated arm has been exemplified, but the present invention is not limited to this. For example, two-dimensional or three-dimensional along a plurality of rails extending in different directions. A welding robot having an arm capable of moving operation may be used. Further, the case where the setting device 26 and the filler power supply control device 25 are provided as separate units has been illustrated, but a control device in which these are integrated may be used. In these cases, the same effect as above can be obtained.
[0032]
【The invention's effect】
According to the present invention, it is possible to provide a double-wire welding system which can be easily and inexpensively constructed from existing single-wire welding equipment without special modification.
[Brief description of the drawings]
FIG. 1 is a schematic diagram in which a portion functioning as a single-wire type welding facility is extracted and represented in the overall configuration of an embodiment of a welding system according to the present invention.
FIG. 2 is a table showing extracted portions of the entire configuration of an embodiment of the welding system according to the present invention which are added to the single-wire welding equipment of FIG. 1 in order to construct a double-wire welding system. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Welding robot 1a Arm 2 Welding torch 4 Consumable electrode wire 5 Consumable electrode wire feeding device 7 Welding power supply 8 Base material 12 Control device 18 Filler wire 19 Filler wire feeding device 21 Filler power supply 25 Filler power control device 26 Setting device 28 Connection Cable 32 Arc 33 Weld pool

Claims (4)

In a welding system for feeding a filler wire to a molten pool while generating an arc between the base material and the consumable electrode wire to melt the base material and the consumable electrode wire,
A welding torch for holding the consumable electrode wire inserted,
A consumable electrode wire feeding device for feeding the consumable electrode wire to a welding point through the welding torch,
A welding power supply for supplying power to the consumable electrode wire and the consumable electrode wire feeding device;
A control device for controlling at least a current value and a voltage value applied to the consumable electrode wire, and having at least one external signal output terminal;
A filler wire feeding device for feeding the filler wire to the molten pool through the welding torch,
A filler power supply for supplying power to the filler wire and the filler wire feeding device;
A current value to be applied to the filler wire, a filler wire feed speed, a setting device for setting a feed start time of the filler wire to the molten pool,
According to an output signal from the control device and a setting value from the setting device, a current value applied to the filler wire, the filler wire feed speed, and a start of feed of the filler wire to the molten pool are controlled, and at least one A power control device for a filler having two external signal input terminals;
A welding system comprising a connection cable for connecting an external signal output terminal of the control device and an external signal input terminal of the filler power control device. The welding system according to claim 1, further comprising a welding robot that attaches the welding torch to a tip of an arm and moves the welding torch in response to a command signal from the control device. 3. The welding system according to claim 1, wherein the welding power supply supplies a current from the consumable electrode wire to the base material side, and the filler power supply applies a current to the filler wire from the base material side. 4. Welding system. In response to a command from the control device, an arc is generated between the consumable electrode wire and the base material fed to the welding location via the welding torch, and welding equipment for melting the consumable electrode wire and the base material,
A filler wire feeding device for feeding a filler wire through the welding torch, a filler power supply for feeding the filler wire and the filler wire feeding device, a current value applied to the filler wire, a filler wire feeding speed, and a filler wire to the molten pool. A setting device for setting the feeding start time of the current, a current value applied to the filler wire, connected to the control device via a connection cable, according to an output signal from the control device and a setting value from the setting device, Filler wire feed speed, and a filler power supply control device that controls the start of feed of the filler wire to the molten pool is additionally provided,
Applying a current to the consumable electrode wire to generate the arc, applying a current to the filler wire in a direction opposite to the consumable electrode wire, and feeding the filler wire to a molten pool generated by the heat of the arc. Characteristic welding method.

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