JP2005279739A - Welding apparatus - Google Patents
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Abstract
Description
本発明は、消耗電極である溶接ワイヤと被溶接物である溶接母材との間にアークを発生させて溶接出力制御を行う溶接装置に関するものである。 The present invention relates to a welding apparatus that performs welding output control by generating an arc between a welding wire that is a consumable electrode and a welding base material that is a workpiece.
通常、消耗電極式アーク溶接では、溶接出力電圧の供給と溶接ワイヤの送給を停止することで、溶接を終了させていた。 Normally, in consumable electrode arc welding, welding is terminated by stopping the supply of the welding output voltage and the feeding of the welding wire.
このとき、溶接ワイヤの送給は、溶接ワイヤ送給モータ及び溶接ワイヤ送給機構等の慣性や、溶接トーチ内の溶接ワイヤのたるみ及び送給抵抗等により、溶接ワイヤ先端が完全に停止するまでに時間を要していた。 At this time, the welding wire is fed until the tip of the welding wire completely stops due to the inertia of the welding wire feeding motor and the welding wire feeding mechanism, the slack of the welding wire in the welding torch, the feeding resistance, and the like. It took time to.
これに対して、溶接出力電圧の供給は、インバータ周波数(10kHz)程度の応答速度で、瞬時に停止させることができていた。 On the other hand, the supply of the welding output voltage could be stopped instantaneously at a response speed of about the inverter frequency (10 kHz).
このように両者の停止時間には差があるので、仮に、溶接終了の指示と同時に溶接ワイヤ送給モータと溶接出力電圧の供給を停止すると、溶接出力停止後も溶接ワイヤのみが送給され、溶接ワイヤが被溶接物に溶着(以下、スティックという。)する不具合が生じる。公知の技術においては、上記のスティックを防止するために、溶接終了の指示と同時に溶接出力電圧の供給を停止せず、予め、溶接終了の指示を起点とし溶接ワイヤが停止するまでの溶接ワイヤ停止時間に対応する溶接終了制御時間を設け、前記溶接終了制御時間中は、溶接出力電圧を供給することにより所定の終了状態を得ていた。 Thus, since there is a difference between both stop times, if the welding wire feed motor and the supply of the welding output voltage are stopped simultaneously with the instruction to end welding, only the welding wire is fed even after the welding output is stopped, There arises a problem that the welding wire is welded (hereinafter referred to as a stick) to the workpiece. In the known technique, in order to prevent the stick, the welding output voltage is not stopped at the same time as the welding end instruction, but the welding wire is stopped in advance until the welding wire stops with the welding end instruction as a starting point. A welding end control time corresponding to the time is provided, and a predetermined end state is obtained by supplying a welding output voltage during the welding end control time.
しかし、このような方法では、溶接ワイヤ停止時間に対して溶接終了制御時間が長過ぎるとアーク長が過大となり、溶接ワイヤ先端の溶融玉が過大に成長して、次のアークスタート時にスタート不良の原因の一つとなっていた。このような課題の解決方法として、従来の消耗電極式パルスアーク溶接装置では、溶接終了制御時間経過後の最終パルス出力直後に溶接電源の出力を停止することで溶接終了直前のアーク長を適正値にすることが提案されている。 However, in such a method, if the welding end control time is too long with respect to the welding wire stop time, the arc length becomes excessive, and the molten ball at the tip of the welding wire grows excessively. It was one of the causes. As a solution to such a problem, in the conventional consumable electrode type pulse arc welding apparatus, the arc length immediately before the end of welding is set to an appropriate value by stopping the output of the welding power source immediately after the final pulse output after the end of the welding end control time. It has been proposed to
また、溶接終了の指示以降に溶接ワイヤの送給モータの電機子電圧が所定値以下になったことを検出して溶接ワイヤの送給の停止とし、パルス通電した後に溶接電源の出力を停止するものも提案されている(例えば特許文献1参照)。
しかし、上述した従来の溶接終了制御の様に、溶接終了の指示を起点とし溶接ワイヤが停止するまでの溶接ワイヤ停止時間に対応させて溶接終了制御時間を設定し、溶接ワイヤを溶融離脱させるものでは、溶接ワイヤ送給モータや送給機構の慣性のバラツキ、トーチケーブル長、溶接用トーチ内の溶接ワイヤのたわみ等、多くの因子により発生する溶接ワイヤ停止時間のバラツキに対応できず、その結果、溶接終了時の溶接ワイヤ先端の状態が不規則となっていた。 However, like the conventional welding end control described above, the welding end control time is set in accordance with the welding wire stop time from the start of welding instruction until the welding wire stops, and the welding wire is melted and separated. However, it cannot cope with variations in the welding wire stop time caused by many factors, such as variations in the inertia of the welding wire feeding motor and feeding mechanism, torch cable length, and deflection of the welding wire in the welding torch. The state of the welding wire tip at the end of welding was irregular.
上記のように、溶接ワイヤ停止時間にバラツキがあると溶接終了時のスパッタの増大、溶接品質の悪化、スティック、チップ融着といった不具合が発生していたと共に、溶接終了時の溶接ワイヤ先端の状態が不規則であると、次のアークスタート時のアークスタート不良の原因の一つにもなるという課題を有していた。 As described above, when there is variation in the welding wire stop time, problems such as increased spatter at the end of welding, deterioration in welding quality, stick and tip fusion occurred, and the state of the tip of the welding wire at the end of welding If it is irregular, there is a problem that it becomes one of the causes of arc start failure at the next arc start.
さらに、溶接終了制御時間は、定常溶接時の溶接ワイヤ送給モータの回転数や溶接ワイヤ径、溶接ワイヤ材質等により異なるため、それぞれの組み合わせで実験を行い最適値を選定するために多くの工数を要するという課題も有していた。 Furthermore, since the welding end control time varies depending on the number of rotations of the welding wire feed motor, welding wire diameter, welding wire material, etc. during steady welding, many man-hours are required to conduct experiments in each combination and select the optimum value. It also had the problem of requiring.
また、溶接終了の指示以降に溶接ワイヤの送給モータの電機子電圧が所定値以下になったことを検出して溶接ワイヤの送給の停止とし、パルス通電した後に溶接電源の出力を停止する方法では、溶接終了の指示以降溶接ワイヤ停止までの間のアーク長の変動による、溶接ビード外観や溶接品質の悪化、スパッタの発生を抑制することは難しいという課題を有していた。 Also, after the welding end instruction is detected, it is detected that the armature voltage of the welding wire feeding motor has become a predetermined value or less, the feeding of the welding wire is stopped, and the output of the welding power source is stopped after pulse energization. This method has a problem that it is difficult to suppress the deterioration of the weld bead appearance, the welding quality, and the occurrence of spatter due to the change in the arc length from the instruction to end welding to the stop of the welding wire.
本発明は、溶接終了制御時間の選定といった実験により最適値を求める作業をすることなく、溶接終了の指示以降溶接ワイヤ停止までの間のアーク長をほぼ一定に維持しながら、溶接終了時の溶接ワイヤ先端の状態のバラツキを抑え、溶接作業性や溶接品質を向上させると共に次のアークスタート時のアークスタート性をも向上させる溶接装置を提供することを目的とする。 In the present invention, welding at the end of welding is performed while maintaining the arc length from the end of welding to the stop of the welding wire substantially constant without performing an operation of obtaining an optimum value by an experiment such as selection of a welding end control time. An object of the present invention is to provide a welding apparatus that suppresses variations in the state of the wire tip, improves welding workability and welding quality, and also improves arc start performance at the next arc start.
上記目的を達成するために本発明の溶接装置は、溶接起動信号を出力する起動手段と、前記起動手段からの溶接起動信号によって溶接ワイヤを溶接部分に送給し、前記起動手段からの溶接終了の指示によって溶接ワイヤの送給量を減少させて停止させる溶接ワイヤ送給手段を備え、前記溶接終了の指示以降または溶接終了の指示の前の溶滴移行からの溶接ワイヤの送給量を算出する算出手段と、前記算出手段で算出された送給量が所定の値になった時に溶滴を移行させる移行手段とを設けたものである。 In order to achieve the above object, a welding apparatus of the present invention includes a starting means for outputting a welding start signal, and a welding wire is fed to a welding portion by a welding start signal from the start means, and welding from the start means is completed. Welding wire feeding means for reducing and stopping the welding wire feeding amount according to the instruction of the welding wire, and calculating the welding wire feeding amount from the droplet transfer after the welding end instruction or before the welding end instruction And a transfer means for transferring the droplet when the feed amount calculated by the calculation means reaches a predetermined value.
そして、この構成により本発明の溶接装置は溶接終了の指示以降に送給された溶接ワイヤとほぼ同量が被溶接物に移行し、溶接終了制御時間の選定といった実験により最適値を求める作業をすることなく、溶接終了の指示以降溶接ワイヤ停止までの間のアーク長をほぼ一定に維持しながら、溶接終了時の溶接ワイヤ先端の溶融玉を小径で適正な大きさに安定して制御してバラツキを抑え、溶接作業性や溶接品質を向上させると共に次のアークスタート時のアークスタート性をも向上させる作用を有する。 With this configuration, the welding apparatus according to the present invention performs an operation for obtaining an optimum value by an experiment such as selection of a welding end control time, in which almost the same amount of welding wire fed after the instruction to end welding is transferred to the workpiece. Without changing, the arc length from the end of welding to the stop of the welding wire is kept almost constant, and the molten ball at the end of the welding wire at the end of welding is stably controlled to a small diameter and an appropriate size. It has the effect of suppressing variations, improving welding workability and welding quality, and improving the arc start performance at the next arc start.
以上のように、本発明は、起動信号がオフしてからワイヤ停止までに送給されるワイヤ量の殆ど全てを移行させることが出来る上、定常溶接時のアーク長と溶接終了の指示以降のアーク長との間に大きな差を発生させることなく、溶接ワイヤの燃え上がりやチップと溶接ワイヤとの融着を防止でき、さらにスティックを防止するに十分なワイヤ先端と母材との間隙を保ち、溶接終了時の溶接ワイヤ先端の状態のバラツキを抑えて安定して制御することができるので、溶接作業性や溶接品質を向上させることが出来、次のアークスタートを良好に行うことが可能となる。 As described above, the present invention can transfer almost all of the amount of wire that is sent from the start signal being turned off until the wire stops, and after the arc length at the time of steady welding and the instruction for the end of welding. Without causing a large difference from the arc length, it is possible to prevent the welding wire from burning up and the fusion between the tip and the welding wire, and to maintain a sufficient gap between the wire tip and the base material to prevent sticking, Since it is possible to control stably by suppressing variations in the state of the welding wire tip at the end of welding, welding workability and welding quality can be improved, and the next arc start can be performed satisfactorily. .
(実施の形態1)
図1は本発明に係る消耗電極式アーク溶接装置の実施の形態1を表すブロック図を示すものである。
(Embodiment 1)
FIG. 1 is a block diagram showing Embodiment 1 of a consumable electrode type arc welding apparatus according to the present invention.
起動手段4から出力される溶接起動信号に基づいて溶接ワイヤ送給手段5は溶接ワイヤを送給および停止し、電力出力手段3は溶接ワイヤ1と被溶接物2との間に所望波形の電力を供給および停止する。算出手段7は溶接ワイヤ1の送給量を算出し、移行手段8は算出手段7で算出された溶接ワイヤ1の送給量が所定の値になった時に溶滴を移行させる。 The welding wire feeding means 5 feeds and stops the welding wire based on the welding activation signal output from the activation means 4, and the power output means 3 has a desired waveform of power between the welding wire 1 and the workpiece 2. Supply and stop. The calculating means 7 calculates the feeding amount of the welding wire 1, and the shifting means 8 shifts the droplet when the feeding amount of the welding wire 1 calculated by the calculating means 7 reaches a predetermined value.
次に図2を用いて動作の説明をする。本図は、消耗電極式アーク溶接の一例として、特に消耗電極式パルスアーク溶接を説明する図である。 Next, the operation will be described with reference to FIG. This figure is a diagram for explaining consumable electrode type pulse arc welding as an example of consumable electrode type arc welding.
図2に示すように、溶接ワイヤ1を溶接部分に送給して溶接する定常溶接時に、溶接起動信号TSがオフし溶接終了の指示がなされると、溶接ワイヤ送給モータには停止信号が入り、溶接ワイヤ送給速度vが減衰を始める。ここで、溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤ1の送給量Vを算出し、前記送給量Vが所定の値Mの整数倍になった時に溶滴を移行させる。 As shown in FIG. 2, when the welding start signal TS is turned off and a welding end instruction is given during steady welding in which the welding wire 1 is fed to the welded portion and welded, a stop signal is sent to the welding wire feeding motor. Then, the welding wire feeding speed v starts to attenuate. Here, the feed amount V of the welding wire 1 from the droplet transfer time tb after the welding end instruction time t0 or before the welding end instruction is calculated, and the feed amount V is an integral multiple of a predetermined value M. The droplets are transferred when
図2では溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤ1の送給量Vとして溶接終了の指示時刻t0以降の溶接ワイヤ1の送給量を示した。 In FIG. 2, the feeding amount of the welding wire 1 after the welding end instruction time t0 is indicated as the feeding amount V of the welding wire 1 after the welding end instruction time t0 or after the droplet transfer time tb before the welding end instruction. Indicated.
本実施の形態例では、溶滴の移行手段としてIaに示すようにパルス状の電気的出力を用いた。 In this embodiment, a pulsed electrical output is used as droplet transfer means, as indicated by Ia.
さらに、電気的出力Ibに示したように前記電気的出力Iaに加えて溶接ワイヤ1の停止時刻teにパルス出力を供給することで、溶滴を移行させてもよい。 Further, as shown in the electrical output Ib, the droplets may be transferred by supplying a pulse output at the stop time te of the welding wire 1 in addition to the electrical output Ia.
溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤ1の送給量は、溶接ワイヤ送給速度vを時間積分することで算出出来る。ここで、溶接ワイヤ送給速度vは、非接触光学式速度検出器やレーザドップラセンサ等によって検出することが出来る。また、溶接ワイヤ1の送給量は溶接ワイヤ送給用モータの回転数から算出することも出来る。ここで、溶接ワイヤ送給用モータの回転数は、前記非接触光学式速度検出器、レーザドップラセンサの他、接触式回転系や溶接ワイヤ送給用モータに取り付けられたエンコーダ等を用いて検出することが出来る。 The feed amount of the welding wire 1 after the welding end instruction time t0 or before the droplet transfer time tb before the welding end instruction can be calculated by time-integrating the welding wire feeding speed v. Here, the welding wire feed speed v can be detected by a non-contact optical speed detector, a laser Doppler sensor, or the like. Further, the feeding amount of the welding wire 1 can be calculated from the number of rotations of the welding wire feeding motor. Here, the number of rotations of the welding wire feed motor is detected by using the non-contact optical speed detector, the laser Doppler sensor, an encoder attached to the contact type rotation system or the welding wire feed motor, or the like. I can do it.
以下に、前記所定の値Mおよび溶接終了の指示以降のワイヤ送給量Vおよび溶滴の移行タイミングの算出方法の例を示す。 Below, the example of the calculation method of the predetermined value M and the wire feed amount V after the instruction | indication of completion | finish of welding and the transfer timing of a droplet is shown.
溶接ワイヤ1の直径をa(mm)、溶接ワイヤ1を溶接部分に送給して溶接する定常溶接時のワイヤ送給速度をv0(mm/sec)、溶滴の移行周波数をf(Hz)とすると、前記所定の値Mは The diameter of the welding wire 1 is a (mm), the wire feed speed at the time of steady welding in which the welding wire 1 is fed to the welded portion and welded is v0 (mm / sec), and the droplet transfer frequency is f (Hz). Then, the predetermined value M is
一方、溶接終了の指示時刻t0以降溶滴の移行タイミングti(i=1,2,3,・・・・・)までの間に送給される溶接ワイヤ1の送給量Vは、溶接ワイヤ送給速度をvとすると On the other hand, the feed amount V of the welding wire 1 fed between the instruction end time t0 of welding and the transition timing ti (i = 1, 2, 3,...) Of the droplet is the welding wire. If the feed speed is v
従って、溶接起動信号TSがオフしてからi(i=1,2,3,・・・・・)番目の溶滴相当の溶接ワイヤ1の送給量が送給される溶滴の移行タイミングti(i=1,2,3,・・・・・)は(1)式及び(2)式より Accordingly, the droplet transfer timing at which the feed amount of the welding wire 1 corresponding to the i (i = 1, 2, 3,...) Droplet after the welding start signal TS is turned off is fed. ti (i = 1, 2, 3,...) is obtained from equations (1) and (2).
以上のように、溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤ1の送給量Vを算出し、前記送給量Vが所定の値Mの整数倍になる時間tiに溶滴を移行させることにより、溶接起動信号TSがオフしてから溶接ワイヤの停止までに送給される溶接ワイヤ量の殆ど全てを移行させることが出来る。 As described above, the feed amount V of the welding wire 1 is calculated after the welding end instruction time t0 or after the droplet transfer time tb before the welding end instruction, and the feed amount V is a predetermined value M. By transferring the droplets at time ti that is an integral multiple, almost all of the amount of welding wire fed from when the welding activation signal TS is turned off to when the welding wire is stopped can be transferred.
つまり、溶接終了制御時間の選定といった実験により最適値を求める作業無しで、定常溶接時のアーク長と溶接終了の指示以降のアーク長との間に大きな差を発生させることなく、溶接ワイヤ1の燃え上がりやチップと溶接ワイヤとの融着を防止できる。さらに、スティックを防止するに十分なワイヤ先端と被溶接物2との間隙を保ち、溶接終了時の溶接ワイヤ先端の溶融玉を小径の適正な大きさにバラツキを抑えて安定して制御することが出来るので、溶接作業性や溶接品質を向上させることが出来、次のアークスタートを良好に行うことが可能となる。また、溶接ワイヤ1の送給量の算出の際に、溶接終了の指示時刻t0以降ではなく溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤの送給量を算出することで、溶接ワイヤ1を溶接部分に送給して溶接する定常溶接時と起動信号TSがオフし溶接終了の指示がなされたt0以降とのパルス周期が乱れることなく安定して連続的に発生する。 That is, without an operation of obtaining an optimum value by an experiment such as selection of the welding end control time, the welding wire 1 is made without causing a large difference between the arc length at the time of steady welding and the arc length after the instruction to end welding. It can prevent burning and fusion between the tip and the welding wire. Furthermore, the gap between the wire tip and the work piece 2 that is sufficient to prevent sticking is maintained, and the molten ball at the tip of the welding wire at the end of welding is stably controlled with a small size and an appropriate size. Therefore, welding workability and welding quality can be improved, and the next arc start can be performed satisfactorily. Further, when calculating the feed amount of the welding wire 1, by calculating the feed amount of the welding wire from the droplet transfer time tb before the welding end instruction rather than after the welding end instruction time t0, It is generated stably and continuously without disturbing the pulse period at the time of steady welding in which the welding wire 1 is fed to the welding portion and welding is started and after the start signal TS is turned off and the instruction to end welding is given.
上記は、溶接起動信号TSがオフの期間は1パルスで1回の溶滴の移行をさせる場合であるが、移行パルス以外に移行を伴わない複数のパルスを出力することもある。 The above is a case where one droplet is transferred by one pulse while the welding activation signal TS is OFF, but a plurality of pulses not accompanied by the transfer may be output in addition to the transfer pulse.
なお、上記図2における実施の形態は、消耗電極式パルスアーク溶接で説明したが、これに限定されるものではなく、他の消耗電極式アーク溶接法においても同様の効果を奏するものである。 Although the embodiment in FIG. 2 has been described with consumable electrode type pulse arc welding, the present invention is not limited to this, and the same effect can be achieved with other consumable electrode type arc welding methods.
(実施の形態2)
図3は本発明に係る消耗電極式アーク溶接装置の実施の形態2を表すブロック図である。本実施の形態において実施の形態1と同様の構成については同一の番号を付して詳細な説明を省略する。
(Embodiment 2)
FIG. 3 is a block diagram showing Embodiment 2 of the consumable electrode type arc welding apparatus according to the present invention. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.
算出手段7は溶接ワイヤ1の送給量を算出し、移行手段8は算出手段7で算出された溶接ワイヤ1の送給量が所定の値になった時に溶滴を移行させると共に、溶滴の移行タイミングとして比較手段10に溶滴移行タイミング信号を出力する。 The calculating means 7 calculates the feeding amount of the welding wire 1, and the shifting means 8 moves the droplet when the feeding amount of the welding wire 1 calculated by the calculating means 7 reaches a predetermined value. The droplet transfer timing signal is output to the comparison means 10 as the transfer timing.
時間推定手段9は溶接ワイヤが停止する時間を推定し、比較手段10によって時間推定手段9の推定結果と移行手段8からの溶滴移行タイミング信号を比較する。制御手段6は、比較手段10によって溶滴の移行タイミングが溶接ワイヤ1の停止よりも遅くなると推定された場合に溶滴の移行タイミングが溶接ワイヤ1の停止よりも遅くなると推定された溶滴の移行タイミングよりも前の溶滴の移行で溶接ワイヤ1への電気的出力を停止する。 The time estimation means 9 estimates the time when the welding wire stops, and the comparison means 10 compares the estimation result of the time estimation means 9 with the droplet transfer timing signal from the transfer means 8. The control means 6 is configured such that when the comparison means 10 estimates that the droplet transfer timing is later than the stop of the welding wire 1, the droplet transfer timing is estimated to be later than the stop of the welding wire 1. The electrical output to the welding wire 1 is stopped by the transfer of the droplet before the transfer timing.
次に、図4を用いて動作の説明をする。 Next, the operation will be described with reference to FIG.
実施の形態1と異なるのは、溶接ワイヤ1の停止時刻teを推定し、溶滴の移行タイミングtiとを比較して、溶滴の移行タイミングtiが溶接ワイヤ1の停止よりも遅くなると推定された場合、溶滴の移行タイミングtiが溶接ワイヤ1の停止よりも遅くなると推定された溶滴の移行タイミングtiよりも前の溶滴の移行で予め溶接ワイヤ1への電力の供給を停止する点である。 The difference from the first embodiment is that the stop time te of the welding wire 1 is estimated and compared with the droplet transfer timing ti, and it is estimated that the droplet transfer timing ti is later than the stop of the welding wire 1. In this case, the supply of power to the welding wire 1 is stopped in advance by the transfer of the droplet before the transfer timing ti of the droplet estimated that the transfer timing ti of the droplet is later than the stop of the welding wire 1. It is.
図4では、溶接終了の指示以降の溶接ワイヤ1の送給量Vが4Mとなる溶滴の移行タイミングが溶接ワイヤ1の停止時刻teよりも遅くなると推定されるため、溶接終了の指示以降の溶接ワイヤ1の送給量Vが3Mとなる溶滴の移行タイミングである時刻t3の溶滴の移行で出力を停止させている。 In FIG. 4, since the transfer timing of the droplets at which the feed amount V of the welding wire 1 after the instruction to end welding is 4 M is estimated to be later than the stop time te of the welding wire 1, The output is stopped at the transition of the droplet at time t3, which is the droplet transition timing at which the feed amount V of the welding wire 1 becomes 3M.
溶接ワイヤ1の停止までの時間である溶接ワイヤ1の停止時刻te−溶接終了の指示時刻t0の推定には溶接終了の指示以降の溶接ワイヤ1の送給量の減少度を測定して推定する方法や溶滴の移行周期を測定し、各溶滴の移行周期の変化から推定する方法がある。 In order to estimate the welding wire 1 stop time te, which is the time until the welding wire 1 stops, and the welding end instruction time t0, the degree of decrease in the feed amount of the welding wire 1 after the welding end instruction is measured and estimated. There are methods and methods of measuring the transition period of droplets and estimating from the change of the transition period of each droplet.
以下に、溶接ワイヤ1の停止までの時間の推定方法の例を示す。 Below, the example of the estimation method of the time until the stop of the welding wire 1 is shown.
まず、溶接終了の指示以降溶接ワイヤ1の送給量の減少度を測定して推定する方法を示す。溶接終了の指示時刻t0と溶接終了の指示時刻t0以降の時刻での溶接ワイヤ送給速度を測定し、溶接ワイヤ送給速度vの時間変化の指数近似を行うことにより、溶接ワイヤ送給速度が所定の速度になる時刻を溶接ワイヤ1の停止時刻として推定できる。次に、各溶滴の移行周期を測定し各溶滴の移行周期の変化から推定する方法を示す。時刻の異なる3回の溶滴の移行周期を測定してt0以降の溶滴の移行周期の時間変化を指数近似し、溶滴の移行周期が所定の周期になる時刻を溶接ワイヤ1の停止時刻として推定できる。 First, a method of measuring and estimating the degree of decrease in the feed amount of the welding wire 1 after the instruction to end welding will be shown. By measuring the welding wire feed speed at the welding end instruction time t0 and the time after the welding end instruction time t0 and performing exponential approximation of the time change of the welding wire feed speed v, the welding wire feed speed is The time when the predetermined speed is reached can be estimated as the stop time of the welding wire 1. Next, a method of measuring the transition period of each droplet and estimating from the change of the transition period of each droplet is shown. The transition period of three droplets at different times is measured, the time change of the droplet transition period after t0 is exponentially approximated, and the time at which the droplet transition period becomes a predetermined period is the stop time of the welding wire 1 Can be estimated.
以上のように、溶接ワイヤ1の停止時刻teを推定し、溶滴の移行タイミングtiとを比較して、溶滴の移行タイミングtiが溶接ワイヤ1の停止よりも遅くなると推定された場合、溶滴の移行タイミングtiが溶接ワイヤ1の停止よりも遅くなると推定された溶滴の移行タイミングtiよりも前の溶滴の移行で予め溶接ワイヤ1への電力の供給を停止させることにより、溶接起動信号TSがオフしてから溶接ワイヤ停止までに送給される溶接ワイヤ量の殆ど全てを移行させつつ、溶接ワイヤ1が停止する直前の溶滴の移行後に溶接ワイヤ1に余分な電力が供給されることなく溶接ワイヤ1への電力の供給を停止することが可能となり、溶接終了制御時間の選定といった実験により最適値を求める作業無しで、定常溶接時のアーク長と溶接終了の指示以降のアーク長との間に大きな差を発生させることがなく、溶接ワイヤ1の燃え上がりやチップと溶接ワイヤ1との融着を防止できる。さらに、スティックを防止するに十分な溶接ワイヤ先端と被溶接物2との間隙を保ち、溶接終了時の溶接ワイヤ先端の溶融玉を小径の適正な大きさにバラツキを抑えて安定して制御することができるので、溶接作業性や溶接品質を向上させることが出来、次のアークスタートを良好に行うことが可能となる。 As described above, when the stop time te of the welding wire 1 is estimated and compared with the droplet transfer timing ti, it is estimated that the droplet transfer timing ti is later than the stop of the welding wire 1. Starting the welding by stopping the supply of power to the welding wire 1 in advance at the transition of the droplet before the transition timing ti of the droplet estimated that the droplet transition timing ti is later than the stop of the welding wire 1 Excess power is supplied to the welding wire 1 after the transition of the droplet just before the welding wire 1 stops, while transferring almost all of the amount of welding wire fed from the time when the signal TS is turned off until the welding wire is stopped. It is possible to stop the supply of power to the welding wire 1 without the need to obtain the optimum value by experiments such as selection of the welding end control time, and the arc length and the welding end during steady welding. Without generating a large difference between the arc length of the subsequent instruction can prevent fusion between the kindling and chip of the welding wire 1 and the welding wire 1. Furthermore, the gap between the welding wire tip and the work piece 2 sufficient to prevent sticking is maintained, and the molten ball at the welding wire tip at the end of welding is stably controlled with a small size and an appropriate size. Therefore, welding workability and welding quality can be improved, and the next arc start can be performed satisfactorily.
なお、上記図4における実施の形態は、消耗電極式パルスアーク溶接で説明したが、これに限定されるものではなく、他の消耗電極式アーク溶接法においても同様の効果を奏するものである。 Although the embodiment in FIG. 4 has been described with consumable electrode type pulse arc welding, the present invention is not limited to this, and the same effect can be achieved with other consumable electrode type arc welding methods.
(実施の形態3)
図5は上記の目的を達成する消耗電極式アーク溶接装置の原理図を示すものである。本図は、消耗電極式アーク溶接法の一例として、特に消耗電極式パルスアーク溶接を説明する図である。
送給量推定手段11は溶接終了の指示以降または溶接終了の指示の前の溶滴移行からの溶接ワイヤ1の総送給量を推定し、移行手段8は送給量推定手段11で推定された総送給量を溶滴として移行させる。
(Embodiment 3)
FIG. 5 shows a principle diagram of a consumable electrode type arc welding apparatus that achieves the above object. This figure is a diagram for explaining consumable electrode type pulse arc welding as an example of the consumable electrode type arc welding method.
The feed amount estimation means 11 estimates the total feed amount of the welding wire 1 from the droplet transfer after the welding end instruction or before the welding end instruction, and the transition means 8 is estimated by the feed amount estimation means 11. The total feed amount is transferred as a droplet.
次に、図6を用いて動作の説明をする。本実施の形態において実施の形態1、2と同様の構成については同一の番号を付して詳細な説明を省略する。実施の形態1、2と異なるのは、溶接終了の指示以降または溶接終了の指示の前の溶滴移行から溶接ワイヤ停止までの間の溶接ワイヤ1の総送給量を推定し、推定した溶接ワイヤ1の総送給量を溶かす電力をパルス状に溶接ワイヤ1に供給する点である。 Next, the operation will be described with reference to FIG. In the present embodiment, the same configurations as those in the first and second embodiments are denoted by the same reference numerals, and detailed description thereof is omitted. The difference from the first and second embodiments is that the welding amount is estimated by estimating the total feed amount of the welding wire 1 from the droplet transfer to the welding wire stop after the welding end instruction or before the welding end instruction. It is a point which supplies the electric power which melts the total feeding amount of the wire 1 to the welding wire 1 in a pulse shape.
図6に示すように、溶接ワイヤ1を溶接部分に送給して溶接する定常溶接時に、起動信号TSがオフし溶接終了の指示がなされると、溶接ワイヤ送給速度vが減衰を始める。ここで、溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbから溶接ワイヤ1の停止時刻teまでの間の溶接ワイヤ1の総送給量を推定し、前記の推定した溶接ワイヤ1の総送給量を溶かす電力を溶接終了の指示時刻t0以降に出力する。 As shown in FIG. 6, when the start signal TS is turned off and an instruction to end welding is given during steady welding in which the welding wire 1 is fed to the welding portion and welded, the welding wire feeding speed v starts to attenuate. Here, the total feeding amount of the welding wire 1 between the droplet transfer time tb after the welding end instruction time t0 or before the welding end instruction and the stop time te of the welding wire 1 is estimated. Electric power that melts the total feed amount of the welding wire 1 is output after the welding end instruction time t0.
溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤ1の総送給量の推定には、溶接終了の指示以降の溶接ワイヤ1の送給量の減少度を測定して推定する方法がある。 For estimation of the total feed amount of the welding wire 1 after the welding end instruction time t0 or before the droplet transfer time tb before the welding end instruction, the decrease in the feeding amount of the welding wire 1 after the welding end instruction is given. There is a method of measuring and estimating the degree.
以下に、溶接終了の指示時刻t0以降の溶接ワイヤ1の総送給量の推定方法の例を示す。まず、溶接終了の指示移行の溶接ワイヤ1の送給量の減少度を測定して推定する方法を示す。溶接終了の指示時刻t0と溶接終了の指示時刻t0以降の時刻での溶接ワイヤ送給速度を測定して、溶接ワイヤ送給速度vの時間変化の指数近似を行うことにより、溶接ワイヤ送給速度が所定の速度になる時刻を溶接ワイヤ1の停止時刻として推定できる。ここで、溶接ワイヤ送給速度vの時間変化の指数近似式を溶接終了の指示時刻t0から前記溶接ワイヤ1の停止時刻までを時間積分することで溶接終了の指示時刻t0からの溶接ワイヤ1の総送給量が推定出来る。 Below, the example of the estimation method of the total feed amount of the welding wire 1 after the instruction | indication time t0 of welding completion is shown. First, a method for measuring and estimating the degree of decrease in the feeding amount of the welding wire 1 at the end of welding instruction transfer will be described. By measuring the welding wire feeding speed at the welding end instruction time t0 and the time after the welding end instruction time t0 and performing exponential approximation of the time variation of the welding wire feeding speed v, the welding wire feeding speed is obtained. Can be estimated as the stop time of the welding wire 1. Here, the exponential approximate expression of the time change of the welding wire feed speed v is integrated over time from the welding end instruction time t0 to the welding wire 1 stop time, so that the welding wire 1 from the welding end instruction time t0 is integrated. The total amount of feed can be estimated.
次に、各溶滴の移行周期を測定し各溶滴の移行周期の変化から推定する方法を示す。時刻の異なる3回の溶滴の移行周期を測定してto以降の溶滴の移行周期の時間変化を指数近似し、溶滴の移行周期が所定の周期になる時刻を溶接ワイヤ1の停止時刻として推定できる。また、溶接終了の指示時刻toと溶接終了の指示時刻to以降の時刻での溶接ワイヤ送給速度を測定して、溶接ワイヤ送給速度vの時間変化の指数近似を行う。溶接ワイヤ送給速度vの時間変化の指数近似式を溶接終了の指示時刻t0から前記溶接ワイヤ1の停止時刻までを時間積分することで溶接終了の指示時刻t0からの溶接ワイヤ1の総送給量が推定出来る。 Next, a method of measuring the transition period of each droplet and estimating from the change of the transition period of each droplet is shown. The transition period of three droplets at different times is measured, the time change of the droplet transition period after to is exponentially approximated, and the time when the droplet transition period becomes a predetermined period is the stop time of the welding wire 1 Can be estimated. Further, the welding wire feed speed at the welding end instruction time to and the time after the welding end instruction time to is measured, and exponential approximation of the time change of the welding wire feed speed v is performed. By integrating the exponential approximation formula of the time change of the welding wire feeding speed v from the welding end instruction time t0 to the welding wire 1 stop time, the total feeding of the welding wire 1 from the welding end instruction time t0. The amount can be estimated.
ここでは、溶接終了の指示時刻t0以降の溶接ワイヤ1の総送給量の推定方法を示したが、溶接終了の指示の前の溶滴移行時刻tbからの溶接ワイヤ1の総送給量の推定の場合には、溶接終了の指示時刻t0以降の溶接ワイヤ1の総送給量の推定結果に定常溶接時である溶接終了の指示の前の溶滴移行時刻tbから溶接終了の指示時刻t0までの溶接ワイヤ1の送給量を加算すれば良い。 Here, the method for estimating the total feed amount of the welding wire 1 after the welding end instruction time t0 is shown. However, the total feed amount of the welding wire 1 from the droplet transfer time tb before the welding end instruction is shown. In the case of estimation, the welding end instruction time t0 from the droplet transfer time tb before the welding end instruction, which is normal welding, to the estimation result of the total feed amount of the welding wire 1 after the welding end instruction time t0. What is necessary is just to add the feed amount of the welding wire 1 until.
溶接終了の指示時刻t0以降の溶接ワイヤ1には、溶接電流Id、Ieに示したようにパルス状の電力を供給してもよい。この場合、上記の所定の周期Tにn(n=1,2,3,・・・・・)パルスで1溶滴が移行する値を設定してもよい。この時、溶接終了の指示時刻t0以降の溶接ワイヤ1に供給するパルス状の電力のパルス周期は、溶接電流Idに示したように溶接ワイヤ1を溶接部分に送給して溶接する定常溶接時のパルス周期と略同一としてもよいし、溶接電流Ieに示したように溶接電圧のフィードバックに基づいて決定されるパルス周期でもよい。 Pulse-shaped power may be supplied to the welding wire 1 after the welding end instruction time t0 as shown by the welding currents Id and Ie. In this case, a value at which one droplet is transferred with n (n = 1, 2, 3,...) Pulses in the predetermined period T may be set. At this time, the pulse period of the pulsed power supplied to the welding wire 1 after the welding end instruction time t0 is as shown in the welding current Id during steady welding in which the welding wire 1 is fed to the welding portion and welded. The pulse period may be substantially the same, or may be a pulse period determined based on the feedback of the welding voltage as shown in the welding current Ie.
以上のように、溶接終了の指示時刻t0以降または溶接終了の指示の前の溶滴移行時刻tbから溶接ワイヤ停止時刻teまでの間の溶接ワイヤ1の総送給量を推定し、前記総送給量を溶かす電力をパルス状に溶接ワイヤ1に供給することにより、起動信号TSがオフしてから溶接ワイヤ1の停止までに送給される溶接ワイヤ量の殆ど全てを移行させることが出来る。さらに、溶接終了の指示以降の溶接ワイヤ1に余分な電力が供給されることなく溶接ワイヤ1への電力の供給を停止することが可能となり、溶接終了制御時間の選定といった実験により最適値を求める作業無しで、定常溶接時のアーク長と溶接終了の指示以降のアーク長との間に大きな差を発生させることがなく、溶接ワイヤ1の燃え上がりやチップと溶接ワイヤとの融着を防止できる。さらに、スティックを防止するに十分な溶接ワイヤ先端と母材との間隙を保ち、溶接終了時の溶接ワイヤ先端の溶融玉を小径の適正な大きさにバラツキを抑えて安定して制御することができるので、溶接作業性や溶接品質を向上させることが出来、次のアークスタートを良好に行うことが可能となる。なお、上記図3における実施の形態は、消耗電極式パルスアーク溶接で説明したが、これに限定されるものではなく、他の消耗電極式アーク溶接法においても同様の効果を奏するものである。 As described above, the total feed amount of the welding wire 1 between the droplet transfer time tb after the welding end instruction time t0 or before the welding end instruction and the welding wire stop time te is estimated, and the total feed By supplying electric power for melting the supply amount to the welding wire 1 in a pulse shape, almost all of the welding wire amount supplied from when the start signal TS is turned off until the welding wire 1 is stopped can be shifted. Furthermore, it becomes possible to stop the supply of power to the welding wire 1 without supplying excess power to the welding wire 1 after the instruction to end welding, and an optimum value is obtained by an experiment such as selection of the welding end control time. Without work, there is no great difference between the arc length during steady welding and the arc length after the instruction to end welding, and it is possible to prevent the welding wire 1 from burning up and the tip and the welding wire from fusing together. Furthermore, it is possible to maintain a sufficient gap between the tip of the welding wire and the base metal to prevent sticking, and to control the molten ball at the tip of the welding wire at the end of welding to an appropriate size with a small diameter and stably controlling it. Therefore, welding workability and welding quality can be improved, and the next arc start can be performed satisfactorily. Although the embodiment in FIG. 3 has been described with consumable electrode type pulse arc welding, the present invention is not limited to this, and the same effect can be achieved with other consumable electrode type arc welding methods.
本発明の溶接装置によれば、溶接作業性や溶接品質を向上させると共に次のアークスタート時のアークスタート性をも向上させることができるので、特に消耗電極式アーク溶接装置に有用である。 According to the welding apparatus of the present invention, the welding workability and the welding quality can be improved and the arc start performance at the next arc start can be improved, so that it is particularly useful for a consumable electrode type arc welding apparatus.
1 溶接ワイヤ
4 起動手段
5 溶接ワイヤ送給手段
6 制御手段
7 算出手段
8 移行手段
9 時間推定手段
10 比較手段
11 送給量推定手段
TS 起動信号
v 溶接ワイヤ送給速度
V 溶接終了の指示以降の溶接ワイヤの送給量
Vi 所定の値
t0 溶接終了の指示時刻
tb 溶接終了の指示の前の溶滴移行の時刻
te 溶接ワイヤの停止時刻
ti 起動信号TSがオフしてからi(i=1,2,3・・・)番目の溶滴相当のワイヤ送給量が送給される時刻
DESCRIPTION OF SYMBOLS 1 Welding wire 4 Starting means 5 Welding wire feed means 6 Control means 7 Calculation means 8 Transition means 9 Time estimation means 10 Comparison means 11 Feed amount estimation means TS Start signal v Welding wire feed speed V After welding end instruction Feeding amount of welding wire Vi Predetermined value t0 Welding end instruction time tb Droplet transfer time before welding end instruction te Welding wire stop time ti i (i = 1, 1) after start signal TS is turned off 2,3 ...) Time when wire feed amount equivalent to the 2nd droplet is fed
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JPWO2013136643A1 (en) * | 2012-03-16 | 2015-08-03 | パナソニックIpマネジメント株式会社 | Arc welding control method and arc welding apparatus |
CN116174865A (en) * | 2022-12-30 | 2023-05-30 | 深圳市麦格米特焊接技术有限公司 | Consumable electrode gas shielded welding system, control method thereof, controller and medium |
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2004
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
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JPWO2013136643A1 (en) * | 2012-03-16 | 2015-08-03 | パナソニックIpマネジメント株式会社 | Arc welding control method and arc welding apparatus |
US10537955B2 (en) | 2012-03-16 | 2020-01-21 | Panasonic Intellectual Property Management Co., Ltd. | Method for controlling arc welding and arc welding device |
CN116174865A (en) * | 2022-12-30 | 2023-05-30 | 深圳市麦格米特焊接技术有限公司 | Consumable electrode gas shielded welding system, control method thereof, controller and medium |
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