JP2017196656A - Welding device and welding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a welding device and a welding method, enabling control for passing a large current for a short time, having no generation of scorch or distortion due to impression or heat on the rear face of a workpiece when welding, and capable of efficiently controlling power to achieve power saving.SOLUTION: An objective welding device comprises: a welding transformer 10 converting a current generated on a secondary coil by supply of high frequency AC to a primary coil into a direct current to enable supply of a large current for a short time; and a welding gun 6 which is retained on a flat table placing a workpiece in a lateral posture parallel to the table, and to which a one-side electrode 200 enabling welding from one direction is loaded without needing a lower side electrode and the current generated to the secondary coil of the welding transformer 10 and converted into a direct current is supplied.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an object to be welded by a welding gun (for example, a stack of two metal plates such as steel plates) placed on a flat table and held in a lateral orientation parallel to the table. In particular, the present invention relates to a welding apparatus and a welding method using a one-side electrode.

As a welding apparatus capable of efficiently performing spot welding, the inventors of the present application have provided a welding apparatus including a table on which an object to be welded is placed (see Patent Document 1 and Patent Document 2).
In spot welding, generally, an object to be welded is sandwiched between two upper and lower electrodes arranged opposite to each other, and a welding current is supplied between the upper and lower electrodes to weld the object to be welded.
On the other hand, in recent years, there are many so-called one-side welding inventions in which welding is performed by pressing an electrode against a workpiece from one direction (mainly upward) rather than pressing the electrode against the workpiece from both the upper and lower directions. (For example, see Patent Documents 3 to 6).

Japanese Patent Laid-Open No. 06-328265 JP 2011-183421 A JP 2011-031269 A JP 2012-071311 A JP2012-096249A JP 2013-052427 A

However, one-side welding is technically difficult and has the following problems.
That is, since control for energizing a large current for a short time has not been established, when welding the workpiece, the back surface of the workpiece (for example, of two stacked steel plates, far from one electrode) On the other side), there are many indentations, heat burns and distortions, and the aesthetics are impaired. In particular, when a steel sheet having a protective sheet pasted on the back surface is welded, the sheet is burnt or thermally discolored. Moreover, in the steel plate with the coating on the back surface, the coating is thermally discolored.

  In addition, since control for energizing a large current for a short time has not been established, efficient power control is difficult and power consumption increases.

  The present invention has been made in view of such circumstances, and enables control for energizing a large current for a short time, and when welding the workpiece, the back surface of the workpiece is burned by indentation or heat, An object of the present invention is to provide a welding apparatus and a welding method that do not cause distortion and that can perform efficient power control to save power.

  A welding apparatus according to the present invention includes a welding transformer that converts a current generated in a secondary coil into a direct current when high-frequency alternating current is supplied to the primary coil, a flat table on which a workpiece is placed, and the table. A welding gun that is held in a lateral orientation parallel to the welding gun and is supplied with a direct current generated in the secondary coil of the welding transformer, an inverter circuit that supplies high-frequency alternating current to the primary coil of the welding transformer, A welding control circuit for controlling the operation of the inverter circuit, wherein the welding transformer includes an annular magnetic core constituted by a parallel part and U-shaped curved parts at both ends, and the annular magnetic core A primary coil that is divided into a plurality of portions and is dividedly wound around a parallel portion, and the primary coil is wound around the parallel portion of the annular magnetic core together with the primary coil, and the primary coil is provided on the primary coil. A secondary coil in which a plurality of positive side coils and a plurality of negative side coils are alternately arranged so as to be sandwiched one by one in the gap, and the plurality of positive side coils are all connected in parallel, or all or part of them are The plurality of negative coils are all connected in parallel or all or part of them are connected in series, and the plurality of connected positive coils and the plurality of negative coils are connected in series with each other. As described above, a conductor group that electrically connects the terminals of the positive side coil and the negative side coil is provided, and the positive side coil and the negative side coil are supported and fixed on one surface by the conductor group. One terminal of the plurality of positive side coils is electrically connected to a first connecting plate extending in a direction parallel to the parallel portion of the annular magnetic core on the other surface of the connection board. One of the plurality of negative coils The terminal is electrically connected to a second connecting plate extending in a direction parallel to the parallel portion of the annular magnetic core on the other surface side of the connection board, and the other terminal of the positive coil and the negative coil are connected to each other. Both of the other terminals are electrically connected to a third connection plate extending in a direction parallel to the parallel portion of the annular magnetic core on the other surface side of the connection board, and the first connection plate includes: A positive-side conductor is connected, a negative-side conductor is connected to the second connecting electrode plate, and the positive-side conductor and the negative-side conductor are perpendicular to the other surface on the other surface side of the connection board. A pair of conductor plates stacked via an insulating layer disposed on a boundary surface extending in a direction away from the positive electrode, sandwiched between the positive side conductor and a first electrode plate to which a positive electrode is connected. A first rectifier element in which a positive electrode contacts a side conductor and a negative electrode contacts the first electrode plate; and the negative conductor A second rectifier element sandwiched between a negative electrode and a second electrode plate connected to the negative electrode, a positive electrode in contact with the negative conductor, and a negative electrode in contact with the second electrode plate, the first electrode plate, A third electrode plate that supports the second electrode plate and electrically connects the two electrode plates, and the welding gun is formed in a cylindrical shape with both ends open, and can be inserted into the outer electrode, A cylindrical inner electrode whose tip portion is exposed from the tip surface of the outer electrode when inserted into the outer electrode; a first insulating member that insulates between the outer electrode and the inner electrode; A L-shaped electrode having a second insulating member that covers the surface of the tip portion of the inner electrode; and the one-side electrode held by the tip portion, the tip portion being bent in a substantially right angle direction with respect to the main body portion. The positive electrode of the welding transformer is connected to the inner electrode and the one-side electrode. The shank holder for connecting to either one of the outer electrodes and the minus electrode of the welding transformer are connected to one of the inner electrode and the outer electrode of the one-side electrode that is not connected to the shank holder. The welding control circuit, wherein the welding current supplied to the one-side electrode reaches a maximum value within 15 milliseconds from the supply start time, and welding is performed with an energization time of 50 milliseconds or less. The operation of the inverter circuit is controlled to complete.

  According to the above configuration, it has a welding transformer that can supply a large current in a short time, can be moved in the horizontal direction, and can be welded from one direction without requiring a lower electrode. Since it has a welding gun with a single-side electrode attached, when welding a work piece with a protective sheet on one side, welding is hardly caused on the back side of the work piece by indentation or heat. In addition, when welding an object to be welded that has been coated on one side, the welding can be performed with almost no burning or thermal discoloration. That is, welding can be performed without impairing the appearance of the back surface of the workpiece. Further, since welding is completed in a short time, power saving can be achieved.

  In the above configuration, the outer electrode of the one-side electrode has a fixed portion that holds the inner electrode and a center of one end surface that is in close contact with the distal end surface of the fixed portion and is in contact with the fixed portion as a fulcrum. And a movable part capable of moving in an arc around the axis.

  According to the above configuration, since the movable portion of the outer electrode can move in an arc around the axis, a plurality of projections (projections) previously formed on the workpiece when the one-side electrode is applied to the workpiece. ) Can be reduced, and a reliable joining can be achieved without causing a joining failure.

  The welding method of the present invention is a welding method in which a workpiece is spot-welded using the above-described welding apparatus, and the workpiece is a plurality of metal plates, excluding one of the plurality of metal plates. For each of the remaining metal plates, an escape hole of a size that allows the inner electrode to pass therethrough is formed, and a plurality of projections are formed along the concentric circles around the outer side of the escape hole on each one surface. Thereafter, the release plate and the metal plate on which the projection is not formed are placed at the bottom, and all the metal plates on which the release hole and the projection are formed are provided on the respective formation surfaces of the projections. Directed downward and stacked sequentially so that the centers of the respective escape holes coincide with each other, and after stacking all the metal plates, the escape holes were formed. Insert and press the tip of the inner electrode into the escape hole of each metal plate, and start supplying welding current in the direction of flow from the outer electrode to the inner electrode, within 15 milliseconds from the supply start time. The welding current is controlled so that the welding is completed with the maximum value and the energization time of 50 milliseconds or less.

  According to the above method, when welding an object to be welded with a protective sheet on one side, welding can be performed with almost no indentation or heat burning or distortion on the back surface of the object to be welded. In addition, when welding an object to be welded on which one side is coated, welding can be performed with almost no burning or thermal discoloration. That is, welding can be performed without impairing the appearance of the back surface of the workpiece.

  According to the present invention, it is possible to control for energizing a large current for a short time, and when welding an object to be welded, welding is performed on the back surface of the object to be welded without causing indentation or heat burning or distortion. In addition, power can be saved because welding can be performed in a short time.

Side view showing the appearance of the welding apparatus according to the present embodiment The top view which shows the external appearance of the welding apparatus which concerns on this embodiment The side view which shows the external appearance including the partial fracture surface of the welding gun of the welding apparatus which concerns on this embodiment Sectional drawing which shows the structure of the front-end | tip part of the welding gun of the welding apparatus which concerns on this embodiment, and the structure of one side electrode The figure which shows schematic structure of the power supply unit of the welding apparatus which concerns on this embodiment. The figure which shows the connection with the welding transformer and welding gun of the welding apparatus which concerns on this embodiment. Connection diagram for explaining the operation of the welding transformer of the welding apparatus according to the present embodiment Connection diagram for explaining the operation of the welding transformer of the welding apparatus according to the present embodiment The figure which shows the control pulse for controlling the electric current supplied to the primary side of the welding transformer of the welding apparatus which concerns on this embodiment, the primary current, and the welding current after rectification | straightening. The perspective view which shows the external appearance of the welding transformer of the welding apparatus which concerns on this embodiment. The perspective view which shows the assembly state of the welding transformer of the welding apparatus which concerns on this embodiment. In the welding apparatus which concerns on this embodiment, the wave form diagram which shows the welding current supplied to a welding gun from a welding transformer Sectional drawing and top view which show an example of the to-be-welded object used with the welding apparatus which concerns on this embodiment Sectional drawing for demonstrating the flow of the welding current between the one side electrode with which the welding gun of the welding apparatus which concerns on this embodiment was equipped, and a to-be-welded object

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments for carrying out the invention will be described in detail with reference to the drawings.

  FIG. 1 is a side view showing an appearance of a welding apparatus 1 according to an embodiment of the present invention. FIG. 2 is a plan view showing an appearance of the welding apparatus 1 according to the present embodiment. Moreover, FIG. 3 is a side view which shows the external appearance including the partial fracture surface of the welding gun 6 of the welding apparatus 1 which concerns on this embodiment. 1 and 2, a welding apparatus 1 according to this embodiment includes a cooling unit 2, a power supply unit 3, a support post 4, a support arm 5, a welding gun 6, a conductive cable 7, and a table 8. , A welding condition setting unit 9, a welding transformer 10, and a table driving unit 100.

  The cooling unit 2 supplies cooling water for cooling the heat generated by the welding gun 6 during welding. The cooling unit 2 always operates while the power is on, and circulates the cooling water between the cooling gun 2 and the welding gun 6. The power supply unit 3 converts the three-phase alternating current power supplied from the power receiving facility 450 (see FIG. 5) into direct current with a rectifier, and further converts the converted direct current into a high frequency alternating current and outputs it. Details of the power supply unit 3 will be described later. The conductive cable 7 is composed of two cables, one end is connected to the secondary output end of the welding transformer 10 built in the front portion of the table driving unit 100, and the other end is connected to the welding gun 6. The welding transformer 10 is a resistance transformer for resistance welding previously proposed by the inventors of the present application in JP2012-210654A and JP2013-179205A. Details of the welding transformer 10 will be described later.

  The support post 4 is erected in the vertical direction in the vicinity of the cooling unit 2 and the power supply unit 3, and supports the support arm 5 so as to be rotatable in the horizontal direction. The support arm 5 holds the welding gun 6, and includes a horizontal arm portion 5A extending in the horizontal direction with respect to the support post 4, and a vertical arm extending vertically downward from the tip portion of the horizontal arm portion 5A. It is substantially L-shaped with the part 5B. Rotating shafts 5Aa are respectively provided at the base end portion 5a and the intermediate portion 5b of the horizontal arm portion 5A of the support arm 5, and the welding gun 6 can be moved in the horizontal direction by these rotating shafts 5Aa. It has become.

  The table 8 is formed in a substantially square flat plate shape, and places an object to be welded thereon. The work piece is a metal plate such as a steel plate. The table 8 is moved up and down by the table driving unit 100. The table 8 is used when adjusting the distance between the welding gun 6 and the workpiece. The operator moves the table 8 up and down. The welding condition setting unit 9 sets welding conditions such as the material of the workpiece and the plate thickness. A welding current corresponding to the welding conditions set by the welding condition setting unit 9 is determined.

  In FIG. 3, the welding gun 6 has a handle 6B having a lever-type start switch 6A on the base end side. The start switch 6A of the handle 6B is for issuing a welding command. When the handle 6B is gripped, the switch is turned on and a welding designation is output. When the welding command is output, the welding command is taken into the power supply unit 3, and the power supply unit 3 operates thereby to output high-frequency alternating current. The high-frequency alternating current output from the power supply unit 3 is supplied to the primary coil 12 (see FIG. 6) of the welding transformer 10.

Next, the welding gun 6 will be described in detail.
FIG. 4 is a cross-sectional view showing the structure of the tip 301 of the shank holder 300 and the structure of the one-side electrode 200. In the figure, the welding gun 6 includes a one-sided electrode 200, a shank holder 300 that attaches the one-sided electrode 200 to the tip portion 301, and a bus bar conductor 400 that is fed to the shank holder 300. The one-side electrode 200 does not require a lower electrode and enables welding from one direction, and includes an outer electrode 201 and an inner electrode 202. Details of the one-side electrode 200 will be described later.

  The shank holder 300 is formed in a substantially L shape in which the tip portion 301 is bent in a substantially right angle direction with respect to the main body portion 302 (see FIG. 3). The shank holder 300 is made of a metal material having excellent conductivity such as copper. The shank holder 300 is electrically connected to the outer electrode 201 of the one-side electrode 200. A flow path 303 for allowing cooling water to flow therethrough is formed inside the shank holder 300, and a tube 350 for sending the cooling water is inserted into the flow path 303. The tube 350 has flexibility with a diameter smaller than the diameter of the flow path 303 of the shank holder 300, and is made of, for example, a fluororesin tube. The distal end of the tube 350 reaches the distal end portion 301 of the shank holder 300 and the rear end of the tube 350 reaches the cooling unit 2 described above.

  A short tube 351 is connected to the distal end portion of the tube 350 and is inserted into the outer electrode 201. The tube 351 is flexible like the tube 350, and is made of, for example, a fluororesin tube. Cooling water sent from the cooling unit 2 through the tube 350 is injected into the outer electrode 201 from the tube 351. The cooling water overflowed by being injected into the outer electrode 201 enters the flow path 303 in the shank holder 300 and returns to the cooling unit 2 through the flow path 303 and a tube (not shown). The cooling water circulates between the cooling unit 2 and the one-side electrode 200 to cool the one-side electrode 200 attached to the welding gun 6.

  For the bus bar conductor 400, a metal material having excellent conductivity such as copper is used. The bus bar conductor 400 is electrically connected to the inner electrode 202 of the one-side electrode 200. The shank holder 300 is connected to the plus electrode 22 (see FIG. 6) of the welding transformer 10, and the bus bar conductor 400 is connected to the minus electrode 24 (see FIG. 6) of the welding transformer 10. As a result, the welding current supplied to the one-side electrode 200 flows in a direction from the outer electrode 201 toward the inner electrode 202. In the present embodiment, the welding electrode 10 has a positive electrode 22 connected to the outer electrode 201 of the one-side electrode 200, and a negative electrode 24 of the welding transformer 10 is connected to the inner electrode 202 of the one-side electrode 200. However, the flow may be reversed in the direction from the outer electrode 201 toward the inner electrode 202. That is, the plus electrode 22 of the welding transformer 10 may be connected to the inner electrode 202 of the one-side electrode 200, and the minus electrode 24 of the welding transformer 10 may be connected to the outer electrode 201 of the one-side electrode 200.

  In addition to the outer electrode 201 and the inner electrode 202 described above, the one-side electrode 200 includes an inner electrode fixing portion 203, a resin guide bush 500 inserted between the inner electrode fixing portion 203 and the outer electrode 201, and a resin The flat washer 501, the resin guide bushing 502 and the resin flat washer 504 inserted between the outer electrode 201 and the inner electrode 202, and the inner electrode 202 are welded via the inner electrode fixing portion 203. A biasing portion 505 formed by laminating a plurality of disc springs for biasing to the side, flat washers 506 and 507 made of resin provided at both ends of the biasing portion 505, and the tip and flat of the shank holder 300 A resin cap 508 interposed between the washer 507 and the washer 507.

  Both guide bushes 500 and 502 are formed in a cylindrical shape with both ends opened. The cap 508 is formed in a substantially U-shaped cross section, and a hole (reference numeral omitted) through which the upper end of the outer electrode 201 communicates is formed at the bottom having a flat surface perpendicular to the axial direction. ing.

  The outer electrode 201 is formed in a substantially crank shape, and has a fixed portion 201a that holds the inner electrode 202 and a center of one end surface that comes into close contact with the tip surface of the fixed portion 201a and contacts the fixed portion 201a as a fulcrum. And a movable portion 201b that can move in an arc around the axis. In the outer electrode 201, a hole 201c having a depth substantially corresponding to its length is formed in the central axis direction at a base end portion (that is, a portion joined to the tip portion of the shank holder 300). The tube 351 described above is inserted into the hole 201c. A portion for holding the inner electrode 202 of the fixing portion 201a of the outer electrode 201 is formed in a cylindrical shape having both ends opened. The movable part 201b of the outer electrode 201 is formed in a cylindrical shape with both ends opened. The inner electrode 202 is inserted into the inner electrode holding portion and the movable portion 201b of the fixed portion 201a of the outer electrode 201. The above-described guide bush 502 is housed in the upper end portion of the inner electrode holding portion of the fixing portion 201a of the outer electrode 201.

  Here, the inner diameter of the upper end portion of the inner electrode holding portion of the fixing portion 201 a of the outer electrode 201 is larger than the other portions by the thickness of the guide bush 502. Further, the inner electrode holding portion of the fixing portion 201 a of the outer electrode 201 has an inner diameter (excluding the inner diameter of the portion in which the guide bushing 502 is housed) slightly larger than the inner electrode 202, and the inner electrode 202 is smooth. Movement is possible. However, the inner side of the guide bushing 502 prevents the inner electrode 202 from coming into contact with the outer electrode 201 as the inner electrode 202 moves (ie, the inner electrode 202 does not touch the outer electrode 201 due to lateral movement). The moving direction of the electrode 202 is regulated. Note that an insulating material (for example, a resin film) may be provided between the inner electrode 202 and the outer electrode 201 so that the inner electrode 202 does not contact the outer electrode 201.

  The movable portion 201b of the outer electrode 201 is connected so as to be in close contact with the fixed portion 201a of the outer electrode 201 by an elastic connecting member 550. The connection member 550 is formed in a C-shaped cross section that is open at both ends and has a notch in the axial direction. Further, the connection member 550 is provided with protrusions (not shown) having a triangular cross section along the circumferential direction on the inner surface on the upper end side and the inner surface on the lower end side. Each of the outer peripheral surface of the distal end portion of the fixed portion 201a of the outer electrode 201 and the outer peripheral surface of the movable portion 201b of the outer electrode 201 has a V-shaped groove (notation mark) that fits the protrusion formed on the connection member 550. Abbreviation) is formed in the circumferential direction. In a state where the movable portion 201b of the outer electrode 201 is in contact with the fixed portion 201a of the outer electrode 201, the connecting member 550 is mounted so as to span the fixed portion 201a and the movable portion 201b of the outer electrode 201. A connecting member so that protrusions having a triangular cross-section formed on both the upper and lower ends on the inner side are fitted into V-shaped grooves formed on the outer peripheral surfaces of the fixed portion 201a and the movable portion 201b of the outer electrode 201, respectively. By adjusting the vertical position of 550, the movable part 201b of the outer electrode 201 is rotatably connected to the fixed part 201a of the outer electrode 201.

  Of the surfaces of both the fixed portion 201a and the movable portion 201b of the outer electrode 201, the surface on the fixed portion side is formed into a slightly convex spherical surface, and the surface on the movable portion side is extremely slightly concave. It is formed on the spherical surface. By adopting such a structure, the movable portion 201b of the outer electrode 201 can move in an arc around an axis with the center of one end surface in contact with the fixed portion 201a of the outer electrode 201 as a fulcrum. That is, the movable part 201b can be rotated so as to swing the head. By making the movable portion 201b of the outer electrode 201 swingable, a plurality of (mainly three) formed on the workpiece when the one-side electrode 200 is pressed against the workpiece during welding. The difference in the applied pressure of the outer electrode 201 with respect to the projection can be reduced. That is, when the single-side electrode 200 is used, a plurality of projections are formed in advance on the workpiece, but if the outer electrode 201 is not evenly pressed against each projection during welding, there is a difference in the molten state in each projection. Will occur and uniform welding will not be performed. For this reason, the movable portion 201b of the outer electrode 201 can be swung freely so that the pressure applied to each projection by the outer electrode 201 is uniform. However, the amount of deflection of the outer electrode 201 to the outside of the movable portion 201b is such that the movable portion 201b does not come into contact with the inner electrode 202, and the opposing surface of the connecting portion of the fixed portion 201a of the outer electrode 201 and the movable portion 201b. Needless to say, it is necessary to regulate the shape of the.

  Note that the shape of the opposing surface of the connecting portion of the fixed portion 201a and the movable portion 201b of the outer electrode 201 may be reversed. That is, the surface on the fixed portion side of the outer electrode 201 may be a slightly concave spherical surface, and the surface on the movable portion side may be a very slightly convex spherical surface.

  The inner electrode 202 has a substantially cross-shaped cross section having a threaded portion 202a and a flange 202b on the proximal end side. A portion on the tip side of the flange 202b of the inner electrode 202 (a lower portion facing the drawing) is an inner electrode portion 202c. Since the inner electrode 202 is fixed to the inner electrode fixing portion 203, the inner electrode fixing portion 203 is formed with a screw hole (not shown) for fixing the inner electrode 202. The inner electrode 202 is fixed to the inner electrode fixing portion 203 by screwing the screw portion 202a of the inner electrode 202 into the screw hole. However, the screwing amount of the inner electrode 202 into the inner electrode fixing portion 203 is regulated by the flange 202b of the inner electrode 202.

  The distal end portion of the inner electrode portion 202c is formed with a smaller diameter than the other portions, and a stainless steel ring 503 is fitted into the smaller diameter portion. The surface of the ring 503 is subjected to a surface coating treatment for imparting insulating properties, and insulates so that the tip of the inner electrode portion 202c does not come into contact with the workpiece during welding.

  The inner electrode fixing portion 203 is formed in a substantially rectangular solid shape. The inner electrode fixing portion 203 is formed with a through hole (not shown) for passing the fixing portion 201a of the outer electrode 201 and a threaded through hole (not shown) for fixing the inner electrode 202. ing. A front end portion of the bus bar conductor 400 is fixed to the inner electrode fixing portion 203 by a bolt 203a. The above-described guide bush 500 is housed in the through hole through which the fixing portion 201a of the outer electrode 201 is passed.

  When welding the workpiece in the welding gun 6 having such a structure, as shown in FIG. 4, the inner electrode portion 202c of the inner electrode 202 has two workpieces 600A and 600B to be welded. The other workpiece 600B is pressed inside the escape hole 601 (see FIG. 13) provided in one workpiece 600A, and at the same time, the outer electrode 201 presses one workpiece 600A. The welding current is supplied immediately after the inner electrode 202 presses the other workpiece 600B and the outer electrode 201 presses the first workpiece 600A. One workpiece 600A is formed with a plurality of projections 602 at the joint with the other workpiece 600B (the outer periphery of the escape hole), and these projections 602 are pressed and fed by the outer electrode 201. The objects to be welded 600A and 600B are joined by melting. Since the movable portion 201b of the outer electrode 201 can swing freely, the projections 602 are evenly pressed when the outer electrode 201 presses the workpiece 600A, so that no bonding failure occurs. Securely joined.

Next, the power supply unit 3 will be described.
FIG. 5 is a diagram showing a schematic configuration of the power supply unit 3. In the figure, the power supply unit 3 includes a rectifier 80, a smoothing capacitor 81, a welding control circuit 82, and an inverter circuit 83. The rectifier 80 employs a single-phase full-wave rectification type, and rectifies and converts three-phase alternating current from the power receiving facility 450 into direct current. The welding control circuit 82 controls the magnitude of the welding current and the energization time. The welding control circuit 82 is configured using a microcomputer, for example. The microcomputer holds a welding control program and operates according to the program. The welding control circuit 82 detects a welding command from the start switch 6A provided in the welding gun 6, and thereby generates a timing signal corresponding to the material and thickness of the workpiece set by the welding condition setting unit 9. It is generated and output to the inverter circuit 83. In this case, the welding control circuit 82 generates a timing signal so that the welding current becomes a maximum value within 15 milliseconds from the start of energization and the welding is completed within an energization time of 50 milliseconds or less.

  The inverter circuit 83 includes an inverter control unit 831, four switches S <b> 1 to S <b> 4 using, for example, an IGBT (Insulated Gate Bipolar Transistor), and a current sensor 832 using, for example, a CT (Current Transformer). The inverter control unit 831 performs on / off control of each of the switches S1 to S4 based on the timing signal generated by the welding control circuit 82 and the primary current detected by the current sensor 832 to generate high-frequency alternating current. The magnitude of the high-frequency alternating current generated by the inverter control unit 831 varies depending on the on / off duty of each of the switches S1 to S4. By changing the on / off duty of each of the switches S1 to S4, the width of W of the switching waveform changes as shown in FIG.

  FIG. 6 is a diagram showing the connection between the welding transformer 10 and the welding gun 6. In the figure, the primary coil 12 of the welding transformer 10 is connected to the output terminal of the inverter circuit 83 of the power supply unit 3. By outputting high-frequency alternating current from the inverter circuit 83, a primary current flows through the primary coil 12 of the welding transformer 10. The secondary coil 15 of the welding transformer 10 does not need to consider the polarity itself, but for the sake of convenience, the secondary coil 15 of the welding transformer 10 has a positive coil 14 and a negative coil 16 connected in series. I will call it. The anode (positive electrode) of the first rectifying element 18 is connected to one end of the positive side coil 14, and the anode (positive electrode) of the second rectifying element 20 is connected to one end of the negative side coil 16. The cathode (negative electrode) of the first rectifying element 18 and the cathode (negative electrode) of the second rectifying element 20 are commonly connected to the plus electrode 22. The other end of the positive side coil 14 and the other end of the negative side coil 16 are commonly connected to the negative electrode 24. The welding gun 6 is connected to the plus electrode 22 and the minus electrode 24 via the conductive cable 7. In this case, in the one-side electrode 200 of the welding gun 6, the outer electrode 201 is connected to the plus electrode 22 of the welding transformer 10, and the inner electrode 202 is connected to the minus electrode 24 of the welding transformer 10. The outer electrode 201 may be connected to the minus electrode 24 of the welding transformer 10 and the inner electrode 202 may be connected to the plus electrode 22 of the welding transformer 10.

  FIG. 7 is a diagram illustrating a circuit operation when a forward current flows through the first rectifying element 18. FIG. 8 is a diagram showing a circuit operation when a forward current flows through the second rectifier element 20. 7 and 8, an equivalent inductance component that causes a problem in circuit operation is added to the circuit shown in FIG. That is, it includes the inductance of the positive conductor 30 connecting the positive coil 14 and the first rectifier 18, the inductance of the negative conductor 32 connecting the negative coil 16 and the second rectifier 20, and the conductive cable 7. It is considered that the inductance of the conductor in the welding gun 6 affects the performance of the welding apparatus 1.

  If a large amount of heat generated in each of the welding guns 6 including the welding transformer 10 and the conductive cable 7 can be suppressed, energy saving of the welding apparatus 1 can be achieved, and a large power saving effect can be expected. This can be realized if it can be controlled so that a larger current than in the prior art is supplied to the welding gun 6 for a short time. On the other hand, in order to supply the optimum welding current for the material or structure to be welded, it is necessary to control the welding current supply time with extremely high accuracy. This can be realized by connecting the inverter circuit 83 to the primary side of the welding transformer 10 for supplying the welding current, and controlling the magnitude of the welding current and the supply time by PWM control.

  FIG. 9 is a diagram illustrating a control pulse for controlling a current supplied to the primary side of the welding transformer 10, a primary current, and a welding current after rectification. In the figure, the pulse (switching pulse) having a width W controlled by the inverter circuit 83 is repeated a certain number of times within a certain time H, in this case, a total of 10 times including a positive pulse and a negative pulse. It is supplied to the primary coil 12. As a result, a primary current as shown in FIG. 9B flows through the primary coil 12 of the welding transformer 10. When the primary current flows through the primary coil 12 of the welding transformer 10, the secondary current generated on the secondary side of the welding transformer 10 is full-wave rectified by the rectifying elements 18 and 20, and is shown in FIG. Such a welding current flows to the welding gun 6.

  The magnitude of the welding current can be adjusted by increasing or decreasing the pulse width W shown in FIG. In addition, the welding time can be adjusted by increasing or decreasing the number of times of pulse supply. That is, when the pulse repetition frequency is increased, the welding time can be finely adjusted. Further, if the power supplied to the primary coil 12 of the welding transformer 10 is increased, a larger welding current can be taken out from the secondary coil 15.

  Here, for example, the conventional welding apparatus is configured to supply a welding current of 200 milliseconds to 700 milliseconds at 10,000 amperes, but when the welding current is doubled to 20,000 amperes, other than the welding gun 6 In this place, the power loss consumed as thermal energy becomes extremely large, which is a practical problem. Therefore, even if the welding current is doubled, if the welding time is reduced to 1/10, the power consumption can be reduced to 1/5, which is not a problem in practice.

  On the other hand, the control pulse of the inverter circuit for supplying the welding current has conventionally used a repetition frequency of about 1 kHz. However, in order to supply a large current for a short time, a control pulse with higher resolution is required. become. In the inverter circuit 83 of the welding apparatus 1 of the present embodiment, pulses with a repetition frequency of about 5 kHz to 50 kHz are output. When a pulse having a repetition frequency as high as several times to several tens of times is supplied to a conventional welding transformer, a predetermined welding current cannot be obtained. However, the welding transformer 10 used in the welding apparatus 1 of this embodiment is a conventional one. It has a structure capable of obtaining a predetermined welding current even with a pulse having a repetition frequency as high as several times to several tens of times. Hereinafter, the structure of the welding transformer 10 used in the welding apparatus 1 of the present embodiment will be described.

  FIG. 10 is a perspective view showing an appearance of the welding transformer 10 of the welding apparatus 1 of the present embodiment. FIG. 11 is a perspective view showing an assembled state of the welding transformer 10. 10 and 11, the welding transformer 10 is divided into a plurality of portions, an annular magnetic core 25 constituted by a parallel portion 25a and U-shaped curved portions 25b at both ends, and a parallel portion 25a of the annular magnetic core 25. The primary coil 12 that is divided and wound with a gap 12a, and the primary coil 12 are wound around the parallel portion 25a of the annular magnetic core 25 so as to be sandwiched one by one in each gap 12a provided in the primary coil 12. The secondary coil 15 in which a plurality of positive side coils 14 and a plurality of negative side coils 16 are alternately arranged, and the plurality of positive side coils 14 are all connected in parallel or all or part of them are connected in series, The negative side coils 16 are all connected in parallel or all or part of them are connected in series, and the positive side coils 16 and the negative side coils 16 are connected in series so that the connected positive side coils 14 and the negative side coils 16 are connected in series. Connection board having a conductor group electrically connecting the terminals of the cable 14 and the negative side coil 16 and supporting and fixing all the positive side coil 14 and the negative side coil 16 on one surface by the conductor group. 62, and one terminal of each of the plurality of positive side coils 14 is electrically connected to the first connecting pole plate 44 extending in the direction parallel to the parallel portion 25a of the annular magnetic core 25 on the other surface of the connection substrate 62. One terminal of the plurality of negative side coils 16 is electrically connected to the second connecting electrode plate 46 extending in the direction parallel to the parallel part 25a of the annular magnetic core 25 on the other surface side of the connection substrate 62, and is connected to the positive side. The other terminal of the coil 14 and the other terminal of the negative coil 16 are both connected to the third connecting pole plate 48 extending in the direction parallel to the parallel portion 25 a of the annular magnetic core 25 on the other surface side of the connection substrate 62. The first conductor plate 44 is electrically connected to the positive conductor 30, The negative electrode conductor 32 is connected to the two-connection electrode plate 46, and the positive electrode conductor 30 and the negative electrode conductor 32 extend on the other surface side of the connection board 62 in a direction perpendicular to the other surface. A pair of conductor plates stacked via an insulating layer 31 disposed between the positive electrode 30 and the first electrode plate 34 to which the positive electrode 22 (see FIG. 6) is connected. A first rectifying element 18 having an anode (positive electrode) in contact with the side conductor 30 and a cathode (negative electrode) in contact with the first electrode plate 34; a second electrode plate 36 to which the negative conductor 32 and the negative electrode 24 are connected; The second rectifying element 20 having the anode (positive electrode) in contact with the negative conductor 32 and the cathode (negative electrode) in contact with the second electrode plate 36, the first electrode plate 34, and the second electrode plate 36 are And a third electrode plate 38 that supports and electrically connects the both.

  Since the welding transformer 10 has such a structure, a predetermined welding current can be obtained even with a pulse having a high frequency (about 5 kHz to 50 kHz) from the inverter circuit 83.

  By the way, a full-wave rectification type secondary circuit using two rectifying elements 18 and 20 as shown in FIG. 6 has a smaller number of rectifying elements than a circuit using a bridge, and can be reduced in size and power loss. Since it is small, it is known that it is suitable for a welding apparatus. However, in this secondary circuit, when the voltage induced in the secondary coil 15 is reversed due to the polarity reversal of the current flowing through the primary coil 12, the load current supplied through one rectifier element is A commutation that changes the flow occurs on the rectifying element side.

  When the welding current becomes large, the current energy accumulated in the inductance of each part of the circuit becomes very large. The commutation time during which this current energy moves from one rectifying element to the other rectifying element becomes longer as the inductance of each part of the secondary coil 15 shown in FIGS. If the commutation of the secondary circuit is not completed during the time M from the start of the fall of the current of the primary coil 12 shown in FIG. 9 to the end of the rise of the current of the opposite polarity, the rise of the secondary current is delayed. As indicated by the broken line 9, the planned welding current cannot be obtained.

  As described above, the welding transformer 10 shown in FIGS. 10 and 11 is equivalent to the welding transformer described in Japanese Patent Laid-Open No. 2013-179205, and can follow high-speed and precise large-current welding control. It is. FIG. 12 is a waveform diagram showing a welding current supplied from the welding transformer 10 to the welding gun 6. In the figure, the portion where the current increase rate is the maximum from the welding current supply start time t0 to the subsequent time t1 is called the start-up control period T1, and the peak current value C1 from the subsequent time t1 to the time t2 is shown. A period during which a current of a predetermined level is maintained is referred to as a peak level control period T2, and a period from time t2 to the current cutoff time t3 is referred to as a temperature maintenance control period T3. The period T1 is 10 milliseconds or less, the sum (T1 + T2) of the start-up control period T1 and the peak level control period T2 is 15 milliseconds or less, the start-up control period T1, the peak level control period T2, and the temperature maintenance control period T3. The sum (T1 + T2 + T3) time is controlled to be 50 milliseconds or less. Thus, the energization time of the welding current iw is suppressed to 50 milliseconds or less. This is about one fifth of the conventional energization time. In FIG. 12, symbol C2 indicates the end value of the welding current iw.

  In the welding transformer 10 used in the welding apparatus 1 of the present embodiment, the positive side conductor 30 and the negative side conductor 32 are in close contact with each other through the insulating layer 31, and the positive side coil 14 and the negative side coil of the secondary coil 15. Since these coils are arranged so that the primary coil 12 is sandwiched between 16, the inductance at the time of commutation of the secondary circuit of the welding transformer 10 is reduced, and the commutation time in the secondary circuit is reduced. Shorter. Therefore, by using the welding transformer 10, higher frequency inverter control is possible.

  Moreover, the welding transformer 10 can make the heat distribution of the whole welding transformer uniform by the arrangement of the primary coil 12 and the secondary coil 15.

  Further, since the welding transformer 10 divides and winds the positive coil 14 and the negative coil 16 of the primary coil 12 and the secondary coil 15, respectively, the primary coil 12 and the secondary coil 15 are coupled to each other. The coupling between the secondary coil 12 and the secondary coil 15 can be strengthened, and magnetic saturation due to a large secondary current can be prevented.

  In addition, since the relationship between the positive coil 14 and the negative coil 16 of the primary coil 12 and the secondary coil 15 is uniform everywhere, the welding transformer 10 can be disposed in close contact with each other and welded. The transformer 10 can be miniaturized.

  Next, a welding method using the welding apparatus 1 according to this embodiment will be described. Although the welding method using the welding apparatus 1 has been briefly described above, it will be described in detail here with reference to FIGS. 13 and 14. A procedure for welding two steel plates using a copper plate as an object to be welded will be described. 13A is a cross-sectional view showing the copper plate 600A, and FIG. 13B is a plan view showing the copper plate 600A. FIG. 14 is a diagram illustrating the flow of the welding current iw at the tip portion of the one-side electrode 200.

  As shown in FIG. 13, the copper plate 600 </ b> A is formed with an escape hole 601 having a size that allows the tip of the inner electrode 202 of the one-side electrode 200 to pass therethrough, and three pieces on the same circumference outside the escape hole 601. A projection 602 is formed. Note that the interval between the three projections 602 is preferably equal (120 degree intervals). The projection 602 is formed only on the copper plate 600A and not on the copper plate 600B. It is assumed that a protective sheet is pasted or painted on one side of the copper plate 600B.

  After the relief hole 601 and the projection 602 are formed in the copper plate 600A, the operator places the copper plates 600A and 600B on the table 8. At this time, the copper plate 600A is placed on the copper plate 600B and the copper plate 600A is stacked thereon. After placing the copper plates 600A and 600B on the table 8, the operator moves the welding gun 6 directly above the copper plates 600A and 600B. Next, the operator rotates the welding gun 6 to insert the inner electrode 202 of the one-side electrode 200 provided at the tip of the welding gun 6 into the escape hole 601 of the copper plate 600A and press it against the copper plate 600B. At this time, due to the insulating ring 503 attached to the inner electrode portion 202c of the inner electrode 202, the tip portion of the inner electrode portion 202c does not contact the plate thickness surface of the copper plate 600A.

  After placing the copper plates 600A and 600B on the table 8 and bringing the welding gun 6 to a predetermined position, the operator holds the handle 6B of the welding gun 6 and switches it on to give a welding command. When a welding command is output from the welding gun 6, an air cylinder (not shown) on the welding gun 6 is activated, the proximal end side of the welding gun 6 is pulled upward, and the outer electrode 201 presses the copper plate 600A. Then, the inner electrode 202 presses the copper plate 600B. At this time, the inner electrode 202 receives a drag force from the copper plate 600B when it hits the copper plate 600B, but is urged by the urging portion 505, so that it firmly contacts the copper plate 600B.

  Immediately after the outer electrode 201 presses the copper plate 600A and the inner electrode 202 presses the copper plate 600B, supply of the welding current iw is started. As shown in FIG. 14, the welding current iw flows through the path of the outer electrode 201 → the projections 602 of the copper plate 600 </ b> A → the copper plate 600 </ b> B → the inner electrode 202. The copper plates 600A and 600B are melted at the portions of the projections 602 where the contact resistance is the highest due to the welding current iw flowing, and the copper plates 600A and the copper plates 600B are joined.

  Since the movable portion 201b of the outer electrode 201 moves in a circular arc as if it swings its head, the three projections 602 are evenly pressurized when the movable portion 201b presses the copper plate 600A. Thereby, the difference of the molten state between projections becomes small, and welding with little dispersion | variation is attained.

  Note that the number of projections 602 formed on the copper plate 600A is not limited to three, but is arbitrary.

  The shape of the projection 602 may be a small projection in order to maintain the appearance quality of the back surface of the weld depending on the application of the product, and may be a large projection when priority is given to the welding strength.

Moreover, the number of sheets to be welded is not limited to two and may be three or more. An example of welding three copper plates is as follows.
For each of the remaining copper plates except for one of the three copper plates, an escape hole 601 having a size through which the inner electrode 202 can pass is formed, and concentrically around the outer side of the escape hole 601 on one surface of each. Three projections 602 are formed along the copper plate, and then the copper plate on which the relief holes 601 and the projections 602 are not formed is placed at the bottom, and all the copper plates on which the relief holes 601 and the projections 602 are formed, The formation surface of the projection 601 is directed downward, and the stacking holes 601 are sequentially stacked so that the centers of the respective relief holes 601 coincide with each other. The distal end portion of the inner electrode 202 is inserted and pressurized to flow into the inner electrode 202 from the outer electrode 201 And starting the supply of welding current in countercurrent, the maximum value within 15 ms, and is controlled so as to weld is completed in 50 milliseconds or less conduction time.

  Thus, according to the welding apparatus 1 which concerns on this embodiment, while having the welding transformer 10 which can supply a large current in a short time, the movement to a horizontal direction is possible, and a lower electrode is required Since the welding gun 6 having the one-side electrode 200 that can be welded in one direction without being attached is provided, an indentation is formed on the back surface of the workpiece when welding the workpiece having a protective sheet on one side. Welding can be performed with almost no burning or distortion due to heat, and when welding an object to be welded on one side, welding can be performed with almost no burning or thermal discoloration. . That is, welding can be performed without impairing the appearance of the back surface of the workpiece. Further, since welding is completed in a short time, power saving can be achieved.

  In addition, the welding gun 6 that can move in the horizontal direction has an opening on the upper surface, and welds at a portion directly below the extension of the box having an extension extending inward from the periphery of the opening. In such a case, welding can be easily performed even if the extended portion is present.

  Although the present invention has been described with reference to particular embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention.

  The present invention enables control for energizing a large current for a short time, so that when the workpiece is welded, the back surface of the workpiece is not indented, burned by heat, or distorted, and more efficient. It has the effect that good power control can be performed to save power and can be applied to spot welding.

DESCRIPTION OF SYMBOLS 1 Welding device 2 Cooling unit 3 Power supply unit 4 Support post 5 Support arm 5A Horizontal arm part 5a Base end part 5b Intermediate part 5Aa Drive shaft 5B Vertical arm part 6 Welding gun 7 Conductive cable 8 Table 9 Welding condition setting device 10 Welding transformer 12 Primary coil of welding transformer 14 Positive coil of secondary coil of welding transformer 15 Secondary coil of welding transformer 16 Negative coil of secondary coil of welding transformer 18 First rectifying element 20 Second rectifying element 22 Plus of welding transformer Electrode 24 Negative electrode of welding transformer 82 Welding control circuit 83 Inverter circuit 100 Table drive part 200 One side electrode 201 Outer electrode 201a Fixed part 201b Movable part 202 Inner electrode 202a Screw part 202b Flange 202c Inner electrode part 203 Inner electrode fixed part 300 Nkuhoruda 400 bus bar conductor 450 power receiving equipment 600A, 600A weld object 601 escape hole 602 Projection

Claims (3)

A welding transformer that converts the current generated in the secondary coil into direct current by supplying high-frequency alternating current to the primary coil;
A welding gun which is held on a flat table on which a workpiece is placed and is held in a horizontal posture parallel to the table, and which is supplied with a direct current generated in a secondary coil of the welding transformer;
An inverter circuit for supplying high-frequency alternating current to a primary coil of the welding transformer;
A welding control circuit for controlling the operation of the inverter circuit;
A welding apparatus comprising:
The welding transformer includes an annular magnetic core composed of a parallel portion and U-shaped curved portions at both ends, and a primary coil that is dividedly wound around the parallel portion of the annular magnetic core with a plurality of portions with a gap therebetween. And a plurality of positive side coils and a plurality of negative side coils wound around the parallel part of the annular magnetic core together with the primary coil, and sandwiched one by one in the gaps provided in the primary coil, And the plurality of positive side coils are all connected in parallel or all or part of them are connected in series, and the plurality of negative side coils are all connected in parallel or all or one. A group of conductors that are electrically connected between the terminals of the positive side coil and the negative side coil so that the plurality of positive side coils and the plurality of negative side coils connected in series are connected in series. And having the conductor To provide a connection board that supports and fixes all the positive and negative coils on one surface, and one terminal of each of the plurality of positive coils is on the other surface of the connection board, The first connecting pole plate extending in a direction parallel to the parallel part of the annular magnetic core is electrically connected, and one terminal of the plurality of negative coils is on the other surface side of the connection substrate, The second connecting electrode plate extending in a direction parallel to the parallel portion is electrically connected, and the other terminal of the positive coil and the other terminal of the negative coil are both on the other surface side of the connection board, It is electrically connected to a third connecting plate extending in a direction parallel to the parallel part of the annular magnetic core, a positive conductor is connected to the first connecting plate, and a negative side is connected to the second connecting plate. Conductor is connected, the positive side conductor and the negative side conductor on the other surface side of the connection board, A pair of conductor plates stacked via an insulating layer disposed on a boundary surface extending in a direction perpendicular to the other surface, and between the positive electrode and the first electrode plate to which the positive electrode is connected Sandwiched between a first rectifier element in which a positive electrode is in contact with the positive conductor and a negative electrode is in contact with the first electrode plate, and a second electrode plate in which the negative conductor and the negative electrode are connected. A second rectifying element having a positive electrode in contact with the negative conductor and a negative electrode in contact with the second electrode plate, and a third electrode for supporting and electrically connecting the first electrode plate and the second electrode plate. The welding gun has a cylindrical outer electrode open at both ends, and is freely insertable into the outer electrode, and a tip portion of the outer electrode is inserted into the outer electrode. A cylindrical inner electrode exposed from the tip surface is insulated from the outer electrode and the inner electrode. A one-sided electrode provided with a first insulating member and a second insulating member covering the surface of the tip portion of the inner electrode, and holding the one-side electrode at the tip portion, the tip portion being approximately the body portion A L-shape bent in a right angle direction, a shank holder for connecting the plus electrode of the welding transformer to either the inner electrode or the outer electrode of the one-side electrode, and the minus of the welding transformer A bus bar conductor for connecting an electrode to one of the inner electrode and the outer electrode of the one-side electrode not connected to the shank holder, and the welding control circuit supplies the one-side electrode to the one-side electrode A welding apparatus that controls the operation of the inverter circuit so that the welding current becomes a maximum value within 15 milliseconds from the supply start time and the welding is completed within a current supply time of 50 milliseconds or less.   The outer electrode of the one-side electrode has a fixed portion that holds the inner electrode, and an arc around an axis that has a first end surface in close contact with the distal end surface of the fixed portion and a center of one end surface that contacts the fixed portion. The welding apparatus according to claim 1, further comprising a movable part that is movable.   A welding method for spot welding a workpiece using the welding apparatus according to claim 1 or 2, wherein the workpiece is a plurality of metal plates, and one of the plurality of metal plates. For each of the remaining metal plates excluding, an escape hole having a size through which the inner electrode can pass is formed, and a plurality of projections are formed along the concentric circles around the outer side of the escape hole on each one surface. Forming the relief hole and the projection without forming the relief hole and the projection, and forming all the metal plates with the relief hole and the projection on the surface of the metal plate. With the surface facing down, stack the metal holes one after the other so that the centers of the escape holes coincide with each other. In addition, the tip portion of the inner electrode is inserted and pressed into the escape holes of all the metal plates, and the supply of welding current is started in the direction of flow from the outer electrode to the inner electrode, within 15 milliseconds from the supply start time. A welding method in which the welding current is controlled so that the welding is completed in a current value of 50 milliseconds or less at a maximum value.