JP3675304B2 - Arc welding condition setting method and arc welding condition setting device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an arc welding condition setting method and an arc welding condition setting device.
[0002]
[Prior art]
As shown in FIG. 6, the conventional arc welding condition automatic calculation method is based on the premise of a process 201 for selecting a welding device based on a workpiece material and a plate thickness, a joint shape, a welding speed (torch feed speed), a torch target position, and the like. Step 202 that is input as a condition, step 203 that calculates a welding current and voltage value from the relationship between the amount of input metal (wire) and the amount of weld metal (bead), and actual arc welding with the calculated welding current and voltage value Welding / confirmation step 204 for confirming whether or not the welding conditions calculated and executed are appropriate so as not to cause welding defects, and welding defects such as undercut, spatter, burn-off, humping (weld bead width is determined in step 204) When it is confirmed that a phenomenon that fluctuates in the welding direction) has occurred, the calculation in step 204 is performed again by changing the preconditions, etc., and new welding conditions are calculated to perform welding. The that cycle is repeated until the defective welding does not occur, a feedback step 205 partially including a welding process, consisted.
[0003]
[Problems to be solved by the invention]
However, the conventional arc welding condition calculation method has the following problems.
(1) Since feedback control including a welding process is performed to reach an appropriate welding condition that does not cause poor welding, it takes too much time and cost to reach the appropriate welding condition.
(2) Normally, welding current, voltage and speed are fixed in mass production. In the conventional welding condition calculation method, when the fluctuation factors of the workpiece gap and the torch aiming position change, the appropriate welding current, voltage, and speed change accordingly, and the fixed conditions are not established, so it is not practical.
(3) Since the welding conditions are calculated only in the balance of the amount of metal in the step 203, and the amount of metal mainly depends on the welding current value, the influence of voltage, welding speed, joint shape, etc. is large. , Humping, spatter generation, etc. cannot be predicted.
An object of the present invention is to provide an arc welding condition setting method and an arc welding condition setting apparatus capable of setting appropriate welding conditions by calculation before performing welding.
Another object of the present invention is to keep welding conditions such as welding current and voltage fixed even if fluctuation factors such as the work gap and the torch aiming position fluctuate, as long as they are within the allowable values of the fluctuation factors. Another object of the present invention is to provide an arc welding condition setting method and an arc welding condition setting device that can afford a welding variation factor.
Another object of the present invention is to provide an arc welding condition setting method and an arc welding condition setting device capable of suppressing undercut, humping, spatter generation and the like.
[0004]
[Means for Solving the Problems]
The present invention for achieving the above object is as follows.
(1) selecting welding equipment and inputting welding preconditions;
Enter the required product quality, enter the tolerance range of welding fluctuation factors,
A process of calculating appropriate welding conditions that satisfy the product required quality even if the variation factor fluctuates within the allowable range, based on a correlation analysis result and boundary conditions based on past welding results;
An arc welding condition setting method comprising:
(2) The selection conditions of the welding equipment include at least one condition of workpiece material and plate thickness, and the welding precondition includes at least one condition of joint shape, workpiece plate thickness and welding speed, and the product requirement Quality includes conditions for at least one of penetration depth, leg length, throat thickness and / or unconditional conditions for at least one of undercut, melt-down, spatter, and the welding variation factors include at least one of gap, aim, extension The arc welding condition setting method according to (1), wherein the appropriate welding condition includes a condition for at least one of a welding current, a voltage, a torch angle, and a target position.
(3) Welding equipment selection means for selecting a welding equipment, precondition reading means for reading the preconditions for welding, product requirement quality reading means for reading the product requirement quality, and fluctuation factor reading means for reading the allowable range of the welding fluctuation factor Based on the read data, correlation analysis results and boundary conditions based on past welding results are used to calculate appropriate welding conditions that satisfy the required product quality even if the fluctuation factors fluctuate within the allowable range. A suitable computer for calculating welding conditions;
A portable terminal divided from the host computer, having transfer means for transferring appropriate welding conditions calculated by the host computer to a robot controller of the welding robot;
An arc welding condition setting device comprising:
[0005]
In the arc welding condition setting method of (1) and (2) and the arc welding condition setting device of (3), the appropriate welding conditions can be obtained by one calculation before welding, and conventional welding is performed. It is not necessary to repeatedly determine the appropriate welding conditions, and the time and cost for determining the appropriate welding conditions can be reduced.
In addition, it reads the required product quality, reads the allowable range into the welding fluctuation factor, and satisfies the required product quality even if the fluctuation factor fluctuates within the allowable range due to the correlation analysis results and boundary conditions based on past welding results. Since appropriate welding conditions are determined, even if fluctuation factors such as target deviation, gap, extension, etc. fluctuate within the input allowable range, the tolerance is given so that the welding is in an appropriate range that satisfies the required product quality. Even if the fluctuation factors fluctuate, it is not necessary to change the welding current and voltage, and welding can be continued under fixed conditions. This matches the current welding current and constant voltage welding.
In addition, by setting boundary conditions for undercut, humping, meltdown, spatter generation, etc., by calculating appropriate welding conditions in areas other than each area such as undercut, humping, meltdown, spatter generation, Undercut, humping, melt-down, and spatter generation can be suppressed.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
An arc welding condition setting method and an arc welding condition setting apparatus according to an embodiment of the present invention will be described with reference to FIGS. The types of weld shape and weld failure are shown in FIG.
As shown in FIG. 5, the arc welding condition setting of the embodiment of the present invention includes a host computer 1, a terminal 2 that can be connected to the host computer, and a robot controller 3 that is connected to the terminal 2.
The host computer 1 has an input / output interface (input / output interface) 1b, a CPU 1a for executing calculations, and storage means (RAM, ROM) 1c.
The terminal 2 is composed of a portable terminal that is divided from the host computer 1 and has a transfer means 2a for transferring appropriate welding conditions calculated by the host computer 1 to the robot controller 3 of the welding robot and an input / output means 2b. The terminal 2 may be a portable small computer. By separating the host computer 1 and the terminal 2, it is possible to manufacture at a low cost without the need to install a host computer for each facility. It is possible to check the conditions before completion. In addition, online teaching at the terminal 2 is possible, and workability is improved.
A robot controller 3 is provided in each arc welding robot.
[0007]
A calculation routine shown in FIG. 1 is installed in the host computer 1.
The calculation routine includes a welding equipment selection means for selecting a welding equipment (means for executing step 101), a precondition reading means for reading a precondition for welding (means for executing step 102), and a product for reading the required product quality. Based on the required welding quality reading means (means for executing step 103), fluctuation factor reading means for reading the allowable range of welding fluctuation factors (means for executing step 104), and past welding results from these read data. Based on the correlation analysis result and the boundary condition, an appropriate welding condition calculation means (means for executing step 105) for calculating an appropriate welding condition that satisfies the product required quality even if the fluctuation factor fluctuates within the allowable range, Have.
[0008]
In the above, the welding equipment selection means selects the welding equipment from at least one condition of the material and thickness of the plate work to be welded.
The precondition reading means reads at least one condition of the joint shape, workpiece thickness, and welding speed.
The product requirement quality reading means reads a condition for at least one of a penetration depth, a leg length, and a throat thickness and / or an unconditional condition for at least one of an undercut, a melt-down, and a spatter. For example, it is read that the penetration is 20% or more, cannot be melted down, cannot be undercut, and so on.
The welding fluctuation factor reading means reads at least one of a gap (a gap amount between workpieces), a target (shift of the target position of the torch), and an extension (amount of protrusion of the wire from the torch). For example, the target is read as 0.6 mm or less.
The appropriate welding condition calculation means calculates an appropriate condition for at least one of a welding current, a voltage, a torch angle, and a target position.
[0009]
In the appropriate welding condition calculation means, the following calculation is performed.
Correlation analysis is performed between a parameter (for example, penetration X) related to product welding quality and a parameter (for example, current I, voltage V, plate thickness d, joint shape, etc.) having a correlation therewith. The correlation function is determined based on past welding results.
X = f (current I, voltage V, plate thickness d, joint shape, etc.) (1)
It can be expressed. When the workpiece and joint type are determined, the plate thickness d and joint shape value are constants, and the predetermined relationship between current I and voltage V is I = aV + b (2)
Therefore, equation (1) is
X = f (current I) (3)
It becomes. Here, the range of the current is determined from the required quality condition, for example, the condition where the penetration X is 20% or more, and is substituted into the equation (2).
It is determined that I = 125A or more, V = 21V or more, and the like.
On the other hand, from the condition of not being burnt out (melting is 70% or less, for example, this condition is a requirement quality and a boundary condition), for example,
I = 280A or less, V = 31V or less, and the like, and the range of current I and voltage V is determined. Although the above has described the penetration depth, other welding quality parameters are similarly calculated.
As described above, the parameters relating to the product welding quality (penetration depth, leg length, throat thickness, etc.) and the parameters (for example, current I, voltage V, plate thickness d, joint shape, etc.) correlated therewith. From the correlation analysis, the condition range of the latter parameters (for example, current I, voltage V, plate thickness d, joint shape, etc.) to satisfy the required product quality is obtained.
[0010]
Next, even if the fluctuation factors (target, gap, extension, etc.) fluctuate with tolerance (allowable maximum value of fluctuation), the above parameters (for example, current I, voltage V, Calculation to reduce the range of conditions (plate thickness d, joint shape, etc.).
For example, the target is taken as a variation factor, and the tolerance of the variation is 0.6 mm. Assume that there is a correlation in FIG. 4 between the penetration depth and the target position based on past welding results. In the example of FIG. 4, a shift of 0.6 mm in each of the target positions + and − gives a 15% variation in the penetration depth. Therefore, the range of the penetration depth of 20 to 70% described in the required quality is as follows. Reduced by 15% to 35-55%. Correspondingly, when the current value is calculated using the expression (3), the current values 125 to 280A corresponding to the penetration depth 20 to 70% are changed to the current values 150 to 250A corresponding to the penetration depth 35 to 55%. It becomes. Correspondingly, the voltage value is 22.5 to 29 V from the equation (2). FIG. 2 shows this range.
Therefore, when the welding current and voltage value are selected from the reduced current value range 125 to 280A and the voltage value range 22.5 to 29V, the penetration depth is 20% regardless of the target fluctuation within the allowable value of 0.6 mm. As described above, no burn-through is satisfied.
The above describes a case where the boundary condition that does not cause welding defects is not burned out, regardless of the variation factor. However, other variation factors, such as gaps and extensions, have other welding defects (arc breakage). , Sputter, undercut, and humping), the appropriate region (triangle region where the proper mark in FIG. 2 exists) is obtained from the correlation analysis and the boundary conditions based on the past results. By selecting the current, voltage, torch angle, and target position within this proper range, the required quality of the product is still satisfied even if the fluctuation factors fluctuate, and undercut, humping, burnout, spatter, arc breakage Appropriate welding conditions are required so that welding defects such as these do not occur.
[0011]
As shown in FIG. 1, the arc welding condition setting method according to the embodiment of the present invention selects the welding equipment, inputs the welding preconditions 101 and 102, inputs the required product quality, and accepts the welding fluctuation factor. Calculate the appropriate welding conditions that satisfy the required product quality even if the fluctuation factors fluctuate within the allowable range, based on the correlation analysis results and boundary conditions based on the past welding results and the processes 103 and 104 for inputting the ranges. Step 105. Any of the steps 101 and 102 may be executed first. In addition, any of steps 103 and 104 may be executed first.
[0012]
The selection conditions of the welding equipment in step 101 include at least one condition of the workpiece material and the plate thickness, and the welding equipment, that is, a torch, a wire, a power source, and the like are selected from at least one of the workpiece material and the plate thickness. .
Preconditions for welding in step 102 include at least one of the joint shape, workpiece thickness, and welding speed.
The product requirement quality in step 103 includes conditions for at least one of penetration depth, leg length, and throat thickness and / or conditions for at least one of undercut, meltdown, and spatter.
The welding variation factor in Step 104 includes at least one of a gap, an aim, and an extension.
The appropriate welding conditions in Step 105 include conditions for at least one of welding current, voltage, torch angle, and target position.
[0013]
The process will be described as follows.
In step 101, the material and thickness of the workpiece are read, and welding equipment (torch, wire, power source, etc.) is selected from the information. Also, robot information is read as equipment information.
In step 102, welding preconditions such as joint shape, base metal (workpiece) plate thickness, welding speed (torch speed), etc. are read.
Steps 101 and 102 may be input individually, but may be input collectively for each part (suspension arm, steering column, etc.).
In step 103, the required product quality (penetration depth, leg length, throat thickness, etc.) is read. For example, the penetration is 20% or more, the melt-down is not possible, the undercut is not possible.
In step 104, an allowable range of variation factors (target, gap, extension, etc.) is input. For example, an allowable range such as 0.6 mm or less is input for each direction of the + and − directions.
In step 105, the appropriate welding current, voltage, torch angle, and target position are calculated based on the correlation analysis result and the boundary condition based on the past results (including the test result).
[0014]
In step 105, in the condition calculation, a certain condition range is obtained from the correlation between the current and the plate thickness for the penetration depth or the like that satisfies the quality. For example, a certain condition range is obtained such as I = 125 to 280A and V = 21 to 31V. Thereafter, the boundary condition for suppressing welding failure is used to limit the condition range so that the welding failure can be suppressed even if fluctuation occurs, and an appropriate region is obtained. For example, the condition range is limited such that I = 150 to 250 A and V = 22.5 to 29 V, and the appropriate area is obtained. An example of the appropriate region and various welding failure occurrence regions is shown in FIG.
Then, within this appropriate region, appropriate welding conditions (appropriate current, voltage, torch angle, aiming position, etc.) are selected.
[0015]
Then, arc welding is performed in step 106 under the proper welding conditions.
If welding is performed under these conditions, welding defects should not occur, but there are actually defects due to equipment (robots). For example, the wire feed speed is stabilized by a sudden change in the robot posture during welding. The bead constriction (humping) occurs. This kind of problem still remains because the above-mentioned calculation of appropriate conditions does not consider the facility information.
In order to solve it, when a welding defect (due to equipment) occurs, a troubleshooting collection is created, and the cause investigation and countermeasures are created. In this case, this is configured in a flow chart so that when a certain welding failure occurs, it is possible to know what kind of welding failure is caused by the equipment according to the troubleshooting flowchart and what countermeasures should be taken. Keep it.
[0016]
The problems of the prior art are solved as follows by the arc welding condition setting method and the arc welding condition setting apparatus of the embodiment of the present invention. The following (1) to (3) correspond to the problems (1) to (3) described in the problem to be solved.
The following measures are taken against the problem that it takes too much time and money to obtain the appropriate welding condition (1). That is, in the arc welding condition setting method and the arc welding condition setting device of the present invention, the appropriate welding condition can be obtained by one calculation before welding, and the conventional welding is repeatedly performed and the appropriate welding condition is not obtained. This reduces the time and cost required to determine the proper welding conditions.
[0017]
For the problem (2) that the current and voltage are not fixed, the following measures are taken. That is, in the arc welding condition setting method and the arc welding condition setting apparatus of the present invention, the product required quality is read, the allowable range is read as the welding fluctuation factor, and the fluctuation is caused by the correlation analysis result and the boundary condition based on the past welding results. Even if the factors fluctuate within the permissible range, the optimum welding conditions that satisfy the required product quality are obtained, so even if fluctuating factors such as target deviation, gap, and extension fluctuate within the input permissible range, welding is still possible. It is in an appropriate range that satisfies the required product quality and has a tolerance so as not to cause welding defects. Even if the fluctuation factors fluctuate, welding current and voltage do not need to be changed and welding can be continued under fixed conditions. This matches the current welding current and constant voltage welding.
[0018]
For the problem (3) that the occurrence of poor welding cannot be predicted, the following measures are taken. That is, in the arc welding condition setting method and the arc welding condition setting device of the present invention, by setting boundary conditions for undercut, humping, melting, spatter generation, etc., undercut, humping, melting, spatter generation, etc. By calculating appropriate welding conditions in regions other than these regions, undercuts, humping, melt-down, and generation of spatter can be suppressed.
[0019]
【The invention's effect】
According to the arc welding condition setting method of claims 1 and 2 and the arc welding condition setting device of claim 3, the appropriate welding conditions can be obtained by one calculation before welding, and conventional welding is repeatedly performed. Therefore, it is not necessary to obtain appropriate welding conditions, and the time and cost for obtaining appropriate welding conditions can be reduced.
In addition, it reads the required product quality, reads the allowable range into the welding fluctuation factor, and satisfies the required product quality even if the fluctuation factor fluctuates within the allowable range due to the correlation analysis results and boundary conditions based on past welding results. Since appropriate welding conditions are determined, even if fluctuation factors such as target deviation, gap, extension, etc. fluctuate within the input allowable range, tolerance is given so that welding is in an appropriate range that satisfies the required product quality. Even if the fluctuation factors fluctuate, it is not necessary to change the welding current and voltage, and welding can be continued under fixed conditions. This matches the current welding current and constant voltage welding.
In addition, by setting boundary conditions for undercut, humping, meltdown, spatter generation, etc., by calculating appropriate welding conditions in areas other than each area such as undercut, humping, meltdown, spatter generation, Undercut, humping, melt-down, and spatter generation can be suppressed.
[Brief description of the drawings]
FIG. 1 is a process diagram of an arc welding condition setting method according to an embodiment of the present invention.
FIG. 2 is a map showing boundary conditions based on past results of an arc welding condition setting method according to an embodiment of the present invention, a welding failure occurrence area, and an appropriate area.
FIG. 3 is a cross-sectional view of a workpiece and a welded portion.
FIG. 4 is a graph showing a relationship between a penetration depth and a target position.
FIG. 5 is a block diagram of an arc welding condition setting device according to an embodiment of the present invention.
FIG. 6 is a process diagram of a conventional arc welding condition setting method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Host computer 2 Terminal 3 Robot controller 101 Welding equipment selection process 102 Welding precondition input process 103 Product requirement quality input process 104 Welding variation factor allowable range input process 105 Appropriate welding condition calculation process

Claims (3)

Selecting welding equipment and entering welding prerequisites;
Enter the required product quality, enter the tolerance range of welding fluctuation factors,
A process of calculating appropriate welding conditions that satisfy the product required quality even if a variation factor fluctuates within the allowable range according to a correlation analysis result and boundary conditions based on past welding results;
An arc welding condition setting method comprising: The selection conditions of the welding equipment include at least one condition of workpiece material and plate thickness, the preconditions for welding include at least one condition of joint shape, workpiece plate thickness, and welding speed, and the required quality of the product blends. Including conditions for at least one of depth, leg length, throat thickness and / or unconditional conditions for at least one of undercut, burn-through, and spatter, and the welding variation factor includes at least one of gap, aim, extension The arc welding condition setting method according to claim 1, wherein the appropriate welding conditions include a condition for at least one of a welding current, a voltage, a torch angle, and a target position. Welding equipment selection means for selecting welding equipment, precondition reading means for reading preconditions for welding, product requirement quality reading means for reading product requirement quality, fluctuation factor reading means for reading the allowable range of welding fluctuation factors, and reading Based on the results of correlation analysis based on past welding results and boundary conditions, the appropriate welding conditions for calculating the appropriate welding conditions satisfying the required product quality even if the fluctuation factors fluctuate within the allowable range. A host computer having calculation means;
A portable terminal divided from the host computer, having transfer means for transferring appropriate welding conditions calculated by the host computer to the robot controller of the welding robot;
An arc welding condition setting device comprising:

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