KR100725071B1 - Apparatus and method of auto overlay welding - Google Patents

Abstract

The present invention relates to an automatic growth welding machine and a welding method, wherein the wire feeder and the torch are moved at a precisely controlled moving speed on the LM guide by the control of the control unit according to the position detected from the encoder or the potentiometer, but from the edge to the inside or the inside. The moving speed is changed whenever a certain displacement occurs while moving along the center line of the base material to the edge, and the rotational speed of the rotary table on which the base material is located is precisely controlled by the controller according to the position of the torch, and is moved inside. The present invention relates to an automatic continuous growth welding machine and a welding method, which is faster or gradually to the outside so that a uniform growth layer can be formed.

Training, welding, spiral, turntable, torch

Description

Automatic continuous breeding welding method {APPARATUS AND METHOD OF AUTO OVERLAY WELDING}

1 is a view showing a method for growing a circular body by conventional intermittent concentric growth welding

2 is a view showing a method for growing a circular body by conventional concentric circular welding and partial spiral growth welding;

Figure 3 is a perspective view showing the mechanical configuration of the automatic continuous growth welding machine according to the present invention

Figure 4 is a block diagram showing a control unit of the automatic continuous growth welding machine according to the present invention

5 is a view showing the automatic continuous growth welded article according to the present invention

The present invention relates to an automatic continuous growth welding machine and a welding method, and more particularly, the wire feeder and the torch move at a precisely controlled moving speed on the LM guide under the control of the control device, and the rotation speed of the rotary table on which the base material is located. Is precisely controlled by the control unit according to the position of the torch, and relates to an automatic growth welding machine and a welding method for forming a uniform growth layer.

Mechanical parts used in each field of the plant industry require acid resistance, corrosion resistance, high temperature, and high pressure depending on the application and process used.In order to solve this problem, the container is made only with alloys that have the appropriate resistance to the application. Since the cost burden is too high, a steel container is usually formed, and various alloys are raised and welded on the inner surface to reduce costs.

As described above, in the process of performing the welding welding, in consideration of the welding efficiency, the surge electrode arc welding is performed using the target electrode having a large welding amount per working time.

The welding of the disk and the circular curved body using the band-phase electrode was performed an intermittent method of initially welding concentric circles and cutting the arc to reweld the center of the next concentric circles as shown in FIG. 1.

However, this intermittent concentric welding method has a problem in that welding defects frequently occur in the intermittent portion.

Therefore, a combination welding method for welding a combination of concentric welding and partial spiral welding has been developed as a welding welding method for solving the above problem.

As a representative example of such a combination growth welding method, "continuous growth welding method" by JP 53-23850 and 53-25252 is mentioned.

That is, in the combination welding method, as shown in FIG. 2, first, the first concentric circular portion C1, which is the outermost part of the circular body, is concentrically raised and welded, and when the welding process reaches the baseline E1, the length is at E1. The spiral growth welding of the first spiral portion P1 to the start point Cs2 of the second concentric portion C2 is performed, and when the welding process reaches the start point Cs2 of the second concentric portion C2, the second concentric portion ( C2) is concentrically raised and welded, and when the welding process reaches the baseline E2, the spiral growth of the second spiral portion P2 from E2 to the start point Cs3 of the third concentric portion C3 is spirally grown. It is a method of auto-growing a circular body by repeating the part which becomes equal to the length of a part.

However, in this method, automatic fusing welding cannot be performed on the portion where the length of the concentric circle portion is smaller than the length L of the spiral portion.

And uniformly raising and welding the height of the bead is a very important factor because it reduces the time required for post-processing work, but the control device used in the conventional automatic continuous welding machine is uniform the height of the bead due to the limitation of calculation and control function. There was no precise control function.

In addition, the conventional automatic continuous welding machine requires a separate cumbersome work preparation process to arbitrarily change the width of the welding bead by adjusting the pitch, when the customer needs to work closely with the pitch of 5 mm or less. Unacceptable, the site relies on semi-automatic or manual work.

An object of the present invention for solving the above problems is that the wire feeder and the torch moves at a precisely controlled movement speed on the LM guide according to the control of the control device, and at the same time the rotation speed of the rotary table where the base material is located is It is to provide an automatic continuous growth welding machine and a welding method that is precisely controlled by the control unit according to the position, so that a uniform growth layer can be formed.

An embodiment of the present invention for achieving the above object will be described with reference to the accompanying drawings.

Figure 3 is a perspective view showing an automatic growth welder according to the present invention, Figure 4 is a block diagram showing the electrical configuration of the automatic growth welder, Figure 5 is a view showing an automatic continuous growth welded article according to the present invention.

The automatic growth welding machine according to the present invention includes a rotating part 100 that greatly rotates a base material, a frame part 200, and a welding part installed on the frame part 200 to perform spiral welding on the base material at a predetermined thickness ( 300, and a control unit for controlling the operations of the rotating unit 100 and the welding unit 300.

In the above configuration, the rotating part 100 is connected to the rotating plate 110 on which the base material is placed, the rotating plate 110 and the power transmission means to rotate the rotating plate 110, the rotating motor 110, the rotating motor ( Inverter 442 connected to the 120 to reduce the rotational speed of the rotary motor 120 to output a control signal to the rotary motor 120 to continuously change the reducer 130 and the number of revolutions to the rotating plate 110 It is composed of

In addition, the frame part 200 is installed so as to be movable up and down by a vertical guide 210 installed on the side of the rotating part 100 and the transfer means such as a cylinder, a motor, etc. in the vertical guide 210. The shanghai song block 220 and the horizontal arm 230 is rotatably installed on the shanghai song block 220 and positioned above the rotating plate 110, and the horizontal arm 230 is the rotating plate 110. It can be rotated manually or by motor so as not to interfere with placing the base material on).

The welding part 300 is an LM guide 310 installed on the horizontal arm 230, a wire reel 320 is installed on the vertical guide 210, the transfer block 312 of the LM guide 310 The torch 350 and the transfer motor 360 are integrally formed at the front of the wire feeder 330 and the wire 340 supplied through the wire feeder 330 through the wire feeder 330 installed in the wire feeder 330. ), A transfer means (not shown) and a speed reducer for connecting the transfer motor 360 and the transfer block 312 of the LM guide 310 to transfer the transfer block 312 according to the rotation of the transfer motor 360. Not shown), and the position detection sensors (372, 374) for detecting the rotational speed of the transfer motor 360 and the moving position of the transfer block 312, the transfer means is usually used a lead screw, a belt or the like. .

In the above configuration, the position detection sensors 372 and 374 are installed in the transfer motor 360 and the potentiometer 374 for detecting the movement position of the encoder 372 or the transfer block 312 to detect the rotation speed of the transfer motor 360. It consists of.

The control unit includes a MAN MACHINE INTERFACE (MMI) 410 for allowing a user to input and confirm various commands, a memory 420 for storing various data, and the transfer motor 360. ) And a motor driver 430 and 440 for outputting an operation control signal to the rotary motor 120, a torch driver 450 for driving the torch 350, and the position detection sensors 372 and 374. It is composed of a central processing unit (CPU) 460 for outputting an operation control signal to the motor driving unit 430, 440 and the torch driving unit 450 to develop a uniform spiral shape on the base material based on the output signal.

In the above configuration, the MMI 410 is a display unit composed of LEDs, LCDs, and the like so that the user can check various operation states and operation modes, a key switch and a thumb wheel (10) for allowing the user to input various operation modes and parameters. THUMB WHEEL) switch and so on.

In addition, the motor driving unit 440 is an inverter 442 for supplying power to change the rotational speed of the rotary motor 120 by the output frequency is controlled by an analog signal, the CPU 460 to the inverter 442 The DA converter 444 converts the digital signal into an analog signal and outputs the control command of the communication interface 446 so that the CPU 460 and the inverter 442 directly transmit the control message. Rotate the rotating plate located.

In addition, the counter 433 or the potentiometer 374 for counting the signal output from the motor driving circuit 431, the motor interface 432, and the encoder 372 for driving the transfer motor and outputs the signal to the CPU 460 AD converter 434 converts the analog signal output from the digital signal into a digital signal, the potentiometer 374 is the AD converter, the encoder 372 the CPU by the coefficient value of the counter 433, respectively. I am trying to get location information.

In addition, the transfer motor 360 and the rotation motor 120 can control the direction of rotation in the forward or reverse direction so that the welding starts from the edge of the base material and starts from the inside, or from the inside toward the edge. It is possible.

On the other hand, reference numeral 470 (P0 ~ PN) of the present invention is a potentiometer for setting various parameters (such as the dimensions of the base material, processing speed, processing limit point) for welding and 472 converts the signal of the potentiometer 470 described above To AD converter provided to the CPU 460.

Looking at the welding process through the automatic raising welder having the configuration as described above, if the torch 350 is located at the center of the center line of the base material and the zero point adjustment command is input by adjusting the switch unit of the MMI 410, One CPU 460 is set by storing the current position of the torch 350 in a predetermined area of the memory 420 so as to be recognized as "0".

Subsequently, when the manual feed command is input by operating the switch unit and the wire feeder 330 and the torch 350 are moved to the end of the base material, the movement position of the torch 350 is displayed on the display unit, and the CPU 460 moves the position to the outside radius. It is determined that the data is stored in the predetermined area of the memory 420.

On the other hand, the outer radius of the welding parameter is also adjusted by the potentiometer 470 and the user can simply set the outer radius while checking the position of the torch 350 output to the indicator by driving the transfer motor 360.

In addition, the distance between the base material and the torch 350 is appropriately adjusted by driving the shanghai song block 220, and the horizontal arm 230 is moved toward the side of the rotating plate 110 so that the base material is easily placed on the rotating plate 110. After moving, the base material is placed and the horizontal arm 230 is moved onto the centerline of the base material.

When the torch 350 is positioned at the end on the center line of the base material, when the welding command is issued using the switch unit, the CPU 460 causes the rotating motor 120 to idle for a predetermined time, and then the rotating plate 110 at the calculated initial rotational speed. Upon arrival, the CPU 460 sends out the welding machine operation start contact output through the digital output interface, and simultaneously welds the torch 350 to form a spiral at even intervals by starting welding from the end of the base material.

On the other hand, the position control of the rotating plate 110 and the torch 350 in the present invention described above will be described below.

Rotational speed VT (rpm) of the rotating plate, pitch interval P (mm) of the bead, rotational speed VF (rpm) of the feed motor, welding speed S (mm / min), rotation radius of the base material (same as the current position of the torch) R) are the main parameters of continuous automatic welding, and their relations are shown in Equations 1 to 3.

The rotational speed VT of the rotating plate is used to determine the reduction ratio of the reducer connected to the rotating motor so that the practical welding speed is about 200mm to 500mm per minute.

In Equation 1, when the position of the torch is on the outer side of the rotating plate, since the rotation radius (r) of the base material is relatively large, the rotational speed (VT) of the rotating plate becomes low, and as the position of the torch enters the center of the rotating plate, the radius of rotation of the base material (r) becomes small, and the rotational speed VT of a rotating plate becomes high.

According to Equation 3, it can be seen that VF and VT are directly proportional to each other.

As with the rotating plate, the feed motor side is also used to reduce the rotation speed by the reducer.

The rotational power of the feed motor is decelerated by the reducer to drive the LM guide. The feed amount of the screw or belt that drives the LM guide is expressed as the feed distance per revolution, and 50mm or 100mm per revolution to facilitate the calculation of the position and the amount of movement. It is usually designed to have mechanical properties.

Since the transfer distance for one rotation of the transfer motor required in the preferred embodiment is 50 mm or 100 mm, it is relatively large, so that the rotation speed must be reduced at a very large rate in order to precisely position the transfer motor.

Since the reduction ratio of the feed motor for the desired welding speed is more than 10,000: 1, if the high speed reduction gear is adopted, the speed of the torch is increased to the desired position at the beginning or after the welding work. To reduce this problem, the variable speed reducer can be used to solve this problem, and if the operation of the variable speed reducer is considered cumbersome, the drive of the feed motor is not continuously operated during the welding work instead of lowering the ratio of the speed reducer. Without intermittent driving.

The meaning of the rotational speed (VF) in the feed motor is applied when the feed motor is continuously rotated. Therefore, the rotation speed (VF) of the feed motor in case of automatic continuous growth welding by intermittently driving the feed motor is Use the control process as described below to apply it to the control software.

First, the speed per minute (rpm), which is the unit of rotational speed (VF) of the feed motor, is divided by 60 and converted to the speed per second (rps), which may be shorter per hour if necessary, and then 1 per second is applied. Calculate the distance to the target position that the transfer motor should move for a second and move the feed motor a little by intermittent control output so that the feed motor can reach the target position after 1 second has elapsed. By repeatedly performing the method of stopping when positioned at the position, the result is the same as that of adopting a feed motor which is continuously driven by the above-described high rate reducer by controlling the driving period.

For continuous growth welding, spiral welding growth is controlled by adjusting the rotational speed (VT) and the rotational speed (VF) of the feed motor so that Equations 1 and 2 are satisfied according to the position (r) of the torch on the center line. can do. In order to weld the beads precisely to the shape of the circle, it is necessary to update the rotational speed (VT) and the rotational speed (VF) of the feed motor depending on the position (r) of the torch at least once a second.

An example in which control is performed by updating the rotating plate rotation speed VT and the rotational speed VF of the feed motor once per second will be described according to the control algorithm of the present invention.

As shown in Equations 1 and 2, the rotational speed (VT) of the rotating plate and the feed rate of the torch, that is, the rotational speed (VF) of the feed motor, are expressed in rpm, that is, revolutions per minute. When calculating in units of 1 second, apply 60 divided for each to convert the rotational speed (VT) and the rotational speed (VF) of the feed motor to the speed per second.

In the following, the process of operating the control device will be described in detail, for example, when the base material on the rotating plate is zeroed and then the welding operation is started from the outermost side of the base material to the inside.

When welding starts, first measure the current torch position (r) by position sensor.

Equations 1 and 2 calculate the rotational speed (VT) and the rotational speed (VF) of the transfer motor, and control the rotational speed of the rotational plate and the transfer motor by the CPU control program. The position is calculated and elapsed for 1 second.
Initially, the difference in the distance of the torch, which varies from one second to the outside of the base material, is very small in micrometers. Instead, it accumulates the distance to be moved every second and instead controls to send control output for torch transfer to the feed motor when the accumulated distance is at or above the set point (eg 0.1 mm) set to change the position of the torch. In response, the position detection sensor detects the distance as much as the displacement, and if the displacement amount does not reach the target position for the rotational speed update of the feed motor, the control operation is repeated until the target position is reached. Run
When the torch reaches the target position, a control signal for controlling the rotation speed of the feed motor is output.

The rotational speed (VT) of the rotating plate is minute but is calculated every second according to the changing position (r) of the torch and used as the digital data of the DA converter. As a result, the analog voltage of the DA converter is updated so that the frequency of the inverter is updated every second. .

By performing continuous growth welding in this way, a good continuous growth welding without any seam can be achieved.

According to the present invention configured as described above, it is possible to continuously weld welding, so that a weld welding product of very good quality can be obtained without any seams, and the height of the beads is constant so that post-processing work is unnecessary or much reduced, thereby improving productivity. In addition, the automatic continuous fusing welding can be replaced by a simple worker instead of a high-function welder, and the effect of reducing relative labor costs is enormous.

Claims (6)

In the welding method of the automatic breeding welding machine comprising a rotary motor for driving the rotating plate on which the base material is located, and a transfer motor for transferring the torch through the transfer means, After zeroing the base material on the rotating plate, measure the position of the torch (r) by starting welding from the outermost or center of the base material, and then

Find the rotating plate rotation speed (VT) by

According to the rotational speed (VF) of the transfer motor to obtain a motion control signal to operate the rotation motor and the transfer motor at the speed obtained, where P is the pitch interval of the beads (mm), S is the welding speed (mm / min Automatic continuous breeding welding method characterized in that the spiral welding is made to the center of the base material. The method of claim 1, wherein the rotational speed of the rotary motor and the transfer motor is updated at least once per second. The rotation speed update of the feed motor is not changed when the displacement of the torch is too small for the rotation speed update time, and the accumulated distance is accumulated by accumulating the displacement of the torch generated during the rotation speed update time. The control output for driving the feed motor is intermittently controlled when the set value is higher than the set value for the control.The feed motor is intermittently controlled, and it repeats until the accumulated torch displacement becomes the target position for updating the rotational speed of the feed motor. Automatic continuous growth welding method, characterized in that for updating the rotational speed of the feed motor. delete delete delete

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