KR20010010573A - An artificial intelligence type automatic welder - Google Patents

Abstract

PURPOSE: An automatic artificial intellectual welder is provided to standardize a welding quality and to improve the quality by optimally performing a welding work with only the input of regulated logic data. CONSTITUTION: An inverter power supply unit(120) converts the input power of alternating current to the output power of direct low voltage electrifying current to output a stable arc in a large band. A PWM(pulse width modulation) control unit(130) generates a pulse wave by comparing a saw tooth wave with an error of voltage generated from the inverter power supply unit. The PWM control unit controls the inverter power supply unit to output a regular output current by equalizing the pulse wave to a predetermined reference voltage. A memory(140) makes various welding parameters logic data and memorizes the data. A switch manipulation unit(150) selects the logic data of the various welding parameters. A main controller unit(160) controls to output the optimum welding voltage and current by operating the logic data. A use power conversion unit(170) converts power from the inverter power supply unit to use power and supplies the use power to the PWM control and main controller units.

Description

AI type automatic welding machine {AN ARTIFICIAL INTELLIGENCE TYPE AUTOMATIC WELDER}

The present invention relates to an intelligent automatic welding machine, and more specifically, to classify parameters by welding material, welding posture, and welding site by situation, measuring and collecting welding data through actual experiments, and then converting the logic data into a memory. Even if the user changes, it is related to an intelligent automatic welding machine which can greatly improve the welding quality by allowing the best welding to be performed only by inputting some prescribed logic data such as welding material, welding posture, and welding part.

In general, welding refers to metallurgical bonding through heating or pressurization such that atomic bonding between two kinds of solid materials of the same or different types is used. Examples include arc welding, resistance welding, and laser welding. There is this.

At this time, arc welding is a welding method using arc heat generated by arc discharge, and after melting the surface of the base material and the welding part by using the heat obtained by generating an arc between the base material to be welded and the welding torch, The metal of the welding torch is melted again and welded together, and a carbon electrode or a tungsten electrode may be used instead of the welding torch.

In addition, resistance welding refers to a method of heating a joint in a molten state by using heat generated by contact resistance generated when a very large current is sent to the weld, and then welding by welding under physical pressure. It is sometimes divided into resistance welding and butt resistance welding.

In addition, laser welding is a method of welding using a strong energy beam generated by induced radiation between energy levels of atoms or molecules. Laser beam is a concentrated heat source of high energy density. Because of its strong thermal effect on the material and low thermal deformation, it is used for precise welding and cutting, and it is easy to operate because it can work in the atmosphere and can easily guide the beam away from the laser generator. .

On the other hand, the arc welding is roughly divided into an inert gas arc welding and carbon dioxide (CO ₂ ) arc welding, etc. Among these, the inert gas arc welding is a TIG (TIG) welding using a tungsten electrode again (inert-) It is divided into gas tungsten arc welding and inert-gas metal arc welding, which uses filler metal as an electrode.

In this case, the TIG welding using the tungsten electrode does not use the flux (slag) is not generated slag (slag), and thus can be very advantageously applied to metals such as Al and Mg alloy.

In addition, since the TIG welding has no transition of molten metal from the tungsten electrode, there is no instability of the arc and no generation of spatters, and the workability is good and the reliability of welding quality is very high.

MIG welding is a DC reverse polarity and has the characteristic that stable metal migration of molten metal is possible only in the case of high current density. In order to avoid melting of the electrode by resistance heat, a large current must be used. The current must be introduced just before the arc. In addition, since MIG welding has a high current density and a current / voltage characteristic is a rising characteristic, a DC welding machine having a constant voltage characteristic or a rising characteristic suitable for the self-control action of the arc length has been widely put to practical use, thereby obtaining good results.

In the MIG welding, even though a relatively high current density is used in the DC positive polarity, the arc becomes unstable because the molten metal does not become small particles but rather forms a large volume at the electrode end and forms a strong wind of ions from the anode side of the base material. Sometimes a satisfactory weld cannot be achieved.

Therefore, MIG welding is suitable for DC reverse polarity. When the DC reverse polarity increases the current value and exceeds a certain critical current value, the volume becomes microparticles and is sprayed at high speed by plasma airflow so that the spray type transition shape is obtained. In this case, the arc can be very stable and have a strong directivity, so that deep penetration can be obtained, and the welding of all postures is possible.

In addition, in the case of MIG welding, the melting speed of the electrode wire is high at high current density, the voltage and current characteristics of the arc are rising characteristics, and the constant voltage power is used. Therefore, the melting speed itself does not need to be increased or decreased using the automatic control device. It is controlled so that the arc length is always kept constant. In other words, the self-control action of the arc length is characterized by the self-control function by the load characteristic (high current density) and the self-control function by the power supply characteristic (constant voltage power supply). This will be possible.

On the other hand, carbon dioxide arc welding refers to welding collectively known as a shield-type arc welding using carbon dioxide (CO ₂ ) or a mixed gas mainly containing carbon dioxide as a shield gas.

MIG welding using Inner Gas as described above is mainly used for welding non-ferrous metals or alloy steels, including light metals, which are difficult to install for economic reasons, but CO2 arc welding is used for MIG welding using expensive Inert Gas. Differently, since it uses relatively inexpensive carbon dioxide, it is possible to realize welding of a high availability steel structure while maintaining high efficiency of MIG welding.

In the carbon dioxide gas welding, the use of carbon dioxide (CO ₂ ) in the shield gas is different from that of the MIG welding, and in addition, it requires a deoxidizer.

The need for deoxidizer is that the shield gas CO ₂ is at the high temperature of the arc,

This is because dissociation such as 2CO → 2CO + O ₂ generates O ₂ to generate an oxidizing atmosphere. As a result, oxidation of the molten steel occurs,

2Fe + O ₂ → 2FeO

The iron oxide FeO produced as FeO + C → Fe + CO is immediately combined with C in the steel to generate a large amount of CO gas in the molten steel to become solidified and porous including the pores of the weld metal.

As the deoxidizer, one containing an appropriate amount of deoxidizing elements such as Mn, Si or Al, Ti is used, but by addition of these deoxidizers,

FeO + Mm → Fe + MnO, 2FeO + Si → 2Fe + SiO 2 such as deoxidation result deoxidation products of MnO, SiO _2, etc. of the reaction are to be removed as slag floated.

Carbon dioxide arc welding is roughly classified into two types by the supply method of the deoxidizer, the SOLID WIRE method and the FLUX WIRE method.

Therefore, the present applicant intends to explain in detail, while proposing an AI type automatic welding machine using a microprocessor based on the general welding technique as described above.

The present invention has been made through the above-described proposal, and its purpose is to classify the parameters of various welding conditions according to the situation, measure and collect data through actual welding, and then make logic data and input them into a memory. Programmable AI welding machine which can make the best welding by inputting only a few specified logic data such as welding material, welding posture, welding part, and so on, and get great effect on standardization and quality improvement of welding quality. In providing.

1 is a schematic diagram for explaining the intelligent automatic welding machine according to the present invention.

Figure 2 is a block diagram including a specific circuit showing the intelligent automatic welding machine according to the present invention.

3 is a block diagram showing an inverter power supply unit applied to an artificial intelligence welding machine according to the present invention.

Figure 4 is a circuit diagram and waveform diagram for explaining the input rectifier of the inverter power supply unit applied to the intelligent automatic welding machine according to the present invention.

5 is a circuit diagram for explaining a conversion method of an inverter power supply unit applied to an artificial intelligence welding machine according to the present invention.

Figure 6 is a waveform diagram showing the switching operation of the IGBT element that is the configuration of the inverter power supply unit applied to the intelligent automatic welding machine according to the present invention.

7 is a structural diagram showing a transformer of an artificial intelligence welding machine applied to the artificial intelligence welding machine according to the present invention.

8 is an explanatory diagram for explaining a PWM control unit applied to an artificial intelligence welding machine according to the present invention.

Figure 9 is a front view showing a switch operation unit applied to the artificial intelligence automatic welding machine according to the present invention.

10 is a main mode time chart for explaining a state switched to the main mode by the operation of the main / creta / hold mode selection switch applied to the intelligent automatic welding machine according to the present invention.

Figure 11 is a Crete mode time chart for explaining the state switched to Crete mode by the operation of the main / Creta / hold mode selection switch applied to the intelligent automatic welding machine according to the present invention.

12 is a hold mode time chart for explaining a state that is switched to the hold mode by the operation of the main / Creta / hold mode selection switch applied to the intelligent automatic welding machine according to the present invention.

Figure 13a is a waveform diagram showing the welding execution according to the change in the welding current for explaining the process of the database of the welding conditions to be applied to the intelligent automatic welding machine according to the present invention.

Figure 13b is a waveform diagram showing the welding execution according to the welding current changes for explaining the process of the database of the welding conditions to be applied to the intelligent automatic welding machine according to the present invention.

Figure 13c is a waveform diagram showing the welding execution according to the welding current changes for explaining the process of the database of the welding conditions to be applied to the intelligent automatic welding machine according to the present invention.

Figure 14a is a waveform diagram showing the welding execution according to the welding voltage change for explaining the process of the database of the welding conditions to be applied to the intelligent automatic welding machine according to the present invention.

Figure 14b is a waveform diagram showing the welding execution according to the welding voltage change for explaining the process of the database of the welding conditions to be applied to the intelligent automatic welding machine according to the present invention.

Figure 14c is a waveform diagram showing the welding execution according to the welding voltage change for explaining the process of the database of the welding conditions to be applied to the intelligent automatic welding machine according to the present invention.

Explanation of symbols on the main parts of the drawings

10: gas cylinder 20: wire feeder

21: electrode wire 22: remote welding current volume

23: remote welding voltage volume 30: welding gun

31 gas nozzle 32 torch switch

40: base material 100: artificial intelligence automatic welding machine

110: input filter unit 120: inverter power supply unit

121: input rectifier 122: inverter

123: transformer 124: output rectifier

125 reactor 130 PWM control unit

140: memory 150: switch control panel

151: AUTO MODE selector switch

151a: LED 151b: Display

152a: METAL selector switch 152b: gas selector switch

152c: wire thickness selection switch 152d: welding position selection switch

152e: pulse / mig switch 153a: main welding voltage volume

153b: Main welding current volume 154: Preset switch

155a: Crete welding voltage volume 155b: Crete welding current volume

156: local / remote control selector switch 157: main / creta / hold mode selector switch

158: channel select switch 159: save switch

160: main controller unit 170: use power conversion unit

180: torch filter unit 190: microcomputer board

The present invention for achieving the above object is provided with a remote welding current volume for changing the supply speed of at least the motor supplying the electrode wire and a remote welding voltage volume for varying the welding voltage and the wire connected to the welding gun is installed torch switch An artificial intelligence automatic welding machine for implementing precise welding through the feeder; An inverter power supply unit for smoothly converting an AC input power input from the outside into a DC low voltage high current output power so as to output a stable arc over a wide range from low current to high current; PWM (Pulse) for controlling the inverter power supply to output a uniform output current by generating a pulse wave by comparing the error of the voltage generated from the inverter power supply to a saw tooth wave and matching to a reference voltage already set Width Modulation) control unit; A memory for logically storing and storing various welding parameters such as types of welding materials to be welded, types of gases used, welding postures, types of electrode wires, and the like; A switch operation unit for selecting and selecting logic data of various welding parameters stored in the memory; A main controller unit controlling the logic data of the welding parameters stored in the memory to output the optimum desired welding voltage and the desired welding current by selecting the switch operating unit; It is characterized in that the technical configuration consisting of a power supply converting unit for converting the power supplied from the inverter power supply unit to the power used to supply the PWM control unit and the main controller unit.

Hereinafter, a preferred embodiment of an artificial intelligence welding machine according to the present invention will be described with reference to FIGS. 1 and 2.

Figure 1 is a schematic diagram for explaining the intelligent automatic welding machine according to the present invention, Figure 2 is a block diagram including a specific circuit showing the intelligent automatic welding machine according to the present invention.

The artificial intelligence welding machine 100 according to the present invention, as shown in Figure 1 is a gas cylinder (CO ₂ (carbon dioxide) and a protective gas such as Ar (argon), Ar + CO ₂ , Ar + O ₂ (oxygen) 10 is used to precisely weld the base metal 40 such as aluminum, stainless steel, and iron while supplying the electrode wire 21 through the wire feeder 20.

That is, as shown in FIG. 1, after the welding gun 30 approaches the welding portion of the base material 40, the torch switch 32 is pressed to protect the gas filled in the gas cylinder 10 from the gas of the welding gun 30. The electrode wire 21 of the wire feeder 20 is adjacent to the base material 40 by low voltage and high current through the intelligent type automatic welding machine 100 of the present invention so as to be ejected through the nozzle 31. By generating the melting of the electrode wire 21 by the arc to implement a precision welding.

At this time, the wire feeder 20 has a motor for changing the feeding speed of the electrode wire 21 therein, the feeding speed of the motor is changed by the welding current controlled by the remote welding current volume 22. do. Of course, the wire feeder 20 has a remote welding voltage volume 23 for remotely controlling the welding voltage.

As shown in FIG. 2, the intelligent automatic welding machine 100 according to the present invention filters the input power of AC input from the outside through the input filter unit 110, and then stabilizes the arc in a wide band from low current to high current. An inverter power supply unit 120 for smoothly converting the output power of the direct current with the low voltage and the high current so as to output the power; The inverter power supply unit 120 generates a pulse wave by comparing the error of the voltage generated from the inverter power supply unit 120 with a saw tooth wave, and then outputs a uniform output current by matching the preset reference voltage. PWM (Pulse Width Modulation) control unit 130 for controlling the; A memory 140 for logically storing and storing various welding parameters such as types of welding materials to be welded, types of gases used, types of welding postures, types of electrode wires 21, and the like; A switch operation unit 150 for selecting and selecting logic data of various welding parameters stored in the memory 140; The main controller unit 160 controls the logic data of the welding parameters stored in the memory 140 to be outputted at an optimum desired welding voltage and desired welding current by selecting the switch operating unit 150. ; A use power converting unit 170 converting the power supplied from the inverter power supply unit 120 into use power and supplying the power to the PWM control unit 130 and the main controller unit 160; Torch for filtering the variable welding current and the welding voltage control signal by the operation of the remote welding current volume 22 and the remote welding voltage volume 23 of the wire feeder 20 to supply to the main controller 160. It is made of a filter unit 180.

At this time, the inverter power supply unit 120 for smoothly converting the input power of the AC filtered through the input filter unit 110 to the output power of the low voltage large current of direct current so as to output a stable arc in a wide range from low current to high current As shown in the schematic circuit diagram of FIG. 2 and the block diagram of FIG. 3, an input rectifying unit 121 for converting an AC input power into a DC input power and a DC of a DC converted through the input rectifying unit 121 are shown. An inverter 122 that converts an input power source into a high frequency of 40 mA through an Insulated Gate Bipolar Transistor (IGBT) element, and converts a high frequency of 40 mA AC converted through the inverter 122 into a low voltage high current power source of AC. A transformer 123 to output the low voltage large current power of the alternating current converted through the transformer 123 into a low voltage large current power supply of the direct current Smoothing the rectifier 124 and the power of the direct current low voltage large current converted through the output rectifier 124 to mitigate the impact of the inverter 122 due to the load fluctuation, and the output of the rectifier 124 and the transformer 123 Reactor 125 is made to lower the effective current.

Here, the input rectifier 121 for converting the input power of the AC filtered by the input filter unit 110 into the input power of the DC as shown in Figure 4 used a diode module as a converter (Converter). The rectifier diode module is a three-phase bridge diode, which is a combination of six diodes that rectify the three-phase power supply. The smoothing capacitor (Condensor & CAPACITOR) used at this time mainly uses an electrolytic capacitor.

This electrolytic capacitor can be thought of as a battery with polarity and capable of very small charge and discharge, and its function is to make an irregular alternating current into a direct current state. In addition, the input rectifying unit 121 performs a function of rectifying the commercial power of three-phase 220 [V] or 380 [V], 60 [Hz] to convert the DC power.

For example, when using 3-phase 220V as input AC power, the converted DC voltage is determined as follows.

At this time, the smoothing circuit uses a smoothing capacitor to smooth the current rippled by the diode into a ripple-free DC voltage as shown in the circuit diagram and the waveform diagram of FIG. 4.

The smoothing capacitor determines the capacitance by considering the current of the DC link, the allowable DC ripple rate, and the like. The device may be selected in consideration of the price and volume.

In addition, since the charge and discharge of the capacitor should be the same,

Becomes

here, Is the ripple voltage of DC link, Is the discharge time,

Becomes,

The capacitance of the smoothing capacitor

Is calculated.

In this way, a capacitor of about 2,000 [uF] is required when the ripple voltage is allowed to about 10 [V]. Therefore, as a preferred embodiment, the smoothing capacitor may use a 400 [V] capacitor of 2,200 [uF] in series.

In addition, an inverter 122 for converting the DC input power converted through the input rectifier 121 into a high frequency of AC 40 kW uses an IGBT element.

This Insulated Gate Bipolar Transistor (IGBT) device is a monolithic BI-MOS transistor that connects a PNP transistor and a MOSFET.

At this time, if the MOSFET is connected by applying a positive voltage between the gate and the emitter, the resistance is connected between the base and collector of the PNP transistor, and the PNP transistor portion becomes conductive.

In turn off operation, when the voltage between Gate-Emitter is set to 0 [V], the MOSFET is first cut off, and the PNP transistor is cut off because the BASE current is cut off.

As described above, the IGBT can control the ON / OFF state only by the voltage signal of the gate like the power MOSFET, which can be very usefully applied to the present invention.

Meanwhile, the DC voltage converted by the input rectifier 121 becomes the supply voltage of the inverter 122. If the DC voltage is 311 [V], the voltage rating of the IGBT element is about 600 [V] in consideration of the safety factor. Capacity is sufficient.

In addition, the rated current of the switching element used for the inverter 122 is determined to have a sufficient margin as follows.

Rated Current = Load Capacity ÷ Efficiency ÷ AC Voltage ÷ × X overload rate ripple rate

= Idc × overload rate × ripple rate [A]

Inverter 122 converts the alternating current by switching the DC power supply through the input rectifier 121 to the IGBT element to convert to the desired frequency.

That is, the switching method using the IGBT applies a full bridge method, which is mainly used in a large power circuit. The principle of conversion to fast pulse power is as shown in FIGS. 5 and 6.

5 is a circuit diagram illustrating a conversion method of the inverter 122 of the inverter power supply unit 120 applied to the intelligent automatic welding machine 100 according to the present invention, and FIG. 6 is an artificial automatic welding machine 100 according to the present invention. Is a waveform diagram showing the switching operation of the IGBT, which constitutes the inverter power supply unit 120 applied to the < RTI ID = 0.0 >

I1 shown in FIG. 5 is the turn-on time of the first to fourth transistors TR1 to TR4, and V1 is the output voltage of the transformer primary side.

By adjusting the turn-on time of each of the transistors TR1 to TR4, the magnitude of the output voltage can be changed as shown in FIGS. 5 and 6, and this is the PWM (PULSE WIDTH MODULATION) method. Through this, the desired frequency, i.e., 40 kHz, can be converted.

The transformer 123 for converting the high frequency of the alternating current 40 kW through the inverter 122 into a power source of a low voltage large current plays a decisive role in which the intelligent automatic welding machine 100 of the present invention can be miniaturized and reduced in weight.

The transformer 123 changes the AC voltage and the current value by using an electron induction action, and thus, a desired welding current can be obtained by adjusting the transformer ratio between the primary and secondary.

This transformer 123 is composed of an iron core and primary and secondary windings for efficiently passing the magnet as shown in FIG. Here, an important factor for determining the weight of the transformer 123 is the cross-sectional area of the transformer 123.

E: 1CK voltage F: Frequency N: Number of turns

Bm: Magnetic flux density S: Iron core area

In addition, since the difference between the iron core for 60 Hz and 50,000 Hz applied to the inverter 122 is 833 times larger than the frequency f, it can be seen that as f increases in the above formula, the cross sectional area is inversely proportional to 833 times smaller.

In addition, the ferrite core applied to the inverter 122 has a large magnetic flux density (Bm), which is a factor to reduce the cross-sectional area (S), compared to the general core core, but the number of turns N can be reduced. Will be minimized.

On the other hand, the main controller unit 160 for controlling to output the desired desired welding voltage and the desired welding current by arithmetic processing the logic data of the welding parameters stored in the memory 140 by the selection of the switch operation unit 150 ) Receives the welding condition by the operation of the switch control unit 150 and loads a value corresponding to the input setting from each welding data set in the memory 140 in advance to set the voltage and current references. By outputting A, the entire system can be controlled.

The inverter power supply unit 120 supplies a uniform output current by generating a pulse wave by comparing the error of the voltage generated from the inverter power supply unit 120 to a saw tooth wave, and then matching the preset reference voltage. PWM (Pulse Width Modulation) control unit to control the function to provide a uniform output current by applying the principle of the pulse width modulation basically.

The PWM controller 130 is a comparator (not shown) for generating a pulse by comparing a sawtooth wave and an error voltage detected through an error amplifier (not shown) that specifically detects and amplifies an error of a current. ), And a driving circuit (not shown) for driving the switch of the DC-DC converter.

In this case, only the portion of the potential higher than the sawtooth wave is output at the cross section compared with the sawtooth wave according to the detected error voltage potential, so that the output of the pulse can be adjusted to match the reference voltage of the desired error amplifier. will be.

At this time, the principle of determining the amount of power according to the pulse width is as shown in FIG. 8 is an explanatory diagram for explaining the PWM control unit 130 applied to the intelligent automatic welding machine 100 according to the present invention.

In addition, the output rectifying unit 124 for converting the low voltage high current power converted through the transformer 123 into a low voltage high current power of DC uses a high speed diode differently from the diode used in the input rectifying unit 121.

This high speed diode uses ULTLA FAST RECOVERY or Schottky Barrier DIODE, among which FAST RECOVERY DIODE has high breakdown voltage, which is more suitable for the AI type automatic welding machine 100 of the present invention than Schottky Barrier Diode used for low breakdown voltage. Suitable.

For example, a diode of 30,000Hz to 40,000Hz does not have any problem when it is turned ON in the forward direction, but a short-circuit current is generated when the TURM OFF turns off, which causes noise and decreases efficiency. It can be seen that a high speed diode is suitable because the shorter the TRR, the smaller the amount of short circuit current can be generated.

In addition, by smoothing the power of the low voltage high current of the DC converted through the output rectifier 124 to mitigate the impact of the inverter 122 due to the load fluctuations and lower the effective current of the output rectifier 124 and the transformer 123 Unlike the input rectifier 121, the reactor 125 uses a reactor 125 for a large current without using a capacitor as a smoothing circuit.

The basic principle of the reactor 125 for a large current simply serves to hinder the flow of alternating current and alternating the flow of alternating current, and may also mitigate the impact of the inverter 122 due to load fluctuations in addition to the purpose of smoothing and transforming the transformer 123. And it also serves to lower the effective current of the output rectifier 124.

Since this action is a major factor in determining the characteristics of the load, the large current reactor 125 is suitable for the inverter power supply unit 120 applied to the intelligent automatic welding machine 100 of the present invention.

On the other hand, various memory parameters such as the type of additional upgraded welding material, the type of welding gas, the welding posture, the type of the electrode wire 21, etc., which are logic data stored in an external PC, can be downloaded to the memory 140. The microcomputer board 190 is interface-coupled to the main controller unit 160.

The microcomputer board 190 is interfaced with the microprocessor of the main controller unit 160 to exchange commands with each other, many experiments in advance to realize a high-quality welding through the intelligent automatic welding machine 100 of the present invention After welding, each welding condition is measured, and all the welding data already set are measured, and the data are collected, statistics, error correction, etc., stored in an external PC for a while, ready for download at any time. It is also called a fuzzy microcomputer board 190 because the condition can be converted into a database and exchanged with an external PC.

And, even if the operator is not skilled in welding operation, the switch operation unit 150 is logic data in the memory 140 through the main controller unit 160 by simple switch operation, and stored in the welding material, welding material series, gas It is installed on the front of the intelligent automatic welding machine 100 shown in Figure 1 to realize the optimum welding very simple yet precisely by reading the type, the wire thickness and the like to output a value that meets the conditions, The structure is as shown in FIG.

9 is a front view showing a switch operation unit applied to an artificial intelligence welding machine according to the present invention.

A reference numeral 151 shown in FIG. 9 denotes an auto mode selection switch, and when it is set to auto mode by one touch, the welding material and the welding gas which are already set in the memory 140 through the main controller unit 160. The value of the logic data according to the welding state of the welding wire, etc. is outputted, and if it is set as the manual mode by touching it again, the value of the welding state of the welding material, welding gas, welding wire, etc. input by the user directly It performs the function of converting the output.

That is, when the auto mode selector switch 151 is set to the auto mode, the output value is read from the logic data set in the memory 140 according to the welding material such as the material of the welding material, the welding gas, and the welding wire. When touched and pressed, the LED 151a flashes and is converted into a manual mode so that an operator can directly input welding conditions.

Reference numeral 151b is used as a display unit to display a data value by selection of the switch operation unit 150 to the operator, and reference numeral 152a is a metal (METAL) selector switch, and the auto mode selection switch 151 enters into auto mode. When converted, the main controller unit selects FE material, AL material selection, and SUS (STAINLESS) material selection of the welding material that is already stored in the memory 140 through the main controller unit 160 at each touch. The processor 160 sequentially processes the output data of the logic data stored in the memory 140, and converts the welding material into the FE material and the AL when the auto mode selection switch 151 is converted to the manual mode. It performs the function to output the value selected by the user by material, SUS material, etc.

On the other hand, the material of the welding material can be largely divided into FE (iron), AL (aluminum), SUS (stainless steel). Of these, FE has no series, and AL is divided into five stages ranging from 1,000 to 5,000. And, SUS can be set by dividing the series from 200 to 400.

Reference numeral 152b denotes a gas selection switch, in which the welding is already stored in the memory 140 through the main controller unit 160 every time a touch is made when the auto mode selection switch 151 is converted to the auto mode. The main controller 160 sequentially processes the type of gas in order of CO ₂ and Ar, Ar + CO ₂ , and Ar + O ₂ to output the logic data stored in the memory 140. When the manual mode is converted by the operation of the auto mode selector switch 151, the user selects the welding gas type as CO ₂ , Ar, Ar + CO ₂ , Ar + O _2, or the like. do.

At this time, the welding gas can be classified into four types, such as CO ₂ and Ar, Ar + CO ₂ , Ar + O ₂ , and if the material of the double welding material is FE, two kinds of CO ₂ and Ar + CO ₂ When the material of the welding material is AL, one type of Ar may be selected, and when the material of the welding material is SUS, one type of Ar + O ₂ may be selected.

Of course, it is possible to replace the gas cylinder 10 is filled with the respective CO ₂ and Ar, Ar + CO ₂ , Ar + O ₂ and the like depending on the welding conditions.

Reference numeral 152c denotes a wire thickness selection switch, which is already stored in the memory 140 through the main controller unit 160 every time a touch is made when the auto mode selection switch 151 is converted to the auto mode. The main controller unit 160 sequentially processes the diameters of the electrode wires 21 in a selection order of 0.8, 1.0, and 1.2Φ, and converts them into manual mode by operating the auto mode selection switch 151. When the diameter of the electrode wire 21 is 0.8 and 1.0, 1.2Φ and so on to perform a function to output a value selected directly by the user.

Reference numeral 152d denotes a welding position selection switch, which is already stored in the memory 140 through the main controller unit 160 every time a touch is made when the auto mode selection switch 151 is converted to the auto mode. The main controller unit 160 sequentially processes the welding posture in a selection order of vertical and horizontal, and outputs the welding posture by the user directly and vertically and horizontally when the welding posture is converted to the manual mode by the operation of the auto mode switch. A function of allowing input, 152e is a pulse / MIG selection switch for selecting the presence or absence of a pulse.

Reference numerals 153a and 153b denote a main welding voltage volume and a main welding current volume for setting a main welding voltage and a main welding current, respectively, and reference numeral 154 denotes the main welding before performing welding as a PRESET switch. By controlling the voltage volume 153a and the main welding current volume 153b, a function of setting the initial discharging voltage and the motor speed can be set in advance. In other words, the worker has this landscape ?? The main welding voltage and the motor speed can be set in advance by using the switch 154. While pressing the switch 154 first, the main welding voltage volume 153a and the main welding current volume 153b are turned to set the setting values.

Reference numerals 155a and 155b denote a crete welding voltage volume and a crete welding current volume, respectively, for controlling a Creter welding voltage and a Crete welding current, and reference numeral 156 denotes a local / remote control selection switch. When the main welding voltage volume 153a, the main welding current volume 153b, the crete welding voltage volume 155a, and the crete welding current volume 155b are adjusted, and set to the remote mode, the wire feeder ( 20 to adjust the remote welding voltage volume 23 and the remote welding current volume (22).

Reference numeral 157 denotes a main / creta / hold mode selection switch. When the local / remote control selection switch 156 is in the local mode, the welding voltage is controlled by the main welding voltage volume 153a and the local / When the remote control selector switch 156 is in the remote mode, the main mode for controlling the welding voltage by the remote welding voltage volume 23 of the wire feeder 20, and the torch switch 32 of the welding gun 30. ) Is first turned on so that the welding voltage is adjusted according to the welding voltage volume of the main welding voltage volume 153a or the wire feeder 20, and when the second turning on, the welding voltage is adjusted by the crete welding voltage volume 155a. Crete mode to be adjusted, and when the torch switch 32 of the welding gun 30 is turned on for the first time, welding starts and only the welding voltage is changed according to the main welding voltage volume 153a. It performs the function of each switch in the switch hold (HOLD) mode in which to control.

Figure 10 is a main mode time chart for explaining the state switched to the main mode by the operation of the main / Creta / hold mode selection switch applied to the intelligent automatic welding machine according to the present invention, Figure 11 is an artificial intelligence according to the present invention Creta mode time chart for explaining the state that is switched to Crete mode by the operation of the main / Creta / hold mode selection switch applied to the automatic welding machine, Figure 12 is the main / creta / hold applied to the intelligent automatic welding machine according to the present invention A hold mode time chart for explaining a state in which the mode selection switch has been switched to the hold mode.

For example, when the torch switch 32 of the welding gun 30 is turned on after being switched to the main mode by the operation of the main / creta / hold mode selection switch 157, as shown in FIG. 11. Likewise, the welding voltage is output. At this time, the welding voltage is controlled by the operation of the local / remote control selection switch 156, and the welding voltage is adjusted by the main welding voltage volume 153a, and the operation of the local / remote control selection switch 156 is controlled. By the remote mode, the welding voltage is adjusted by the remote welding voltage volume 23 of the wire feeder 20.

In addition, the main welding voltage volume 153a when the torch switch 32 of the welding gun 30 is first turned on after being switched to the Creta mode by the operation of the main / creta / hold mode selection switch 157. Or the welding voltage is controlled by the remote welding voltage volume 23 of the wire feeder 20, and when the torch switch 32 is turned off, the welding voltage is the same as when the torch switch 32 is first turned on. Adjustment is made. Thereafter, when the torch switch 32 of the second welding gun 30 is turned on, the welding voltage is adjusted by the crete welding voltage volume 155a. At this time, when the sequence (SEQUENCE) is operating, it is possible only when the current signal (when welding) is on, and the creter mode time chart is shown in FIG.

In addition, when the mode is switched to the hold mode by the operation of the main / creta / hold mode selector switch 157, welding is started when the first torch switch 32 of the welding gun 30 is turned on. The welding voltage is regulated only by the main welding voltage volume 153a. That is, it can be seen that it operates according to the sequence shown in FIG. 12 and operates only when there is an ON signal of current.

Reference numeral 158 denotes a channel selection switch, which is operated by the metal selection switch 152a, the gas selection switch 152b, the wire thickness selection switch 152c, and the welding position selection switch 152d according to the welding state and the welding condition. A function of up-selecting each channel so as to store the selected logic data in the memory 140 for each channel, and reference numeral 159 is a save switch, wherein the metal selection switch 152a according to a welding state and a welding condition is used. And storing logic data by operation of the gas selection switch 152b, the wire thickness selection switch 152c, and the welding position selection switch 152d in the desired channel selected by the channel selection switch 158, respectively. .

On the other hand, the variable welding current and welding voltage control signal by the operation of the remote welding current volume 22 and the remote welding voltage volume 23 of the wire feeder 20 is filtered through the torch filter unit 180 to control the main controller. It is preferable to be supplied to the unit 160.

In addition, the AI type automatic welding machine 100 according to the present invention has three types, a main mode, a creter mode, and a hold mode. In the present invention, a sequence by a conventional analog circuit is digitalized as much as possible in the present invention. It is.

Therefore, welding is performed by the operation of the torch switch 32. When the torch switch 32 is turned on, the main controller unit 160 outputs an output voltage reference to the PWM controller 130, and the variable of the output voltage is switched. The control unit 150 or the wire feeder 20 may be changed according to the volume, and the output speed of the electrode wire 21 is changed according to the welding current.

As a result, the conventional welding machine does not have constant data on the material or thickness of the weld, the material or the thickness of the weld, which is a welding parameter value, and according to the skill or taste of the welder, the welding condition is arbitrarily selected. Due to the absolute dependence on the function of the welder, and in addition, many problems occurred in the standardization and quality improvement of the welding quality of the intelligent automatic welding machine 100 according to the present invention according to the welding parameters for each welding material, posture, site After classifying, measuring and collecting data through actual welding, logic data is inputted into the memory 140, and even if the user changes, it is best to input only some prescribed logic data such as welding material, welding posture, and welding part. We can perform welding and learn new condition by user learning welding condition. Possible to force to it can be seen that excellent programmable welder.

Here, the welding transition analysis for the database of welding parameters will be described separately.

GMA (Gas Metal Arc) welding method is a welding method using a protective gas, and it is well known that various welding methods have been developed and used according to the type of protective gas.

And it can be largely classified as MAG (Metal Active Gas) MIG ( Metal Inert Gas) using only welding and pure Ar welding using a gas mixture of CO ₂ welding, Ar and CO ₂ using a CO ₂ gas welding.

The present invention aims to build a foundation for the development of high efficiency GMA welding technology by evaluating the welding conditions, protective gases, etc., which dominately affect the GMA volumetric performance, from the viewpoint of volumetric performance, that is, arc stability.

In GMA welding, the welding current is important in determining the volumetric loading mode, that is, the volumetric loading mode is divided according to the strength of the welding current. The welding current is divided into low current, medium current, and high current regions.

FIG. 13A shows the displacement effect of 120 A as an example of low current for CO ₂ welding.

The volume migration phenomenon can be observed as an instantaneous change in the arc voltage, where the volume migration form is typical of the short circuit implementation where the process of volume migration is clearly divided into arcing time and short time. This type of transition tends to be stabilized in a section of about 200 A or less, and the degree of stabilization is largely controlled by welding voltage, welding power supply, and protection gas.

FIG. 13C shows an example of volumetric displacement in the high current region at 320 A. FIG. This type of welding performance shows a different volume migration phenomenon than the above-mentioned low current region, and the change of arc voltage with welding time shows a certain periodicity. It can be seen that the typical globular performance is shown.

On the other hand, in the medium current region, the welding transition phenomenon coexists in the transition region in which the displacement of the low current region changes from the displacement of the large current region. 13B shows the case of CO ₂ welding as an example of the medium current region.

At this time, the welding execution according to the welding current is short-circuit form (SC; Short circuit shown in Figure 13a, 13b), globular transition form (figure 13c) and instantaneous short-circuit phenomenon (ISC (Instantaneuos short circuit shown in Figure 13b)) It can be seen that they appear in a mixed state.

In particular, the short-circuit phenomenon occurs as a momentary short-circuit of about 1msec, and the arcing state is again caused by the strong electromagnetic force generated by this short-circuit, which does not involve the volumetric phenomena seen in the normal short-circuit process. Accompanied by unstable behavior, this results in unstable arcing that inhibits arc stability and promotes spatter.

As such, the strength of the welding current is an important factor in determining the shape of the displacement because it affects the size of the molten droplets formed at the end of the welding wire and affects the electromagnetic force acting on the volume. It is necessary to make a database after experimenting with.

In addition, the influence of the welding voltage is as follows.

The welding voltage is directly related to the arc length, and the welding voltage V is expressed as follows.

V = k L

Where V: Welding voltage, k: Potential gradient, L: Arc Length

As k is determined by the type of the protective gas, it can be seen that the welding voltage is determined by the arc length under the same protective gas condition. That is, the arc length is changed when the welding voltage is changed.

This change in arc length greatly affects the displacement behavior.

FIG. 14A illustrates an example of observing a change in displacement phenomenon due to a change in arc voltage by changing a welding voltage from 18 V to 26 V in 120 A, which is a low current welding condition during CO ₂ welding.

Although the volumetric displacement pattern shows a typical short-circuit transition shape regardless of the welding voltage change, it can be seen that the arcing time and the short-circuit time that constitute the volumetric transition vary greatly with the welding voltage. In other words, the arcing time gradually increases with the increase of the welding voltage, which causes the dropping frequency to decrease significantly.

As the welding voltage increases, the dropping frequency decreases because the arc length increases. In other words, as the arc length increases, the arcing time becomes longer, and the frequency of dropping decreases, thereby increasing the size of the transferred volume. In addition, when the volume of the volume involved increases, there is a possibility that the spatter generated in the transition process becomes conflicted.

FIG. 14C shows the displacement phenomenon by measuring the arc voltage for each of the welding voltages changed from 32V to 40V under a large current welding condition of 320A. In the case of high current welding conditions, the short-circuit phenomenon (arrow F) occurs frequently when the welding voltage is low, such as 32 V, and it is difficult to evaluate the clear transition phenomenon and the arc is unstable. On the other hand, when the welding voltage is increased to 36V or more, the short-circuit phenomenon is remarkably reduced, and the periodicity of the arc voltage becomes clear, so that the stable globular transition state can be realized. Therefore, in a high current welding condition in which welding is performed by globular transition, rather high welding voltage is required for arc stabilization.

On the other hand, 250A welding condition, which belongs to the transition region, occurs mainly when the welding voltage is low, such as 24V, when the welding voltage is low, the short-circuit phenomenon and the short-circuit transition phenomenon appear mainly.When the welding voltage increases above 30V, the short-circuit and short circuit And it can be seen through Figure 14b that the globular transition phenomenon is complex.

In addition, although various other welding conditions of the present invention are not described, the artificial intelligence automatic method of the present invention is performed by databaseting the optimum welding conditions according to a number of experiments and results through various processes as described above. By applying to the welding machine 100, sometimes downloaded from the PC, sometimes used by the user directly to learn and input, sometimes through the simple selection of the switch operation unit 150 it is possible to implement a very precise and simple welding operation.

As described above, the AI type automatic welding machine 100 according to the present invention utilizes various welding conditions using a microprocessor of the main controller unit 160 as a database, thereby welding material and welding gas, welding thickness, welding posture, and welding part. With a simple input such as the shape, the thickness of the electrode wire 21, there is an excellent effect that can be realized quickly and precisely the optimum welding conditions that can realize high quality welding.

In addition, there is an effect that can improve the welding quality is excellent in arc safety in the broadband from low current to high current than the conventional welding machine without the BURN BACK phenomenon.

In addition, the inverter power supply unit 120 applied to the present invention can reduce the volume and weight by 1/3 or more than the conventional welding machine, there is almost no spatter, and high efficiency that can expect energy saving of 60% or more than the conventional welding machine. Welding work can be realized.

In addition, since the external PC and the microcomputer board 190 can be connected to each other, there is an excellent effect of frequently exchanging data whose welding conditions are upgraded.

Claims (5)

At least a welding gun 30 provided with a torch switch 32 and provided with a remote welding current volume 22 for changing the supply speed of the motor supplying the electrode wire 21 and a remote welding voltage volume 23 for varying the welding voltage. In the intelligent automatic welding machine 100 to implement a precise welding through the wire feeder 20 is connected to; An inverter power supply unit 120 for smoothly converting the input power of AC input from the outside into a low voltage high current output power of DC so as to output a stable arc in a wide band from low current to high current; The inverter power supply unit 120 generates a pulse wave by comparing the error of the voltage generated from the inverter power supply unit 120 with a saw tooth wave, and then outputs a uniform output current by matching the preset reference voltage. PWM (Pulse Width Modulation) control unit 130 for controlling the; A memory 140 for logically storing and storing various welding parameters such as types of welding materials to be welded, types of gases used, types of welding postures, types of electrode wires 21, and the like; A switch operation unit 150 for selecting and selecting logic data of various welding parameters stored in the memory 140; The main controller unit 160 controls the logic data of the welding parameters stored in the memory 140 to be outputted at an optimum desired welding voltage and desired welding current by selecting the switch operating unit 150. ; Artificial intelligence, characterized in that it comprises a power supply conversion unit 170 for converting the power supplied from the inverter power supply unit 120 to the use power supply to the PWM control unit 130 and the main controller unit 160. Automatic welding machine (100). The method of claim 1, It is possible to download various welding parameters such as the type of a separate upgraded welding material, the type of welding gas, the welding posture, and the type of the electrode wire 21 stored in logic data in an external PC to the memory 140. Artificial intelligence automatic welding machine (100) characterized in that it further comprises a microcomputer board (190) interfaced with the main controller unit (160). The method of claim 1, The inverter power supply unit 120, An input rectifier 121 for converting AC input power into DC input power; An inverter 122 for converting an input power of DC converted through the input rectifier 121 into an alternating frequency of 40 kW through an Insulated Gate Bipolar Transistor (IGBT) element; A transformer 123 for converting a high frequency of alternating current 40 kHz converted through the inverter 122 into a low voltage large current power source of alternating current; An output rectifier 124 for converting a low voltage high current power source of AC converted through the transformer 123 into a low voltage high current power source of DC; Reactor for reducing the impact of the inverter 122 due to load fluctuation by smoothing the power of the direct current low voltage high current converted through the output rectifier 124 and lowers the effective current of the output rectifier 124 and the transformer 123 Intelligent automatic welding machine 100, characterized in that comprises a (125). The method of claim 1, The switch operation unit 150, When the touch mode is set to the auto mode, the logic data according to the welding state of the welding material, the welding gas, and the welding wire which are already set in the memory 140 is output through the main controller unit 160. And, if it is set again in the manual mode (HAND MODE) by touching once again the automatic mode selection switch 151 for converting the welding state and the welding gas, the welding state value of the welding wire is output directly; When the auto mode is switched to the auto mode by the operation of the auto mode selection switch 151, the FE material is selected and selected from the material of the welding material already stored in the memory 140 through the main controller unit 160 at each touch. The main controller 160 sequentially processes the AL material and the SUS (STAINLESS) material selection order to output the logic data stored in the memory 140. When the manual mode is converted by the operation of the auto mode selection switch 151, a metal selection switch for outputting a value directly selected by a user, such as FE material, AL material, SUS material, etc. 152a); When the auto mode is switched to the auto mode by the operation of the auto mode selection switch 151, the type of welding gas already stored in the memory 140 through the main controller unit 160 is changed to CO ₂ (discrete) at each touch. To the main controller unit 160 in order of selection of carbon) and Ar (argon), Ar + CO ₂ , and Ar + O ₂ (oxygen) to output the logic data stored in the memory 140. and, When the mode is converted to the manual mode by the operation of the auto mode selection switch 151, a gas for outputting a value selected by the user directly to CO ₂ and Ar, Ar + CO ₂ , Ar + O _2, etc. A selection switch 152b; When the auto mode is switched to the auto mode by the operation of the auto mode selection switch 151, the diameter of the electrode wire 21 stored in the memory 140 through the main controller unit 160 is 0.8 for each touch. And causing the main controller unit 160 to sequentially process the output of the logic data stored in the memory 140 in a selection order of 1.0 and 1.2Φ. When the mode is converted to the manual mode by the operation of the auto mode selection switch 151, the wire thickness selection switch 152c outputs a value directly selected by the user to 0.8, 1.0, 1.2 Φ, etc. of the electrode wire 21. )Wow; When the auto mode is switched to the auto mode by the operation of the auto mode selection switch 151, the welding postures stored in the memory 140 through the main controller unit 160 are changed in the vertical and horizontal selection order each time the touch is made. By the main controller 160 to sequentially process to output the logic data value stored in the memory 140, A welding posture selection switch 152d for allowing a user to directly input the welding posture in a vertical and horizontal manner when the automatic mode switch is operated in the manual mode; A pulse / mig switch 152e for selecting the presence or absence of a pulse; A main welding voltage volume 153a and a main welding current volume 153b for setting a main welding voltage and a main welding current, respectively; Before the welding, the PRESET switch 154 is set to set the initial discharging voltage and the motor speed in advance by adjusting the main welding voltage volume 153a and the main welding current volume 153b. ; A Creta welding voltage volume 155a and a Creta welding current volume 155b for respectively regulating a Creter welding voltage and a Creta welding current; When set to the LOCAL mode, the main welding voltage volume 153a, the main welding current volume 153b, the crete welding voltage volume 155a, and the crete welding current volume 155b can be adjusted, and the remote REMOTE. A local / remote control selection switch 156 for adjusting by the remote welding voltage volume 23 and the remote welding current volume 22 of the wire feeder 20 when the mode is set to the mode; When the local / remote control selector switch 156 is in the local mode, the welding voltage is controlled by the main welding voltage volume 153a. When the local / remote control selector switch 156 is in the remote mode, the wire feeder is used. The main mode to control the welding voltage by the remote welding voltage volume 23 of the 20, and the main welding voltage volume 153a or wire when the torch switch 32 of the welding gun 30 is first turned on. Creta mode to adjust the welding voltage according to the welding voltage volume of the feeder 20 and to control the welding voltage by the Creta welding voltage volume 155a when the second on, and the torch switch of the welding gun 30 The welding starts when the first turn on the 32 turns on the switch HOLD mode, whereby the welding voltage is adjusted according to the main welding voltage volume 153a. And / Crete / hold mode selection switch (157); According to the welding condition and the welding conditions, the logic data selected by the operation of the metal selection switch 152a, the gas selection switch 152b, the wire thickness selection switch 152c, and the welding posture selection switch 152d for each channel is stored in the memory. A channel select switch 158 which selects up and down each channel to be memorized in 140; The channel selection switch 158 provides logic data by operating the metal selection switch 152a, the gas selection switch 152b, the wire thickness selection switch 152c, and the welding position selection switch 152d according to the welding condition and the welding condition. Intelligent automatic welding machine (100) comprising a save switch (159) for storing in each of the desired channel selected by). The method of claim 1, Torch for filtering the variable welding current and the welding voltage control signal by the operation of the remote welding current volume 22 and the remote welding voltage volume 23 of the wire feeder 20 to supply to the main controller 160. Artificial intelligence automatic welding machine 100, characterized in that further comprises a filter unit 180.