WO2010116695A1 - アーク溶接方法およびアーク溶接装置 - Google Patents
アーク溶接方法およびアーク溶接装置 Download PDFInfo
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- WO2010116695A1 WO2010116695A1 PCT/JP2010/002436 JP2010002436W WO2010116695A1 WO 2010116695 A1 WO2010116695 A1 WO 2010116695A1 JP 2010002436 W JP2010002436 W JP 2010002436W WO 2010116695 A1 WO2010116695 A1 WO 2010116695A1
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- short circuit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
- B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
- B23K9/092—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits characterised by the shape of the pulses produced
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
- B23K9/1012—Power supply characterised by parts of the process
Definitions
- the present invention relates to an arc welding method and an arc welding apparatus in which welding is performed by alternately generating a short circuit state and an arc state while feeding a welding wire which is a consumable electrode.
- the short circuit current is controlled in the short circuit period by changing the inclination of the short circuit current in the basic waveform of the appropriate welding waveform and the inflection point of the short circuit current as a response to the disturbance such as a change in welding speed or protrusion length. Things are known.
- the short circuit current It has an inclination J1 of the first stage and an inclination J2 of the second stage.
- the second-stage increase inclination J2 is adjusted from the intermediate increase inclination J2 in the “hard” K direction or the “soft” L direction.
- the knob for adjusting the inclination of the short circuit current is "soft” and the knob for adjusting the inflection point is adjusted to "large”, the arc is stabilized and the spatter generation amount is relatively small. Stable welding can be performed. Also, if the knob for adjusting the inclination of the short circuit current is "soft” and the knob for adjusting the inflection point is adjusted to "small”, although it is weak against protrusion fluctuation, the amount of spatter generation is minimized and high speed welding is possible. Suitable.
- the set voltage is often set to be several V smaller than the normal proper voltage (hereinafter, referred to as unitary voltage).
- the unitary voltage is a voltage suitable for welding corresponding to the set current set by the operator.
- the present invention adjusts the increasing slope of the short circuit current or adjusts the inflection point of the short circuit current simultaneously with the adjustment of the setting voltage, and automatically adjusts the increasing slope or the short circuit current without the welder operating the knob.
- An arc welding method and an arc welding apparatus capable of adjusting a bending point.
- the present invention provides an arc welding method and an arc welding apparatus for automatically controlling the short circuit current by changing the short circuit initial current value and the short circuit initial time without the welding operator operating the knob. It is a thing.
- the arc welding method according to the present invention sets the appropriate voltage corresponding to the set current and the increasing inclination of the short circuit current, feeds the consumable electrode wire, alternately generates the short circuit state and the arc state, and performs welding. It is a type
- the arc welding method of the present invention sets an appropriate voltage corresponding to the set current, a short circuit initial time which is a current flowing between the short circuit initial time which is a predetermined period from the short circuit start time, and a short circuit initial time
- a consumable electrode type arc welding method in which welding is performed by feeding electrode wires and alternately generating a short circuit state and an arc state, and the set voltage is different from the appropriate voltage according to the difference between the set voltage and the appropriate voltage Control of the short circuit current by changing the short circuit initial current value and the short circuit initial time.
- the setting voltage is set to be a few V smaller than the normal appropriate voltage against disturbances such as welding speed increase, change in protrusion length, and gaps between workpieces. It is possible to automatically adjust the increase inclination of the short circuit current, the current value at the inflection point of the short circuit current, the short circuit initial current, and the short circuit initial time without using the hand of the welding operator.
- the welding wire is not repelled, and it is possible to minimize problems such as bead defects due to arc instability, increased spatter, and poor penetration. Therefore, the yield of the object to be welded can be increased, the number of reworking steps can be reduced, and the welding quality in high-speed welding can be improved. In addition, adverse effects on production efficiency and work environment can be suppressed.
- FIG. 1 is a diagram showing a welding current waveform of the arc welding method according to the first embodiment of the present invention.
- FIG. 2 is a diagram showing the relationship between the set voltage of the arc welding method and the increase slope of the short circuit current in the embodiment.
- FIG. 3 is a diagram showing the relationship between the set voltage of the arc welding method and the inflection point of the short circuit current in the embodiment.
- FIG. 4 is a view showing a schematic configuration of the arc welding apparatus in the embodiment.
- FIG. 5 is a diagram showing a welding current waveform of the arc welding method in the second embodiment of the present invention.
- FIG. 6 is a diagram showing the relationship between the set voltage and the short circuit initial current of the arc welding method in the embodiment.
- FIG. 7 is a diagram showing the relationship between the set voltage and the short circuit initial time of the arc welding method in the embodiment.
- FIG. 8 is a view showing a schematic configuration of the arc welding apparatus in the embodiment.
- FIG. 9 is a diagram showing an example of a welding current waveform in conventional arc welding.
- Embodiment 1 In the present embodiment, first, an arc welding method will be described, and then an arc welding apparatus will be described.
- FIG. 1 shows a waveform of welding current in consumable electrode type arc welding in which a short circuit state and an arc state are alternately repeated.
- the time of the short circuit state is indicated by the short circuit period S
- the time of the arc state is indicated by the arc period A.
- time P1 indicates the time when the short circuit is started, and is also the time of the start of the short circuit initial time.
- Time P2 indicates the end time of the short circuit initial time, and is also the time when the output of the increase slope di / dt of the short circuit current is started.
- time P3 is a time when the first stage increase slope di / dt of the short circuit current and the second stage increase slope di / dt become a bending point B (black dot).
- time P4 indicates a point in time when the output of the second stage of the short circuit current increase slope di / dt is finished, and is also a point in time when the short circuit period S ends and an arc occurs.
- time P5 indicates the time when the next short circuit occurs.
- FIG. 1 shows the increase slope di / dt of the short circuit current when the set voltage is set larger or smaller than the unitary voltage, and the increase slope di / dt of the first stage of the short circuit current and the second of the short circuit current
- the example of a change of inflexion point B with increase inclination di / dt of a stage is shown.
- a current waveform in which the set voltage corresponds to the unitary voltage is indicated by a solid line M1.
- a current waveform when the voltage is reduced from the unitary voltage, that is, when the set voltage is smaller than the unitary voltage is indicated by a dotted line M2.
- a current waveform when the voltage is increased from the unitary voltage, that is, when the set voltage is larger than the unitary voltage is indicated by a dashed-dotted line M3.
- the increase slope di / dt of the short circuit current indicates a change amount of the short circuit current value per unit time.
- one short circuit period which is a period from time P1 to time P5 shown in FIG. 1 will be described below.
- the welding wire contacts the object to be welded and a short circuit occurs.
- a short circuit initial current lower than the current at the time of occurrence of the short circuit is output.
- the short circuit initial time and the short circuit initial current value are derived and adopted by experimental verification and the like.
- the short circuit initial time and the short circuit initial current value are stored as a table (for example, a data configuration table in which each parameter such as the short circuit initial time and the short circuit initial current value is associated with the current value) There is.
- the increase slope di / dt of the first stage of the short circuit current is set from the state where the welding wire is short-circuited firmly to the object to be welded.
- the actual short circuit current rises along the first-stage increase slope di / dt of the short circuit current.
- the increased short circuit current reaches the current value which is the inflection point B of the short circuit current at the time of time P3
- the actual short circuit current increases along the set second-step increase slope di / dt of the short circuit current. .
- the basic setting value of the current value to be the inflection point B of the short circuit current is a proper value that enables stable welding even when changing some voltage when welding at a certain welding speed (1 m / min in this embodiment) Values are derived by experimental verification and adopted.
- the short circuit initial time and the short circuit initial current value are tables and formulas in a storage unit (not shown) (e.g., data that relates each parameter such as the short circuit initial time and the short circuit initial current value with the current value etc.) It is memorized as etc.
- the welding speed is 1.5 m / min and the setting voltage is set by the welding operator with respect to the increase slope di / dt at the second stage and the current value which becomes the bending point B of the short circuit current at time P3.
- the weld pool's followability is poor at an appropriate value of welding speed 1m / min and the weld wire is difficult to melt, so it is difficult to open the short circuit from the workpiece. It is easy to generate, and an arc such as wire repelling may generate an unstable state.
- the first-stage increase slope di / dt of the short circuit current from time P2 to time P3 and time P3
- the current difference at the second stage of the short-circuit current di / dt up to time P4 and the inflection point B of the short-circuit current at time P3 is a voltage difference value that is the difference between the set voltage and the unitary voltage. In response, they are automatically changed to be larger.
- the voltage difference value and the increase slope di / dt of the first and second stages and the bending point B are stored in the storage unit (not shown) in association with each other.
- the increase slope di / dt or the bending point B may be determined according to the voltage difference value.
- a formula that associates the voltage difference value with the increase slope di / dt and the inflection point B is stored in the storage unit (not shown), and the increase slope di / dt and the inflection point B are determined according to the voltage difference value. You may do it.
- the increase slope di / dt of the short circuit current is the increase slope di / dt of the short circuit current when the set voltage is the same as the unitary voltage. If the setting voltage is greater than the unitary voltage, change the steeper di / dt of the short circuit current more gradually than the increase di / dt of the short circuit current when the setting voltage is the same as the unitary voltage. To control the short circuit current.
- control in which the increase slope di / dt in the first stage of the short circuit current and the increase slope di / dt in the second stage of the short circuit current are different slopes is carried out. Furthermore, in the present embodiment, control is performed such that the first-stage increase slope di / dt of the short circuit current is steeper than the second-stage increase slope di / dt of the short circuit current.
- FIG. 2 is a diagram showing an example of the relationship between the set voltage and the increase slope di / dt of the first stage of the short circuit current.
- the relationship between the setting voltage and the second-stage increase slope di / dt of the short circuit current is also shown in a similar diagram.
- the increase slope di / dt in the first stage and the increase slope di / dt in the second stage are various according to each parameter, and the increase slope di / dt in the first stage and the increase slope di / dt in the second stage May or may not be the same.
- the second stage has a more gentle slope than the first stage.
- FIG. 1 shows the case where the slope of the second stage is gradually changed from the first stage.
- the increase slope di / dt of the first stage of the short circuit current is 150 A / ms as shown by line M4 in FIG.
- the increase slope di / dt of the short circuit current at this time that is, the increase slope di / dt of the short circuit current corresponding to the unit voltage is hereinafter referred to as a unit value.
- the welding current waveform when the first-stage increase slope di / dt of the short circuit current is 150 A / ms is a solid line M11 shown in FIG.
- the increase slope di / dt of the first stage of the short circuit current is a unit value.
- the welding current waveform when the first-stage increase slope di / dt of the short circuit current is 200 A / ms is a dotted line M21 shown in FIG.
- the increase slope di / dt of the first stage of the short circuit current is a unit value.
- the welding current waveform when the first-stage increase slope di / dt of the short circuit current is 100 A / ms is a dashed-dotted line M31 shown in FIG.
- the change in the increase slope di / dt of the short circuit current may be changed by increasing or decreasing the same value by the same value in the first stage and the second stage, or may be changed individually. good. For example, only the first stage may be made larger or smaller and the second stage may be left unchanged.
- the dotted line M2 is a diagram in which both the increase slope di / dt at the first stage and the second stage are largely changed, and the increase slope di / dt at the second stage is gentler than that at the first stage.
- FIG. 2 shows an example as an absolute value method in which the increase slope of the short circuit current is ⁇ 10 A / ms per difference of ⁇ 1 V between the set voltage and the unit voltage. That is, the example which changes by the absolute quantity corresponding to the difference of setting voltage and unitary voltage was given. However, it may be changed by an amount based on the change rate according to the difference between the set voltage and the unitary voltage. For example, it is good also as a fluctuation rate method like ⁇ 5% / ms per difference ⁇ 1V of setting voltage and unitary voltage.
- FIG. 2 shows an example in which the relationship between the set voltage and the increase slope di / dt of the short circuit current is a linear curve.
- the relationship is not limited to this.
- a quadratic curve such as a quadratic curve may be used.
- the set voltage is set to be smaller than the unitary voltage by performing the control according to the present embodiment, the increase slope di / dt of the short circuit current is increased. Therefore, the melting of the welding wire can be promoted, and the short circuit opening can be performed relatively smoothly.
- FIG. 3 is a figure which shows an example of the relationship between setting voltage and bending point B (short circuit current bending
- the current value at the inflection point B of the short circuit current is 200A, which is a unitary value, as shown by line M5 in FIG.
- the set voltage is set to -5 V than the unit voltage, that is, if the set voltage is set to 5 V smaller than the unit voltage
- the current value at the inflection point B of the short circuit current is 50 A at 200 A which is the unit value. Increased to 250A.
- the example as an absolute value system which sets it as +/- 10 A per +/- 1V was mentioned in FIG. 3, it is good also as a fluctuation-rate system set as +/- 5% per +/- 1V. That is, as described in the change in the increase slope di / dt of the short circuit current, the change of the inflection point B may be changed by an absolute amount corresponding to the difference between the set voltage and the unitary voltage. You may change by the quantity based on the change rate according to the difference of a unit voltage.
- the relationship between the set voltage and the short circuit current bending point is a linear curve, it may be other than the linear curve such as a quadratic curve, for example.
- the set voltage is set to be smaller than the unitary voltage by performing the control according to the present embodiment, the current value at the bending point B of the short circuit current is changed to be larger. Therefore, the melting of the welding wire can be promoted, and the short circuit opening can be made relatively smooth.
- the increase slope di / dt of the current is the second increase slope of the short circuit current following the increase slope di / dt of the first stage of the short circuit current and the increase slope di / dt of the first stage of the short circuit current.
- the case of the increase slope di / dt of the stage has been described.
- the increase slope of the short circuit current has only the increase slope di / dt of the first stage of the short circuit current, sets the increase slope of the unitary voltage and the short circuit current corresponding to the set current Can be applied to consumable electrode type arc welding methods in which welding is performed by alternately
- upper and lower limit values are also provided for the current value that becomes the increasing slope di / dt of the short circuit current and the bending point B. This can prevent excessive adjustment. That is, by setting the upper and lower limit values, it is possible to prevent the increase inclination di / dt of the short circuit current and the fluctuation point B of the short circuit current from increasing excessively, and the spatter significantly increases. It can prevent becoming stable.
- the current value at the inflection point B of the short circuit current is the wire diameter of the consumable electrode wire to be fed, the wire type, the wire protrusion length, the shield gas to be fed, and It is set based on at least one of the set current ranges.
- the welding wire can be melted quickly after the short circuit occurs. Therefore, even when the welding speed is high and the setting voltage is set to be smaller than the unitary voltage, it is possible to prevent the arc from becoming unstable without repelling the wire.
- the increase slope di / dt of the short circuit current from time P2 to time P3 and time P3 to time Since the increase slope di / dt of the short circuit current up to P4 and the current value at the inflection point of the short circuit current at time P3 are automatically adjusted in the decreasing direction, the short circuit open current can be lowered. The effect of reducing spatter can be obtained.
- FIG. 4 is a view showing a schematic configuration of the arc welding apparatus in the present embodiment, which is configured as follows.
- the power from the input power source 1 is rectified by the primary rectifying unit 2, converted to an alternating current by the switching element 3, stepped down by the transformer 4, and is reduced by the secondary rectifying unit 5 and the inductor 6.
- the current is rectified and applied between the welding wire 25 and the workpiece 28.
- a drive unit 7 for controlling the switching element 3 a welding voltage detection unit 8 connected between welding power output terminals 8a and 8b, and a welding output current are provided.
- a welding current detection unit 9 to be detected and a short circuit / arc detection unit 10 to determine whether a short circuit or an arc is generated based on a signal from the welding voltage detection unit 8 are provided.
- the arc welding apparatus of the present embodiment receives an arc signal from the short circuit / arc detection unit 10 and controls the arc voltage during the arc period A, and the short circuit from the short circuit / arc detection unit 10 And a setting current setting unit 29 for setting the setting current by the welding operator.
- the arc welding apparatus according to the present embodiment includes a unitary voltage setting unit 21 for setting a unitary voltage based on the set current set by the operator in the set current setting unit 29, and a set voltage.
- a set voltage setting unit 22 and a unitary / set voltage difference calculation unit 23 for obtaining a difference between the unitary setting voltage set by the unitary voltage setting unit 21 and the set voltage set by the set voltage setting unit 22 are provided.
- the short circuit control unit 12 Based on the set current set by the operator at the set current setting unit 29, the short circuit control unit 12 increases the inclination di / dt of the first stage of the short circuit current and the increase inclination di / dt of the second stage of the short circuit current. And an increase slope di / dt basic setting unit 13 of the short circuit current to set. Further, based on the calculation result of the single / set voltage difference calculation unit 23, the increase inclination di / dt of the short circuit current which is set by the increase inclination di / dt basic setting unit 13 of the short circuit current The dt control unit 14 is provided.
- the short circuit control unit 12 determines from the increase slope di / dt of the first stage of the short circuit current the increase slope di of the second stage of the short circuit current.
- a bending point basic setting unit 15 of a short circuit current is provided which sets a bending point B whose inclination changes to / dt.
- a bending point control unit 16 of the short circuit current is provided to change the current value at the bending point B based on the calculation result of the unitary / set voltage difference calculating unit 23.
- the relationship between the unitary voltage with respect to the set current, the increase slope di / dt of the first stage of the short circuit current, the increase slope di / dt of the second stage of the short circuit current, and the inflection point B is not illustrated, for example. It is stored in the storage unit as a table or a mathematical expression, and is determined based on the set current.
- Welding voltage detection unit 8 is connected between welding power output terminals 8a and 8b, and outputs a signal corresponding to the detected voltage to short circuit / arc detection unit 10.
- the short circuit / arc detection unit 10 determines whether the welding output voltage is above or below a certain value based on the signal from the welding voltage detection unit 8, and the welding wire 25 contacts the workpiece 28 according to the judgment result. It is determined whether the welding arc is generated or not in a non-contact state, and a determination signal is output.
- the short circuit control unit 12 performs the short circuit current increase inclination di / dt basic setting unit 13, the short circuit current increase inclination di / dt control unit 14, the short circuit current bending point basic setting unit 15, and the short circuit It is comprised from the bending point control part 16 of an electric current.
- the difference between the unitary voltage setting unit 21 and the setting voltage setting unit 22 is monitored by the unitary / setting voltage difference calculating unit 23, and the short circuit control unit 12 receives the voltage difference value from the unitary / setting voltage difference calculating unit 23. .
- the increase slope di / dt control unit 14 of the short circuit current and the inflection point control unit 16 of the short circuit current are compared with the values from the increase slope di / dt basic setting unit 13 of the short circuit current and the inflection point basic setting unit 15 of the short circuit current.
- the changed value is output to the drive unit 7.
- each structural part which comprises the arc-welding apparatus shown in FIG. 4 may be comprised independently, respectively, and you may make it combine and comprise several structural part.
- Second Embodiment In the present embodiment, parts similar to those in the first embodiment are assigned the same reference numerals and detailed explanations thereof will be omitted.
- the main point different from the first embodiment is that, when the set voltage is different from the unitary voltage, the short circuit initial current value and the short circuit initial time are varied.
- the short circuit initial current value and the short circuit initial time will be described.
- FIG. 5 shows a welding current waveform in consumable electrode type arc welding in which a short circuit state and an arc state are alternately repeated, as in the first embodiment.
- a current waveform corresponding to the case where the set voltage is a unitary voltage is indicated by a solid line N1.
- a current waveform when the voltage is reduced from the unitary voltage, that is, when the set voltage is smaller than the unitary voltage is indicated by a dotted line N2.
- a current waveform when the voltage is increased from the unitary voltage, that is, when the set voltage is larger than the unitary voltage is indicated by a one-dot chain line N3.
- the weld pool has poor weldability at a proper value of welding speed of 1m / min and the weld wire is difficult to melt. It is likely that a short circuit is difficult to open, and an arc such as wire repelling may cause an unstable state.
- the short circuit initial current value from time P1 to time P2 to increase the short circuit initial current value than the short circuit initial current value when the set voltage is equal to the unitary voltage.
- the short circuit initial time from time P1 to time P2 is shortened, that is, the short circuit initial time is made shorter than the short circuit initial time when the set voltage is the same as the unitary voltage.
- FIG. 6 is a diagram showing an example of the relationship between the set voltage and the short circuit initial current value.
- the short circuit initial current value is 100A which is the unitary value.
- the welding current waveform at this time is a solid line N1 in FIG.
- the set voltage is set to -5 V than the unit voltage, that is, if the set voltage is set to 5 V smaller than the unit voltage, the short circuit initial current value increases 25 A to 100 A, which is the unit value, and 125 A become.
- the welding current waveform at this time is a dotted line N2 in FIG.
- the short circuit initial current value is 100 A, which is a unit value, as shown by dashed dotted line N3. Decrease 25A to 75A.
- the welding current waveform at this time is an alternate long and short dash line N3 in FIG.
- the short circuit initial current value may be changed by an absolute amount corresponding to the difference between the appropriate voltage and the set voltage, or may be changed by an amount based on a change rate corresponding to the difference between the proper voltage and the set voltage.
- the relationship between the set voltage and the short circuit initial current value is a linear curve, it may be other than the linear curve such as a quadratic curve, for example.
- FIG. 7 is a diagram showing an example of the relationship between the set voltage and the short circuit initial time value.
- the short circuit initial time value is 500 ⁇ s which is the unitary value (see solid line N1 of welding current waveform in FIG. 5).
- the set voltage is set to -5 V than the unit voltage, that is, if the set voltage is set to 5 V smaller than the unit voltage
- the short circuit initial time value decreases 250 ⁇ s to 500 ⁇ s, which is the unit value, and 250 ⁇ s. (See the dotted line N2 of the welding current waveform in FIG.
- the short circuit initial time value increases 250 ⁇ s to 500 ⁇ s, which is the unit value, and 750 ⁇ s. (See the dashed-dotted line N3 in FIG. 5 for the welding current waveform).
- the short circuit initial time may also be changed by an absolute amount corresponding to the difference between the proper voltage and the set voltage, or may be changed by an amount based on a change rate corresponding to the difference between the proper voltage and the set voltage.
- the relationship between the set voltage and the short circuit initial time value is a linear curve, it may be other than the linear curve such as a quadratic curve, for example.
- the short circuit initial current value and the short circuit initial time from time P1 to time P2 are set according to this setting. Change.
- upper and lower limit values may be provided for the short circuit initial current value and the short circuit initial time, whereby excessive adjustment can be prevented. That is, by providing the upper and lower limits, it is possible to prevent the occurrence of a state such as a short circuit open immediately after a short circuit due to excessive fluctuation in a direction to increase the short circuit initial current and a direction to shorten the short circuit initial time. Therefore, it can prevent that short circuit periodicity collapses.
- the short circuit initial current value and the short circuit initial time from time P1 to time P2 are added to the difference value between the set voltage and the unit voltage, and the wire diameter of the consumable electrode wire to be fed, wire type, wire protrusion length, feed It is set based on at least one of a shield gas and a set current range of the welding current.
- the welding wire can be melted quickly after the short circuit occurs. Therefore, even when the welding speed is set fast and the set voltage is set to be smaller than the unitary voltage, it is possible to suppress the arc from becoming unstable without repelling the wire.
- the short circuit initial current value from time P1 to time P2 becomes smaller and the short circuit initial time is It is automatically adjusted in the direction of increasing the length. Therefore, a firmer short circuit condition can be secured. Therefore, it is possible to prevent re-shorting that occurs immediately after the short circuit, and to stabilize the short circuit cycle.
- the same parts as those of the arc apparatus described in the first embodiment are designated by the same reference numerals and the detailed description will be omitted.
- the main difference from the configuration of the arc welding apparatus of the first embodiment is the configuration of the short circuit control unit 12.
- the short circuit control unit 12 outputs a short circuit current, a short circuit initial current basic setting unit 17, a short circuit initial current control unit 18, a short circuit initial time basic setting unit 19, and a short circuit initial time control unit 20. And consists of.
- Welding voltage detection unit 8 is connected between welding power output terminals 8a and 8b, and outputs a signal corresponding to the detected voltage to short circuit / arc detection unit 10.
- the short circuit / arc detection unit 10 determines whether the welding output voltage is above or below a certain value based on the signal from the welding voltage detection unit 8, and the welding wire 25 contacts the workpiece 28 according to the judgment result. It is determined whether the welding arc is generated or not in a non-contact state, and a determination signal is output.
- the short circuit control unit 12 sets a short circuit initial current value which is a current to be flowed during a predetermined period from the start of the short circuit based on a set current set by the operator, and a unitary / set voltage difference
- a short circuit initial current control unit 18 changes the short circuit initial current set by the short circuit initial current basic setting unit 17 based on the calculation result of the calculation unit 23.
- the short circuit control unit 12 sets a short circuit initial time which is a period in which the short circuit initial current value flows based on the set current set by the operator, and a single / set voltage difference calculation unit 23
- the short circuit initial time control unit 20 changes the short circuit initial time set in the short circuit initial time basic setting unit based on the calculation result of the short circuit initial time.
- the relationship between the unitary voltage with respect to the set current, the short circuit initial current, and the short circuit initial time is stored, for example, as a table or a formula in a storage unit (not shown) and determined based on the set current.
- the difference between the unitary voltage of the unitary voltage setting unit 21 and the setting voltage of the setting voltage setting unit 22 is monitored by the unitary / setting voltage difference calculation unit 23.
- the short circuit control unit 12 receives the voltage difference value from the unitary / set voltage difference calculation unit 23, and controls the short circuit current as described with reference to FIGS. That is, each of the short circuit initial current control unit 18 and the short circuit initial time control unit 20 changes the values from the short circuit initial current basic setting unit 17 and the short circuit initial time basic setting unit 19 to change the changed values. Output to control the short circuit current.
- the arc speed does not increase when the welding speed is high and the set voltage is different from the unitary voltage as in the first embodiment. It is possible to minimize problems such as bead defects due to stability, increased spatter, and penetration defects. Therefore, it is possible to suppress an adverse effect on production efficiency and work environment.
- the control of the first embodiment and the control of the second embodiment are performed in combination. That is, the increase slope di / dt of the first stage of the short circuit current from time P2 to time P3 and the second stage of the short circuit current from time P3 to time P4 shown in FIG. 1 in the first embodiment Control to vary the increase slope di / dt and the current value to be the inflection point B of the short circuit current at time P3 and the short circuit initial current from time P1 to time P2 shown in FIG. 5 in the second embodiment It combines with the control which fluctuates with the short circuit initial time. As a result, even when the welding speed is higher and the setting voltage is set to be smaller than the unitary voltage, stable welding can be performed without repelling the wire, thereby further improving the welding speed and the lower limit voltage tolerance. It can be done.
- the configuration of the arc welding apparatus of the present embodiment can be realized by combining the configurations in the short circuit control unit 12 shown in FIGS. 4 and 8 of the first embodiment and the second embodiment.
- the welding speed is faster and the setting voltage is set to be smaller than the unitary voltage, as compared to the case where Embodiment 1 or 2 is independently controlled. It is possible to minimize problems such as bead defects due to arc instability, increase in spatter, and penetration defects, and to suppress adverse effects on production efficiency and work environment.
- the consumable electrode type arc welding method of the present invention the appropriate voltage corresponding to the set current and the increase slope of the short circuit current are set, and the consumable electrode wire is fed to perform the short circuit state and the arc state.
- the appropriate voltage corresponding to the set current and the short circuit initial current value which is a current flowing between the short circuit initial time which is a predetermined period from the short circuit start time and the short circuit initial time are set.
- the consumable electrode type arc welding method in which the consumable electrode wire is fed to alternately generate a short circuit state and an arc condition to perform welding, and the set voltage is different from the appropriate voltage. According to the difference, the short circuit initial current value and the short circuit initial time are changed to control the short circuit current.
- the consumable electrode type arc welding apparatus is an arc welding apparatus which performs welding by repeating an arc state and a short circuit state between a welding wire which is a consumable electrode and a workpiece.
- Switching element for controlling welding output welding voltage detection unit for detecting welding voltage, short circuit / arc detection unit for detecting short circuit condition or arc condition based on output of welding voltage detection unit, short circuit
- a short circuit control unit which controls a short circuit current in a short circuit period in response to a short circuit signal from a / arc detection unit, and an arc voltage control in an arc condition period in response to an arc signal from a short circuit / arc detection unit
- the short circuit control unit sets an increase inclination of the short circuit current based on the setting current set by the setting current setting unit, and an increase inclination basic setting unit based on the calculation result of the appropriate / setting voltage difference calculation unit And an inclination controller configured to change the inclination of the short circuit current set in step b.
- the consumable electrode type arc welding apparatus is an arc welding apparatus which performs welding by repeating an arc state and a short circuit state between a welding wire which is a consumable electrode and a workpiece.
- Switching element for controlling welding output welding voltage detection unit for detecting welding voltage, short circuit / arc detection unit for detecting short circuit condition or arc condition based on output of welding voltage detection unit, short circuit
- a short circuit control unit which controls a short circuit current in a short circuit period in response to a short circuit signal from a / arc detection unit, and an arc voltage control in an arc condition period in response to an arc signal from a short circuit / arc detection unit
- the short circuit control unit sets a short circuit initial current value which is a current flowed during a short circuit initial time which is a predetermined period from the start of the short circuit based on the setting current set by the setting current setting unit;
- the short circuit initial current control unit that changes the short circuit initial current value set by the short circuit initial current basic setting unit based on the calculation result of the appropriate / set voltage difference calculation unit, and the short circuit initial operation based on the setting current set by the setting current setting unit It has a short circuit initial time basic setting unit to set the time, and a short circuit initial time control unit to change the short circuit initial time set by the short circuit initial time basic setting unit based on the calculation result of the appropriate / set voltage difference calculation unit. .
- the short circuit control unit is configured to change the short circuit initial current value and the short circuit initial time based on the calculation result of the appropriate / set voltage difference calculation unit.
- the setting voltage is set to be a few V smaller than the normal appropriate voltage against disturbances such as welding speed increase, change in protrusion length, and gaps between workpieces. It is possible to automatically adjust the increase inclination of the short circuit current, the current value at the inflection point of the short circuit current, the short circuit initial current, and the short circuit initial time without using the hand of the welding operator.
- the welding wire is not repelled, and it is possible to minimize problems such as bead defects due to arc instability, increased spatter, and poor penetration. Therefore, the yield of the object to be welded can be increased, the number of reworking steps can be reduced, and the welding quality in high-speed welding can be improved. In addition, adverse effects on production efficiency and work environment can be suppressed.
- the present invention can minimize problems such as bead defects due to arc instability, increased sputtering, and penetration defects, and can suppress adverse effects on production efficiency and working environment.
- problems such as bead defects due to arc instability, increased sputtering, and penetration defects
- it is widely applicable in the industry mainly for high speed welding with thin plates such as automobiles that perform consumable electrode type arc welding application, and is industrially useful.
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Abstract
Description
本実施の形態では、先ず、アーク溶接方法について説明し、その後、アーク溶接装置について説明する。
本実施の形態において、実施の形態1と同様の箇所については同一の符号を付して詳細な説明を省略する。実施の形態1と異なる主な点は、設定電圧が一元電圧と異なっていた場合に、短絡初期電流値と短絡初期時間を変動させる点である。しかし、本発明は、短絡初期電流値と短絡初期時間の両者を変動させる必要はない。すなわち、短絡初期電流値と短絡初期時間の少なくともいずれか一方を変動させればよい。本実施の形態では、短絡初期電流値と短絡初期時間を変動させる場合について説明する。
本実施の形態は、実施の形態1の制御と実施の形態2の制御とを併せて行うものである。すなわち、実施の形態1における、図1に示す、時刻P2から時刻P3までの短絡電流の第1段目の増加傾きdi/dtと、時刻P3から時刻P4までの短絡電流の第2段目の増加傾きdi/dtと、時刻P3での短絡電流の屈曲点Bとなる電流値とを変動させる制御と、実施の形態2における、図5に示す、時刻P1から時刻P2までの短絡初期電流と短絡初期時間とを変動させる制御とを組合せる。このことにより、溶接速度がより速く、設定電圧が一元電圧より小さくなる方向に設定された場合でもワイヤはじくことなく、安定した溶接することが可能であり、溶接速度及び電圧下限裕度を更に向上させることができる。
2 1次整流部
3 スイッチング素子
4 トランス
5 2次整流部
6 インダクタ
7 駆動部
8 溶接電圧検出部
9 溶接電流検出部
10 短絡/アーク検出部
11 アーク制御部
12 短絡制御部
13 短絡電流の増加傾きdi/dt基本設定部
14 短絡電流の増加傾きdi/dt制御部
15 短絡電流の屈曲点基本設定部
16 短絡電流の屈曲点制御部
17 短絡初期電流基本設定部
18 短絡初期電流制御部
19 短絡初期時間基本設定部
20 短絡初期時間制御部
21 一元電圧設定部(適正電圧設定部)
22 設定電圧設定部
23 一元/設定電圧差分計算部(適正/設定電圧差分計算部)
24 ワイヤ送給モータ
25 溶接ワイヤ
26 チップ
27 溶接アーク
28 被溶接物
29 設定電流設定部
Claims (16)
- 設定電流に対応した適正電圧と短絡電流の増加傾きとを設定し、消耗電極ワイヤを送給して短絡状態とアーク状態を交互に発生させて溶接を行う消耗電極式アーク溶接方法であって、設定電圧が前記適正電圧と異なる場合、前記設定電圧と前記適正電圧との差に応じて前記短絡電流の増加傾きを変更して前記短絡電流の制御を行う消耗電極式アーク溶接方法。
- 前記設定電圧が前記適正電圧より小さい場合は、前記短絡電流の増加傾きを前記設定電圧が前記適正電圧と同じ場合の前記短絡電流の増加傾きより急になるように変更し、前記設定電圧が前記適正電圧より大きい場合は、前記短絡電流の増加傾きを前記設定電圧が前記適正電圧と同じ場合の前記短絡電流の増加傾きより緩やかになるように変更して前記短絡電流の制御を行う請求項1記載の消耗電極式アーク溶接方法。
- 前記短絡電流の増加傾きが、短絡電流の第1段目の増加傾きおよび前記短絡電流の第1段目の増加傾きに続く短絡電流の第2段目の増加傾きからなり、前記設定電圧が前記適正電圧と異なる場合、前記設定電圧と前記適正電圧との差に応じて前記短絡電流の第1段目の増加傾きと前記短絡電流の第2段目の増加傾きとを変更して前記短絡電流の制御を行う請求項1記載の消耗電極式アーク溶接方法。
- 前記短絡電流の第1段目の増加傾きと前記短絡電流の第2段目の増加傾きとは異なる傾きである請求項3記載の消耗電極式アーク溶接方法。
- 前記短絡電流の第1段目の増加傾きは、前記短絡電流の第2段目の増加傾きより急である請求項4記載の消耗電極式アーク溶接方法。
- 前記短絡電流の増加傾きを、前記適正電圧と前記設定電圧の差に対応した絶対量により変更する、または、前記適正電圧と前記設定電圧の差に応じた変化率に基づく量により変更する請求項1記載の消耗電極式アーク溶接方法。
- 前記設定電圧が前記適正電圧と異なる場合、前記設定電圧と前記適正電圧との差に応じて、前記短絡電流の第1段目の増加傾きから前記短絡電流の第2段目の増加傾きに傾きが変わる屈曲点となる電流値を変更して前記短絡電流の制御を行う請求項3記載の消耗電極式アーク溶接方法。
- 前記設定電圧が前記適正電圧より小さい場合は、前記屈曲点となる電流値を前記設定電圧が前記適正電圧と同じ場合の前記屈曲点となる電流値より大きくなるように変更し、前記設定電圧が前記適正電圧より大きい場合は、前記屈曲点となる電流値を前記設定電圧が前記適正電圧と同じ場合の前記屈曲点となる電流値より小さくなるように変更して短絡電流の制御を行う請求項7記載の消耗電極式アーク溶接方法。
- 前記屈曲点となる電流値を、前記適正電圧と前記設定電圧の差に対応した絶対量により変更する、または、前記適正電圧と前記設定電圧の差に応じた変化率に基づく量により変更する請求項7記載の消耗電極式アーク溶接方法。
- 設定電流に対応した適正電圧と短絡開始時から所定期間である短絡初期時間と前記短絡初期時間の間に流す電流である短絡初期電流値とを設定し、消耗電極ワイヤを送給して短絡状態とアーク状態を交互に発生させて溶接を行う消耗電極式アーク溶接方法であって、設定電圧が前記適正電圧と異なる場合、前記設定電圧と前記適正電圧との差に応じて前記短絡初期電流値と前記短絡初期時間とを変更して前記短絡電流の制御を行う消耗電極式アーク溶接方法。
- 前記設定電圧が前記適正電圧より小さい場合は、前記短絡初期電流値を前記設定電圧が前記適正電圧と同じ場合の前記短絡初期電流値より大きくなるように変更し、前記設定電圧が前記適正電圧より大きい場合は、前記短絡初期電流値を前記設定電圧が前記適正電圧と同じ場合の前記短絡初期電流値より小さくなるように変更して、前記短絡電流の制御を行う請求項10記載の消耗電極式アーク溶接方法。
- 前記設定電圧が前記適正電圧より小さい場合は、前記短絡初期時間を前記設定電圧が前記適正電圧と同じ場合の前記短絡初期時間より短くなるように変更し、前記設定電圧が前記適正電圧より大きい場合は、前記短絡初期時間を前記設定電圧が前記適正電圧と同じ場合の前記短絡初期時間より長くなるように変更して、前記短絡電流の制御を行う請求項10記載の消耗電極式アーク溶接方法。
- 前記短絡初期電流値と前記短絡初期時間を、前記適正電圧と前記設定電圧の差に対応した絶対量により変更する、または、前記適正電圧と前記設定電圧の差に応じた変化率に基づく量により変更する請求項10記載の消耗電極式アーク溶接方法。
- 消耗電極である溶接ワイヤと被溶接物との間でアーク状態と短絡状態とを繰り返して溶接を行うアーク溶接装置であって、
溶接出力を制御するスイッチング素子と、
溶接電圧を検出する溶接電圧検出部と、
前記溶接電圧検出部の出力に基づいて前記短絡状態であるのか前記アーク状態であるのかを検出する短絡/アーク検出部と、
前記短絡/アーク検出部からの短絡の信号を受けて前記短絡状態の期間に短絡電流の制御を行う短絡制御部と、
前記短絡/アーク検出部からのアークの信号を受けて前記アーク状態の期間にアーク電圧の制御を行うアーク制御部と、
前記短絡制御部および前記アーク制御部の出力に基づいて前記スイッチング素子を駆動する駆動部と、
設定電流を設定するための設定電流設定部と、
前記設定電流設定部で設定した前記設定電流に基づいた適正電圧を設定する適正電圧設定部と、
設定電圧を設定するための設定電圧設定部と、
前記適正電圧と前記設定電圧との差を算出する適正/設定電圧差分計算部とを備え、
前記短絡制御部は、
前記設定電流設定部で設定した前記設定電流に基づいて前記短絡電流の増加傾きを設定する増加傾き基本設定部と、
前記適正/設定電圧差分計算部の算出結果に基づいて前記増加傾き基本設定部で設定した前記短絡電流の増加傾きを変更する増加傾き制御部とを備えたアーク溶接装置。 - 前記短絡電流の増加傾きが、短絡電流の第1段目の増加傾きおよび前記短絡電流の第1段目の増加傾きに続く短絡電流の第2段目の増加傾きからなり、
前記増加傾き基本設定部は、前記短絡電流の第1段目の増加傾きおよび前記短絡電流の第2段目の増加傾きを設定し、
前記増加傾き制御部は、前記適正/設定電圧差分計算部の算出結果に基づいて前記増加傾き基本設定部で設定した前記短絡電流の第1段目の増加傾きまたは前記短絡電流の第2段目の増加傾きのうち少なくとも一方を変更し、
前記短絡電流の第1段目の増加傾きから前記短絡電流の第2段目の増加傾きに傾きが変わる屈曲点を前記設定電流に基づいて設定する屈曲点基本設定部と、
前記屈曲点基本設定部で設定された前記屈曲点を前記適正/設定電圧差分計算部の算出結果に基づいて変更する屈曲点制御部とをさらに備え、
前記短絡制御部は、前記適正/設定電圧差分計算部の算出結果に基づいて前記短絡電流の第1段目の増加傾きまたは前記短絡電流の第2段目の増加傾きのうち少なくとも一方と前記屈曲点とを変更する請求項14記載のアーク溶接装置。 - 消耗電極である溶接ワイヤと被溶接物との間でアーク状態と短絡状態とを繰り返して溶接を行うアーク溶接装置であって、
溶接出力を制御するスイッチング素子と、
溶接電圧を検出する溶接電圧検出部と、
前記溶接電圧検出部の出力に基づいて前記短絡状態であるのか前記アーク状態であるのかを検出する短絡/アーク検出部と、
前記短絡/アーク検出部からの短絡の信号を受けて前記短絡状態の期間に短絡電流の制御を行う短絡制御部と、
前記短絡/アーク検出部からのアークの信号を受けて前記アーク状態の期間にアーク電圧の制御を行うアーク制御部と、
前記短絡制御部および前記アーク制御部の出力に基づいて前記スイッチング素子を駆動する駆動部と、
設定電流を設定するための設定電流設定部と、
前記設定電流設定部で設定した前記設定電流に基づいた適正電圧を設定する適正電圧設定部と、
設定電圧を設定するための設定電圧設定部と、
前記適正電圧と前記設定電圧との差を算出する適正/設定電圧差分計算部とを備え、
前記短絡制御部は、
前記設定電流設定部で設定した前記設定電流に基づいて短絡開始時から所定期間である短絡初期時間の間に流す電流である短絡初期電流値を設定する短絡初期電流基本設定部と、
前記適正/設定電圧差分計算部の算出結果に基づいて前記短絡初期電流基本設定部で設定した前記短絡初期電流値を変更する短絡初期電流制御部と、
前記設定電流設定部で設定した前記設定電流に基づいて前記短絡初期時間を設定する短絡初期時間基本設定部と、
前記適正/設定電圧差分計算部の算出結果に基づいて前記短絡初期時間基本設定部で設定した前記短絡初期時間を変更する短絡初期時間制御部とを備え、
前記短絡制御部は、前記適正/設定電圧差分計算部の算出結果に基づいて前記短絡初期電流値と前記短絡初期時間とを変更するアーク溶接装置。
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JP4807474B2 (ja) * | 2009-06-19 | 2011-11-02 | パナソニック株式会社 | 消耗電極式アーク溶接方法および消耗電極式アーク溶接装置 |
JP4807479B2 (ja) * | 2009-07-10 | 2011-11-02 | パナソニック株式会社 | アーク溶接制御方法およびアーク溶接装置 |
US9050677B2 (en) * | 2009-08-28 | 2015-06-09 | Panasonic Intellectual Property Management Co., Ltd. | Arc welding method and arc welding apparatus |
US8909372B2 (en) * | 2010-02-03 | 2014-12-09 | Panasonic Corporation | Robot system control method |
JP5293884B2 (ja) * | 2010-09-10 | 2013-09-18 | パナソニック株式会社 | アーク溶接制御方法 |
CN102834212B (zh) * | 2010-09-17 | 2015-04-22 | 松下电器产业株式会社 | 焊接条件决定方法及焊接装置 |
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2010
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- 2010-04-02 WO PCT/JP2010/002436 patent/WO2010116695A1/ja active Application Filing
- 2010-04-02 CN CN2010800023056A patent/CN102123812B/zh active Active
- 2010-04-02 JP JP2010544504A patent/JP5083415B2/ja active Active
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Cited By (10)
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JP5170315B2 (ja) * | 2009-07-29 | 2013-03-27 | パナソニック株式会社 | アーク溶接方法およびアーク溶接装置 |
US8809736B2 (en) | 2009-07-29 | 2014-08-19 | Panasonic Corporation | Arc welding method and arc welding apparatus |
CN102756197A (zh) * | 2011-04-28 | 2012-10-31 | 株式会社大亨 | 短路期间的焊接电流控制方法 |
JP2012232312A (ja) * | 2011-04-28 | 2012-11-29 | Daihen Corp | 短絡期間の溶接電流制御方法 |
CN102950366A (zh) * | 2011-08-25 | 2013-03-06 | 株式会社大亨 | 焊接装置 |
CN102990201A (zh) * | 2011-09-14 | 2013-03-27 | 株式会社大亨 | 焊接装置 |
CN102990201B (zh) * | 2011-09-14 | 2016-05-04 | 株式会社大亨 | 焊接装置 |
JP2014083571A (ja) * | 2012-10-25 | 2014-05-12 | Daihen Corp | 短絡期間の溶接電流制御方法 |
US11014186B2 (en) | 2014-02-14 | 2021-05-25 | Panasonic Intellectual Property Management Co., Ltd. | Wire fed arc welding method having abnormal arc or abnormal short circuit welding steps |
EP3219427A4 (en) * | 2014-11-12 | 2018-01-03 | Panasonic Intellectual Property Management Co., Ltd. | Arc welding control method and arc welding device |
Also Published As
Publication number | Publication date |
---|---|
US20130056453A1 (en) | 2013-03-07 |
US20110248012A1 (en) | 2011-10-13 |
EP2292362B1 (en) | 2016-08-10 |
EP2292362A1 (en) | 2011-03-09 |
CN102123812B (zh) | 2013-06-12 |
JPWO2010116695A1 (ja) | 2012-10-18 |
EP2292362A4 (en) | 2015-04-22 |
US10500667B2 (en) | 2019-12-10 |
JP5083415B2 (ja) | 2012-11-28 |
CN102123812A (zh) | 2011-07-13 |
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