WO2017063253A1 - Consumable electrode welder and welding method thereof - Google Patents

Consumable electrode welder and welding method thereof Download PDF

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Publication number
WO2017063253A1
WO2017063253A1 PCT/CN2015/095872 CN2015095872W WO2017063253A1 WO 2017063253 A1 WO2017063253 A1 WO 2017063253A1 CN 2015095872 W CN2015095872 W CN 2015095872W WO 2017063253 A1 WO2017063253 A1 WO 2017063253A1
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WIPO (PCT)
Prior art keywords
module
welding
voltage
arc
arc length
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PCT/CN2015/095872
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French (fr)
Chinese (zh)
Inventor
刘昇澔
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刘昇澔
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Publication of WO2017063253A1 publication Critical patent/WO2017063253A1/en

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Classifications

    • 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
    • B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
    • B23K9/067—Starting the arc
    • 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
    • B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
    • B23K9/067—Starting the arc
    • B23K9/0672—Starting the arc without direct contact between electrodes
    • B23K9/0673—Ionisation of the arc gap by means of a tension with a step front (pulses or high frequency tensions)
    • 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
    • B23K9/095—Monitoring or automatic control of welding parameters
    • 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
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • 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
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors

Definitions

  • the invention relates to the field of welding machines, in particular to a fusion pole welding machine and a welding method thereof.
  • the traditional fusion welding machine adopts the contact short-circuit arcing, and there is a spark splash when the short-circuit arc starts.
  • the molten metal ball forms a molten metal ball, as shown in Fig. 1 ( a)
  • the arc length is very short, the arc voltage is very low, the current is large, the arc temperature is low, and the energy of the melting wire is large; as the amount of molten wire increases, the arc length becomes larger, and the arc voltage also increases.
  • the arc current is reduced, the arc temperature is increased, and the energy of the melting wire is reduced.
  • the droplet at the end of the wire is under the action of gravity, and the portion of the droplet connected to the wire is reduced in diameter, as shown in (b) of FIG.
  • the arc length is longer, the arc voltage is larger, the arc temperature is higher, and the diameter of the arc is further reduced, so that the local current density of the reduced diameter is sharply increased, and a large amount of Joule hot melt welding wire droplets are generated.
  • the droplet separates from the wire and eventually falls on the base material (weld parts to be welded) to complete a complete welding cycle.
  • the traditional fusion welding machine has only a single DC welding mode, DC pulse welding mode, and its application range is narrow.
  • the present invention provides a fusion electrode welder and a welding method thereof, which adopts a high-frequency high-voltage arc-starting method without short-circuit spark splash, and at the same time, during the welding process, the arc length and
  • the welding parameters such as the wire feeding speed are controllable, and the welding speed and the welding quality of the non-melting pole welder can be realized; in addition, the melting electrode welder has various welding methods.
  • a fusion electrode welder comprising a control system module having a synchronous communication interface, a current sampling module, a voltage sampling module, a power input module, a DC constant voltage module, a chopper control module, a constant current feedback module and a welding gun are sequentially connected, and a wire feeding device for pushing the welding wire is connected to the welding gun, and an input end of the current sampling module and the DC constant voltage An output end of the module and an input end of the welding gun are connected, an input end of the voltage sampling module is connected to an output end of the DC constant voltage module and an input end of the welding gun, and an output end of the current sampling module and a voltage sampling module The output ends are all connected to the control system module;
  • the fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting
  • the fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting module The output end is connected to the control system module; the arc length feedback module is connected in series between the synchronous communication interface of the control system module and the welding torch, and the arc length information for welding is fed back to the control system module; a wire feeding control module is connected in series between the synchronous communication interface of the control system module and the wire feeding device for receiving a wire feeding control signal required by the control system module and converting the same into control information. To control the wire feed speed and/or wire feed amount of the wire feeder.
  • the arc length feedback module comprises a voltage acquisition module, an anti-interference module and an arc length calculation module connected in sequence; the voltage acquisition module is connected with the welding gun to obtain a voltage signal when the welding torch is working; the anti-interference The module is configured to eliminate the interference signal in the voltage signal to obtain arc voltage information during welding of the fusion welder; the arc length calculation module is configured to calculate arc length information according to the obtained arc voltage information, and It is fed back to the control system module.
  • the fusion welding machine further includes a human-machine interface operation and display module connected to the control system module; the fusion-pole welding machine further includes an AC-DC conversion control module, wherein the AC-DC conversion control module is connected in series to the An output of the constant current feedback module is coupled to an input of the welding torch.
  • the AC/DC conversion control module has an input positive terminal, an input negative terminal, a first output terminal, and a second output terminal
  • the AC/DC conversion control module includes a first switch module, a second switch module, and a third switch. a module and a fourth switch module; the input positive terminal, the input end of the first switch module, the output end of the first switch module, the input end of the second switch module, the output end of the second switch module, and the input negative terminal Connected in sequence, the input positive end, the input end of the third switch module, the output end of the third switch module, the input end of the fourth switch module, the output end of the fourth switch module, and the input negative end are sequentially connected; One end of the third switch module and the fourth switch module is connected to the first output end, and one end of the third switch module and the fourth switch module is connected to the second output end.
  • an LC series circuit is connected in series between the second output end and the interconnected end of the third switch module and the fourth switch module.
  • the welding electrode welding machine provided by the invention has the following welding methods:
  • the melting pole welding machine uses the high-frequency high-voltage arc starting module to perform arc starting by using a high-frequency high-voltage arcing method
  • the arc length feedback module calculates arc length information at the time of welding based on the signal acquired from the welding torch, and feeds back the arc length information to the control system module;
  • the control system module calculates the wire feed amount required by the melt electrode welder, and sends corresponding control information to the wire feed control module according to the required wire feed amount;
  • the wire feeding control module controls the wire feeding speed of the wire feeding device according to the received control information, so that the arc length of the melting electrode welder in one welding cycle is the same or substantially the same.
  • the arc length feedback module obtains an arc voltage signal by acquiring a voltage signal when the welding torch is working, and then canceling an interference signal in the voltage signal, and finally passing a positive correlation between the arc length and the arc voltage.
  • the arc length information is calculated.
  • the arc length feedback module performs proportional, integral or differential adjustment processing on the arc length information and feeds it back to the control system module.
  • the fusion pole welding machine uses the high-frequency high-voltage arc starting module with its own to start arcing, without short-circuit spark splash, and the welding parameters such as arc length, welding current and wire feeding speed are controllable during the whole welding cycle.
  • the welding speed and the welding quality of the non-melting pole welder can be realized; in addition, the fusion pole welding machine is further provided with an AC/DC conversion control module, so that it has a direct current, a high frequency direct current, a direct current pulse, a high frequency direct current pulse, an alternating current, Various welding modes such as high frequency AC, AC pulse, and high frequency AC pulse.
  • Figure 1 is a schematic view showing a conventional fusion welding machine using a contact short-circuit arc
  • FIG. 2 is a block diagram of a circuit principle module of the fusion welding machine according to an embodiment of the present invention
  • FIG. 3 is a block diagram of another circuit principle module of the fusion welding machine according to an embodiment of the present invention.
  • FIG. 4 is a block diagram showing the principle of the arc length feedback module in the embodiment of the present invention.
  • FIG. 5 is a schematic block diagram of a schematic module of an AC/DC conversion control module according to an embodiment of the present invention.
  • FIG. 6 is a schematic diagram of a specific circuit principle of the AC/DC conversion control module according to an embodiment of the present invention.
  • a fusion welding machine includes a control system module having a synchronous communication interface, a human-machine interface operation and display module connected to the control system module, a current sampling module, and a voltage sampling.
  • the fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting module The output end is connected to the control system module; the arc length feedback module is connected in series between the synchronous communication interface of the control system module and the welding torch, and the arc length information for welding is fed back to the control system module; a wire feed control module is connected in series between the synchronous communication interface of the control system module and the wire feeding device for receiving a wire feed control signal (including wire feed speed and/or wire feed amount) required by the control system module And converting it into corresponding control information to control the wire feed speed and/or wire feed of the wire feeder to achieve the same arc length over a complete weld cycle.
  • a wire feed control signal including wire feed speed and/or wire feed amount
  • the high-frequency high-voltage arc starting module is used for starting arcing in a manner of using a high-frequency high-voltage method in the welding pole welding machine, and when the welding is started, the welding wire is pushed by the wire feeding device to ensure that the tail end of the welding wire and the base material are fixed.
  • the height L when the distance between the welding wire and the base metal is L, the high-frequency high-voltage arc starting module outputs a high-frequency high-voltage signal, and the shielding gas between the welding wire and the base metal is ionized under the action of high-frequency high-voltage, thereby forming an arc, and further This makes the phenomenon of short-circuit spark splash when the arc welding machine is arcing.
  • the fusion welding machine further includes an AC/DC conversion control module connected in series between the output end of the constant current feedback module and the input end of the welding gun.
  • the AC/DC conversion control module By setting the AC/DC conversion control module, it has various welding modes such as direct current, high frequency direct current, direct current pulse, high frequency direct current pulse, alternating current, alternating high frequency, alternating current pulse, alternating high frequency pulse and the like.
  • the functional modules or devices such as the interface operation and the display module, the welding torch, and the wire feeding device are all functional modules or devices that can be realized in the prior art, and the working principle or the specific composition thereof will not be described in detail herein. but It should be noted that, among the above functional modules, multiple functional modules may be integrated into one circuit module according to actual needs to implement their corresponding functions, or the functions of some functional modules may not only use existing hardware circuits or devices.
  • the current sampling module and the voltage sampling module can be integrated in the control system module, or
  • the functions of the current sampling module and the voltage sampling module can be realized by combining hardware and software in the control system module; a functional module can also be divided into multiple functional modules, such as a human-machine interface operation and display module. It is divided into two functions: man-machine interface operation module and man-machine interface operation module.
  • the functional modules in the present invention are not limited to any specific combination of hardware and software; of course, the high frequency high voltage arc starting module, the AC/DC converting control module, and the wire feeding control module are not limited to hardware, or hardware and Software integration.
  • the arc length feedback module, the wire feed control module, and the AC/DC conversion control module in the embodiments of the present invention are further described below.
  • the arc length feedback module includes a voltage acquisition module, an anti-interference module, and an arc length calculation module connected in sequence; the voltage acquisition module is connected to the welding gun to obtain a voltage signal when the welding torch is in operation; The anti-interference module is configured to eliminate an interference signal in the voltage signal to obtain arc voltage information during welding of the fusion welder; the arc length calculation module is configured to calculate an arc according to the obtained arc voltage information Length information and feedback to the control system module.
  • the arc length feedback module obtains the arc voltage signal by acquiring the voltage signal when the welding torch is working, and then eliminating the interference signal in the voltage signal, and finally calculating the arc by the positive correlation between the arc length and the arc voltage. Length information.
  • a high-frequency high-voltage interference signal is generated at the time of arcing, and in the process of obtaining a voltage signal during the operation of the welding torch, there is a melting electrode welding machine during sampling.
  • Some of the specific frequency interferes with the signal, so in order to obtain the actual arc length data, the above-mentioned interference signal (including the high frequency high voltage interference signal and the specific frequency interference signal) is eliminated by the anti-interference module.
  • the high-frequency high-voltage interference signal can be eliminated by means of a hardware circuit, and the specific frequency interference signal can be eliminated by software.
  • the arc length feedback module feeds back the arc length information to a proportional, integral or differential adjustment process and correction process, and then feeds it back to the control system module.
  • the wire feeding control module is configured to receive a wire feeding control signal required by the control system module to send the welding torch, and convert the same into control information, and control the wire feeding speed of the wire feeding device to push the welding wire.
  • the welding current is closely related to the welding process parameters such as wire feeding speed, wire size, and base material thickness. There is a positive correlation between welding current and wire feeding speed when other welding process parameters are unchanged. Therefore, the control system module obtains the welding current information (such as obtained by the current sampling module), and the corresponding welding process parameters (such as the wire size, the base material thickness and the like) are built in the control system module, and finally the welding is calculated.
  • the wire feed speed required for the torch is a wire feeding control signal required by the control system module to send the welding torch, and convert the same into control information, and control the wire feeding speed of the wire feeding device to push the welding wire.
  • the welding current is closely related to the welding process parameters such as wire feeding speed, wire size, and base material thickness. There is a positive correlation between welding current and wire feeding speed when
  • the welding wire is finally matched with the corresponding wire feeding speed and welding current, and finally the arc length is fixed in a complete welding cycle (that is, the arc length is the same in one welding cycle). Or basically the same). Since the arc length is fixed, the arc voltage is fixed, the welding current is fixed, the arc temperature is constant, and the wire feeding speed is constant. Therefore, the fusion electrode welding machine provided by the embodiment of the invention can realize the welding quality and the welding speed of the non-melting pole, and is well solved. Some welding problems exist in the traditional fusion welding machine, such as welding spatter, welding pores, unfused, slag inclusion, uneven wire filling and so on.
  • Appropriate wire feeding speed is a necessary condition for the welding machine to achieve the welding effect with non-melting pole
  • the arc length feedback module is the condition for ensuring the welding effect
  • the information fed back by the arc length feedback module is used to control the system.
  • the module dynamically adjusts the relationship between the welding current and the wire feeding speed, thereby ensuring that the melting electrode welder is always operated in a welding mode in which the arc length is fixed, so that it has a non-melting electrode welding effect.
  • the welding method of the fusion welding machine provided by the embodiment of the present invention is briefly described below, and the welding method includes:
  • the melting pole welding machine uses the high-frequency high-voltage arc starting module to perform arc starting by using a high-frequency high-voltage arcing method
  • the arc length feedback module calculates arc length information at the time of welding based on the signal acquired from the welding torch, and feeds back the arc length information to the control system module;
  • the control system module calculates a wire feed speed required by the fuser welder, and sends corresponding control information to the wire feed control module according to a desired wire feed speed;
  • the wire feeding control module controls the wire feeding speed of the wire feeding device according to the received control information, so that the arc length of the melting electrode welder in one welding cycle is the same or substantially the same.
  • the arc length feedback module when calculating the arc length information, obtains an arc voltage signal by acquiring a voltage signal when the welding torch is working, and then eliminating an interference signal in the voltage signal, and finally calculating a positive correlation between the arc length and the arc voltage. Out arc length information.
  • the arc length feedback module feeds back the arc length information to a proportional, integral or differential adjustment process and correction process, and then feeds it back to the control system module.
  • the fusion electrode welding machine in the embodiment of the present invention preferably has an AC/DC conversion control module.
  • the AC/DC conversion control module has an input positive terminal, an input negative terminal, a first output terminal, and a second output terminal
  • the AC/DC conversion control module includes a first switch module and a second switch module. a third switch module and a fourth switch module; the input positive end, the input end of the first switch module, the output end of the first switch module, the input end of the second switch module, the output end of the second switch module, and The input negative terminals are sequentially connected, the input positive terminal, the input end of the third switch module, the output end of the third switch module, the input end of the fourth switch module, the output end of the fourth switch module, and the input negative end Connecting one end of the third switch module and the fourth switch module as the first output end, and connecting one end of the third switch module and the fourth switch module as the second output end .
  • an LC series circuit is connected in series between the second output end and one end of the third switch module and the fourth switch module.
  • the first switch module, the second switch module, the third switch module and the fourth switch module are the same switch circuit
  • the switch circuit comprises a switching power device, a capacitor and a diode, and the capacitors are connected in parallel Connected between the drain and the source of the switching power device, or the capacitor is connected in parallel between the collector and the emitter of the switching power device;
  • the anode of the diode and the drain of the switching power device a pole or a collector connection, a cathode of the diode being connected to a source or an emitter of the switching power device;
  • a drain or a collector of the switching power device as an input terminal of each switching module, the switching power device
  • a source or an emitter is used as an output of each of the switch modules, and a gate or base of the switching power device is connected to a switch signal source for controlling whether the switching power device is turned on or off.
  • FIG. 6 is a schematic diagram of a specific circuit of the AC/DC conversion control module.
  • the switching power device in this embodiment uses a MOS transistor as a specific embodiment; as shown in FIG. 4, the AC/DC conversion control
  • the module includes MOS tubes Q1, Q2 Q3, Q4, diodes D1, D2, D3, D4, capacitors C1, C2, C3, C4, C5 and inductor L1.
  • the inductor L1 and the capacitor C5 are connected in series to form the LC series circuit.
  • the connection relationship of components such as MOS transistors, diodes, and capacitors is as shown in FIG. 4 and will not be described in detail herein.
  • the gate of each MOS transistor is connected to a switching signal source (not shown in FIG. 4) for controlling the on or off of each MOS transistor.
  • the fusion welding machine By controlling the switching state (on or off) of each switching power device (MOS tube Q1, Q2, Q3, Q4) in the AC/DC module, the fusion welding machine provided by the embodiment of the present invention can have DC and high frequency. DC, DC pulse, high frequency DC pulse, AC, AC high frequency, AC pulse, AC high frequency pulse and other welding modes.
  • the voltage UAB of the two output terminals of the AC/DC conversion control module is always positive (DC); and when the MOS transistors Q2 and Q3 are turned on, Q1 and Q4 are turned off.
  • the voltage UAB of the two output ends of the AC/DC conversion control module is always negative (DC); when the above two states are alternately switched, the voltage UAB of the two output terminals of the AC/DC conversion control module also performs positive and negative voltage polarity.
  • the time ratio between the positive turn-on time and the negative turn-on time of the two output ends of the fusion welding machine can be controlled, and further, according to specific welding materials. Demand, control the heat demand of the workpiece and the wire to achieve the best welding effect, effectively improve the welding quality and welding speed.

Abstract

A consumable electrode welder is provided with a high-frequency high-voltage arc starting module to realize high-frequency high-voltage starting of an arc, thereby preventing short circuit sparks generated by arc starting in a welding process. By arranging an arc-length feedback module and a wire-feeding control module, parameters such as an arc length and a wire-feeding speed can be controlled during a welding process, so that the consumable electrode welder has a welding speed and welding quality of a non- consumable electrode welder. Also disclosed is a welding method of the consumable electrode welder.

Description

一种熔化极焊机及其焊接方法Melting electrode welding machine and welding method thereof
技术领域 Technical field
本发明涉及焊机领域，尤其涉及一种熔化极焊机及其焊接方法。 The invention relates to the field of welding machines, in particular to a fusion pole welding machine and a welding method thereof.
背景技术 Background technique
传统的熔化极焊机采用接触短路起弧,短路起弧时会有火花飞溅的现象，在短路起弧后，在电弧的作用下，焊丝末端形成熔化态的金属球，如图1中的(a)所示，此时电弧长度很短，电弧电压很低，电流很大，电弧温度低、熔解焊丝的能量大；随着熔化的焊丝量增大，电弧长度变大，电弧电压也增大，电弧电流减小，电弧温度升高，熔解焊丝的能量减少,此时焊丝末端的熔滴在重力作用下，熔滴与焊丝相连的部分形成缩径，如图1中的(b)所示；随着熔化的焊丝量进一步增大，电弧长度更长，电弧电压更大，电弧温度更高，缩径进一步变小，所以缩径局部的电流密度激增，产生大量的焦耳热熔化焊丝熔滴，如图1中的(c)所示；当熔滴达到一定限度，熔滴与焊丝分离，并最终落在母材（需要焊接的焊件）上完成一个完整的焊接周期。 The traditional fusion welding machine adopts the contact short-circuit arcing, and there is a spark splash when the short-circuit arc starts. After the short-circuit arcing, under the action of the arc, the molten metal ball forms a molten metal ball, as shown in Fig. 1 ( a), at this time, the arc length is very short, the arc voltage is very low, the current is large, the arc temperature is low, and the energy of the melting wire is large; as the amount of molten wire increases, the arc length becomes larger, and the arc voltage also increases. The arc current is reduced, the arc temperature is increased, and the energy of the melting wire is reduced. At this time, the droplet at the end of the wire is under the action of gravity, and the portion of the droplet connected to the wire is reduced in diameter, as shown in (b) of FIG. As the amount of molten wire is further increased, the arc length is longer, the arc voltage is larger, the arc temperature is higher, and the diameter of the arc is further reduced, so that the local current density of the reduced diameter is sharply increased, and a large amount of Joule hot melt welding wire droplets are generated. As shown in (c) of Figure 1; when the droplet reaches a certain limit, the droplet separates from the wire and eventually falls on the base material (weld parts to be welded) to complete a complete welding cycle.
可见，在传统熔化极焊机的整个焊接周期过程，电弧长度不断变换、电弧电压不断变换、电弧电流不断变换、电弧温度也不断变换；因此在焊接的过程中，焊丝与母材的热量分配不可控，从而使得在焊接过程中导致存在着不少焊接缺陷，如焊接飞溅、焊接气孔、未熔合、夹渣、填丝量不均匀等问题。另外，传统的熔化极焊机只有单一的直流焊接模式、直流脉冲焊接模式，其应用范围较窄。 It can be seen that during the whole welding cycle of the traditional fusion welding machine, the arc length is constantly changing, the arc voltage is constantly changing, the arc current is constantly changing, and the arc temperature is constantly changing; therefore, during the welding process, the heat distribution between the welding wire and the base metal is not possible. Control, so that there are many welding defects in the welding process, such as welding spatter, welding pores, unfused, slag inclusion, uneven wire filling and other issues. In addition, the traditional fusion welding machine has only a single DC welding mode, DC pulse welding mode, and its application range is narrow.
发明内容 Summary of the invention
为了克服现有技术中的不足，本发明提供一种熔化极焊机及其焊接方法，该熔化极焊机采用高频高压起弧方式，没有短路火花飞溅，同时在焊接过程中，电弧长度以及送丝速度等焊接参数可控，可实现非熔化极焊机的焊接速度以及焊接质量；另外，所述熔化极焊机还具有多种焊接方式。 In order to overcome the deficiencies in the prior art, the present invention provides a fusion electrode welder and a welding method thereof, which adopts a high-frequency high-voltage arc-starting method without short-circuit spark splash, and at the same time, during the welding process, the arc length and The welding parameters such as the wire feeding speed are controllable, and the welding speed and the welding quality of the non-melting pole welder can be realized; in addition, the melting electrode welder has various welding methods.
本发明是通过以下技术方案实现的：一种熔化极焊机，所述熔化极焊机包括具有同步通信接口的控制系统模块，电流取样模块，电压取样模块， 依次连接的电源输入模块、直流恒压模块、斩波控制模块、恒流反馈模块以及焊枪，焊枪上连接有用于推送焊丝的送丝装置，所述电流取样模块的输入端与所述直流恒压模块的输出端以及焊枪的输入端均连接，所述电压取样模块的输入端与所述直流恒压模块的输出端以及焊枪的输入端均连接，所述电流取样模块的输出端以及电压取样模块的输出端均与所述控制系统模块连接； 所述熔化极焊机还包括有高频高压起弧模块，电弧长度反馈模块以及送丝控制模块，所述高频高压起弧模块的输入端与焊枪的输入端连接，高频高压起弧模块的输出端与控制系统模块连接； The present invention is achieved by the following technical solutions: a fusion electrode welder comprising a control system module having a synchronous communication interface, a current sampling module, a voltage sampling module, a power input module, a DC constant voltage module, a chopper control module, a constant current feedback module and a welding gun are sequentially connected, and a wire feeding device for pushing the welding wire is connected to the welding gun, and an input end of the current sampling module and the DC constant voltage An output end of the module and an input end of the welding gun are connected, an input end of the voltage sampling module is connected to an output end of the DC constant voltage module and an input end of the welding gun, and an output end of the current sampling module and a voltage sampling module The output ends are all connected to the control system module; The fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting module The output is connected to the control system module;
所述熔化极焊机还包括有高频高压起弧模块，电弧长度反馈模块以及送丝控制模块，所述高频高压起弧模块的输入端与焊枪的输入端连接，高频高压起弧模块的输出端与控制系统模块连接；所述电弧长度反馈模块串联连接于所述控制系统模块的同步通信接口与所述焊枪之间，用于焊接时的电弧长度信息反馈至控制系统模块；所述送丝控制模块串联连接于所述控制系统模块的同步通信接口与所述送丝装置之间，用于接收控制系统模块发出所需的送丝控制信号，并将其转化成相应的控制信息，以控制所述送丝装置的送丝速度和/或送丝量。 The fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting module The output end is connected to the control system module; the arc length feedback module is connected in series between the synchronous communication interface of the control system module and the welding torch, and the arc length information for welding is fed back to the control system module; a wire feeding control module is connected in series between the synchronous communication interface of the control system module and the wire feeding device for receiving a wire feeding control signal required by the control system module and converting the same into control information. To control the wire feed speed and/or wire feed amount of the wire feeder.
优选地，所述电弧长度反馈模块包括依次连接的电压获取模块、抗干扰模块以及电弧长度计算模块；所述电压获取模块与所述焊枪连接，以获取焊枪工作时的电压信号；所述抗干扰模块用于将所述电压信号中的干扰信号消除，以获得熔化极焊机焊接时的电弧电压信息；所述电弧长度计算模块用于根据获得的所述电弧电压信息计算出电弧长度信息，并将其反馈至所述控制系统模块。 Preferably, the arc length feedback module comprises a voltage acquisition module, an anti-interference module and an arc length calculation module connected in sequence; the voltage acquisition module is connected with the welding gun to obtain a voltage signal when the welding torch is working; the anti-interference The module is configured to eliminate the interference signal in the voltage signal to obtain arc voltage information during welding of the fusion welder; the arc length calculation module is configured to calculate arc length information according to the obtained arc voltage information, and It is fed back to the control system module.
进一步地，所述熔化极焊机还包括与控制系统模块连接的人机界面操作及显示模块；所述熔化极焊机还包括交直流变换控制模块，该交直流变换控制模块串联连接于所述恒流反馈模块的输出端与所述焊枪的输入端之间。 Further, the fusion welding machine further includes a human-machine interface operation and display module connected to the control system module; the fusion-pole welding machine further includes an AC-DC conversion control module, wherein the AC-DC conversion control module is connected in series to the An output of the constant current feedback module is coupled to an input of the welding torch.
优选地，所述交直流变换控制模块具有输入正端、输入负端、第一输出端以及第二输出端，所述交直流变换控制模块包括第一开关模块、第二开关模块、第三开关模块以及第四开关模块；所述输入正端、第一开关模块的输入端、第一开关模块的输出端、第二开关模块的输入端、第二开关模块的输出端以及所述输入负端依次连接，所述输入正端、第三开关模块的输入端、第三开关模块的输出端、第四开关模块的输入端、第四开关模块的输出端以及所述输入负端依次连接；所述第三开关模块与第四开关模块的相互连接的一端作为所述第一输出端，所述第三开关模块与第四开关模块的相互连接的一端作为所述第二输出端。 Preferably, the AC/DC conversion control module has an input positive terminal, an input negative terminal, a first output terminal, and a second output terminal, and the AC/DC conversion control module includes a first switch module, a second switch module, and a third switch. a module and a fourth switch module; the input positive terminal, the input end of the first switch module, the output end of the first switch module, the input end of the second switch module, the output end of the second switch module, and the input negative terminal Connected in sequence, the input positive end, the input end of the third switch module, the output end of the third switch module, the input end of the fourth switch module, the output end of the fourth switch module, and the input negative end are sequentially connected; One end of the third switch module and the fourth switch module is connected to the first output end, and one end of the third switch module and the fourth switch module is connected to the second output end.
进一步地，所述第二输出端与所述第三开关模块与第四开关模块的相互连接的一端之间串联连接有LC串联电路。 Further, an LC series circuit is connected in series between the second output end and the interconnected end of the third switch module and the fourth switch module.
本发明提供的熔化极焊机，其焊接方法包括： The welding electrode welding machine provided by the invention has the following welding methods:
所述熔化极焊机利用所述高频高压起弧模块，采用高频高压起弧方式进行起弧； The melting pole welding machine uses the high-frequency high-voltage arc starting module to perform arc starting by using a high-frequency high-voltage arcing method;
所述电弧长度反馈模块根据从焊枪中获取的信号计算出焊接时的电弧长度信息，并将该电弧长度信息反馈至所述控制系统模块； The arc length feedback module calculates arc length information at the time of welding based on the signal acquired from the welding torch, and feeds back the arc length information to the control system module;
所述控制系统模块计算出所述熔化极焊机所需的送丝量，并根据所需的送丝量发出相应的控制信息至所述送丝控制模块； The control system module calculates the wire feed amount required by the melt electrode welder, and sends corresponding control information to the wire feed control module according to the required wire feed amount;
所述送丝控制模块根据接收到的控制信息，控制所述送丝装置的送丝速度，以使所述熔化极焊机在一个焊接周期内的电弧长度相同或基本相同。 The wire feeding control module controls the wire feeding speed of the wire feeding device according to the received control information, so that the arc length of the melting electrode welder in one welding cycle is the same or substantially the same.
优选地，所述电弧长度反馈模块在计算电弧长度信息时，通过获取焊枪工作时的电压信号，然后消除电压信号中的干扰信号获得电弧电压信号，最后通过电弧长度与电弧电压的正相关关系，计算出电弧长度信息。 Preferably, the arc length feedback module obtains an arc voltage signal by acquiring a voltage signal when the welding torch is working, and then canceling an interference signal in the voltage signal, and finally passing a positive correlation between the arc length and the arc voltage. The arc length information is calculated.
优选地，所述电弧长度反馈模块将所述电弧长度信息进行比例、积分或微分的调节处理后再将其反馈至所述控制系统模块。 Preferably, the arc length feedback module performs proportional, integral or differential adjustment processing on the arc length information and feeds it back to the control system module.
本发明提供的熔化极焊机利用自带的高频高压起弧模块进行起弧，没有短路火花飞溅，同时在整个焊接周期过程中，电弧长度，焊接电流、送丝速度等焊接参数可控，可实现非熔化极焊机的焊接速度以及焊接质量；另外，所述熔化极焊机还设置有交直流变换控制模块，使得其具有直流、高频直流、直流脉冲、高频直流脉冲、交流、高频交流、交流脉冲、高频交流脉冲等多种焊接模式。 The fusion pole welding machine provided by the invention uses the high-frequency high-voltage arc starting module with its own to start arcing, without short-circuit spark splash, and the welding parameters such as arc length, welding current and wire feeding speed are controllable during the whole welding cycle. The welding speed and the welding quality of the non-melting pole welder can be realized; in addition, the fusion pole welding machine is further provided with an AC/DC conversion control module, so that it has a direct current, a high frequency direct current, a direct current pulse, a high frequency direct current pulse, an alternating current, Various welding modes such as high frequency AC, AC pulse, and high frequency AC pulse.
附图说明 DRAWINGS
附图1为传统的熔化极焊机采用接触短路起弧的示意图； Figure 1 is a schematic view showing a conventional fusion welding machine using a contact short-circuit arc;
附图2为本发明实施例中所述熔化极焊机的电路原理模块框图； 2 is a block diagram of a circuit principle module of the fusion welding machine according to an embodiment of the present invention;
附图3为本发明实施例中所述熔化极焊机的另一电路原理模块框图； 3 is a block diagram of another circuit principle module of the fusion welding machine according to an embodiment of the present invention;
附图4为本发明实施例中所述电弧长度反馈模块的原理模块框图； 4 is a block diagram showing the principle of the arc length feedback module in the embodiment of the present invention;
附图5为本发明实施例中所述交直流变换控制模块的原理模块框图； 5 is a schematic block diagram of a schematic module of an AC/DC conversion control module according to an embodiment of the present invention;
附图6为本发明实施例中所述交直流变换控制模块的具体电路原理示图。 FIG. 6 is a schematic diagram of a specific circuit principle of the AC/DC conversion control module according to an embodiment of the present invention.
具体实施方式 detailed description
为了便于本领域技术人员的理解，下面结合附图对本发明作进一步的描述。 如附图2所示，一种熔化极焊机，所述熔化极焊机包括具有同步通信接口的控制系统模块，与控制系统模块连接的人机界面操作及显示模块，电流取样模块，电压取样模块，依次连接的电源输入模块、直流恒压模块、斩波控制模块、恒流反馈模块以及焊枪，焊枪上连接有用于推送焊丝的送丝装置，所述电流取样模块的输入端与所述直流恒压模块的输出端以及焊枪的输入端均连接，所述电压取样模块的输入端与所述直流恒压模块的输出端以及焊枪的输入端均连接，所述电流取样模块的输出端以及电压取样模块的输出端均与所述控制系统模块连接； In order to facilitate the understanding of those skilled in the art, the present invention will be further described below in conjunction with the accompanying drawings. As shown in FIG. 2, a fusion welding machine includes a control system module having a synchronous communication interface, a human-machine interface operation and display module connected to the control system module, a current sampling module, and a voltage sampling. a module, a power input module, a DC constant voltage module, a chopper control module, a constant current feedback module and a welding torch, which are connected in sequence, and a wire feeding device for pushing the welding wire is connected to the welding gun, and an input end of the current sampling module and the DC An output end of the constant voltage module and an input end of the welding gun are connected, an input end of the voltage sampling module is connected to an output end of the DC constant voltage module and an input end of the welding gun, and an output end of the current sampling module and a voltage An output of the sampling module is connected to the control system module;
所述熔化极焊机还包括有高频高压起弧模块，电弧长度反馈模块以及送丝控制模块，所述高频高压起弧模块的输入端与焊枪的输入端连接，高频高压起弧模块的输出端与控制系统模块连接；所述电弧长度反馈模块串联连接于所述控制系统模块的同步通信接口与所述焊枪之间，用于焊接时的电弧长度信息反馈至控制系统模块；所述送丝控制模块串联连接于所述控制系统模块的同步通信接口与所述送丝装置之间，用于接收控制系统模块发出所需的送丝控制信号（包括送丝速度和/或送丝量），并将其转化成相应的控制信息，以控制所述送丝装置的送丝速度和/或送丝量，实现在一个完整焊接周期内的电弧长度相同。 The fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting module The output end is connected to the control system module; the arc length feedback module is connected in series between the synchronous communication interface of the control system module and the welding torch, and the arc length information for welding is fed back to the control system module; a wire feed control module is connected in series between the synchronous communication interface of the control system module and the wire feeding device for receiving a wire feed control signal (including wire feed speed and/or wire feed amount) required by the control system module And converting it into corresponding control information to control the wire feed speed and/or wire feed of the wire feeder to achieve the same arc length over a complete weld cycle.
所述高频高压起弧模块用于在所述熔化极焊机采用高频高压的方式起弧，开始焊接时，通过所述送丝装置推送焊丝，确保焊丝的尾端与母材达到固定的高度L，当焊丝与母材的距离为L时，高频高压起弧模块输出高频高压信号，焊丝与母材之间的保护气体在高频高压的作用下产生电离，从而形成电弧，进而使得熔化极焊机在起弧时，避免了短路火花飞溅的现象出现。 The high-frequency high-voltage arc starting module is used for starting arcing in a manner of using a high-frequency high-voltage method in the welding pole welding machine, and when the welding is started, the welding wire is pushed by the wire feeding device to ensure that the tail end of the welding wire and the base material are fixed. The height L, when the distance between the welding wire and the base metal is L, the high-frequency high-voltage arc starting module outputs a high-frequency high-voltage signal, and the shielding gas between the welding wire and the base metal is ionized under the action of high-frequency high-voltage, thereby forming an arc, and further This makes the phenomenon of short-circuit spark splash when the arc welding machine is arcing.
如附图3所示，所述熔化极焊机还包括交直流变换控制模块，该交直流变换控制模块串联连接于所述恒流反馈模块的输出端与所述焊枪的输入端之间。通过设置所述交直流变换控制模块，使得其具有直流、高频直流、直流脉冲、高频直流脉冲、交流、交流高频、交流脉冲、交流高频脉冲等多种焊接模式。 As shown in FIG. 3, the fusion welding machine further includes an AC/DC conversion control module connected in series between the output end of the constant current feedback module and the input end of the welding gun. By setting the AC/DC conversion control module, it has various welding modes such as direct current, high frequency direct current, direct current pulse, high frequency direct current pulse, alternating current, alternating high frequency, alternating current pulse, alternating high frequency pulse and the like.
本发明实施例中，所述的电源输入模块、直流恒压模块、斩波控制模块、恒流反馈模块、电流取样模块、电压取样模块，控制系统模块、人机 界面操作及显示模块、焊枪、送丝装置等各功能模块或装置均为现有技术可实现的功能模块或装置，在此对其工作原理或其具体组成不再详述。但 需说明的是，上述各功能模块中，其可以根据实际需要将多个功能模块集成在一个电路模块来实现其相应的功能，或者某些功能模块的功能不仅可以用现有的硬件电路或装置来实现其功能，还可以通过硬件与软件结合来实现；如电流取样模块、电压取样模块可以集成在控制系统模块中，或者 电流取样模块、电压取样模块的功能可以在控制系统模块内通过硬件与软件结合的方式来实现；还可将某一个功能模块分为多个功能模块来实现，如将人机界面操作及显示模块分为人机界面操作模块、人机界面操作模块两个功能模块等。总之，本发明中的各功能模块不限制于任何特定的硬件和软件结合；当然，包括所述高频高压起弧模块、交直流变换控制模块、送丝控制模块也不限于硬件，或硬件与软件结合。 In the embodiment of the invention, the power input module, the DC constant voltage module, the chopper control module, the constant current feedback module, the current sampling module, the voltage sampling module, the control system module, and the human machine The functional modules or devices such as the interface operation and the display module, the welding torch, and the wire feeding device are all functional modules or devices that can be realized in the prior art, and the working principle or the specific composition thereof will not be described in detail herein. but It should be noted that, among the above functional modules, multiple functional modules may be integrated into one circuit module according to actual needs to implement their corresponding functions, or the functions of some functional modules may not only use existing hardware circuits or devices. To realize its function, it can also be realized by combining hardware and software; for example, the current sampling module and the voltage sampling module can be integrated in the control system module, or The functions of the current sampling module and the voltage sampling module can be realized by combining hardware and software in the control system module; a functional module can also be divided into multiple functional modules, such as a human-machine interface operation and display module. It is divided into two functions: man-machine interface operation module and man-machine interface operation module. In summary, the functional modules in the present invention are not limited to any specific combination of hardware and software; of course, the high frequency high voltage arc starting module, the AC/DC converting control module, and the wire feeding control module are not limited to hardware, or hardware and Software integration.
以下对本发明实施例中的电弧长度反馈模块，送丝控制模块、交直流变换控制模块作进一步的描述说明。 The arc length feedback module, the wire feed control module, and the AC/DC conversion control module in the embodiments of the present invention are further described below.
如附图4所示，所述电弧长度反馈模块包括依次连接的电压获取模块、抗干扰模块以及电弧长度计算模块；所述电压获取模块与所述焊枪连接，以获取焊枪工作时的电压信号；所述抗干扰模块用于将所述电压信号中的干扰信号消除，以获得熔化极焊机焊接时的电弧电压信息；所述电弧长度计算模块用于根据获得的所述电弧电压信息计算出电弧长度信息，并将其反馈至所述控制系统模块。 As shown in FIG. 4, the arc length feedback module includes a voltage acquisition module, an anti-interference module, and an arc length calculation module connected in sequence; the voltage acquisition module is connected to the welding gun to obtain a voltage signal when the welding torch is in operation; The anti-interference module is configured to eliminate an interference signal in the voltage signal to obtain arc voltage information during welding of the fusion welder; the arc length calculation module is configured to calculate an arc according to the obtained arc voltage information Length information and feedback to the control system module.
所述电弧长度反馈模块在计算电弧长度信息时，通过获取焊枪工作时的电压信号，然后消除电压信号中的干扰信号获得电弧电压信号，最后通过电弧长度与电弧电压的正相关关系，计算出电弧长度信息。 When calculating the arc length information, the arc length feedback module obtains the arc voltage signal by acquiring the voltage signal when the welding torch is working, and then eliminating the interference signal in the voltage signal, and finally calculating the arc by the positive correlation between the arc length and the arc voltage. Length information.
由于该熔化极焊机采用高频高压的起弧方式，在起弧时会产生高频高压的干扰信号，同时在获取焊枪工作时的电压信号的过程中，采样时存在着熔化极焊机中的一些特定频率干扰信号，因此为了获得实际的电弧长度数据，通过抗干扰模块来消除上述的干扰信号（包括高频高压干扰信号与特定频率干扰信号）。其中，在消除干扰信号的过程中，可通过硬件电路的方式来消除高频高压干扰信号，通过软件方式来对特定频率干扰信号进行消除。 Since the fusion welding machine adopts a high-frequency high-voltage arcing mode, a high-frequency high-voltage interference signal is generated at the time of arcing, and in the process of obtaining a voltage signal during the operation of the welding torch, there is a melting electrode welding machine during sampling. Some of the specific frequency interferes with the signal, so in order to obtain the actual arc length data, the above-mentioned interference signal (including the high frequency high voltage interference signal and the specific frequency interference signal) is eliminated by the anti-interference module. Among them, in the process of eliminating the interference signal, the high-frequency high-voltage interference signal can be eliminated by means of a hardware circuit, and the specific frequency interference signal can be eliminated by software.
优选地，为了获得更加准确的电弧长度数据，所述电弧长度反馈模块在将所述电弧长度信息进行比例、积分或微分的调节处理与修正处理后，再将其反馈至所述控制系统模块。 Preferably, in order to obtain more accurate arc length data, the arc length feedback module feeds back the arc length information to a proportional, integral or differential adjustment process and correction process, and then feeds it back to the control system module.
所述的送丝控制模块用于接收控制系统模块发出焊枪所需的送丝控制信号，并将其转化成相应的控制信息，控制所述送丝装置推送焊丝的送丝速度。焊接电流的大小，与送丝速度、焊丝大小，母材厚薄等焊接工艺参数密切相关。在其他焊接工艺参数不变的情况下，焊接电流与送丝速度存在着正相关的关系。因此，控制系统模块通过获取焊接电流信息（如通过所述电流采样模块进行获取），并在控制系统模块内置相应的焊接工艺参数（如焊丝大小、母材厚薄等参数），最后计算出在焊接时焊枪所需的送丝速度。 The wire feeding control module is configured to receive a wire feeding control signal required by the control system module to send the welding torch, and convert the same into control information, and control the wire feeding speed of the wire feeding device to push the welding wire. The welding current is closely related to the welding process parameters such as wire feeding speed, wire size, and base material thickness. There is a positive correlation between welding current and wire feeding speed when other welding process parameters are unchanged. Therefore, the control system module obtains the welding current information (such as obtained by the current sampling module), and the corresponding welding process parameters (such as the wire size, the base material thickness and the like) are built in the control system module, and finally the welding is calculated. The wire feed speed required for the torch.
所述熔化极焊机在焊接过程中，焊丝在相应的送丝速度、焊接电流的同步配合下，最终实现了在一个完整焊接周期内的电弧长度固定（即在一焊接周期内，电弧长度相同或基本相同）。由于电弧长度固定，电弧电压相应固定，焊接电流固定、电弧温度恒定，送丝速度恒定，因此本发明实施例提供的熔化极焊机可以实现非熔化极的焊接质量与焊接速度，很好地解决了传统的熔化极焊机存在的一些焊接问题，如焊接飞溅、焊接气孔、未熔合、夹渣、填丝量不均匀等问题。 During the welding process, the welding wire is finally matched with the corresponding wire feeding speed and welding current, and finally the arc length is fixed in a complete welding cycle (that is, the arc length is the same in one welding cycle). Or basically the same). Since the arc length is fixed, the arc voltage is fixed, the welding current is fixed, the arc temperature is constant, and the wire feeding speed is constant. Therefore, the fusion electrode welding machine provided by the embodiment of the invention can realize the welding quality and the welding speed of the non-melting pole, and is well solved. Some welding problems exist in the traditional fusion welding machine, such as welding spatter, welding pores, unfused, slag inclusion, uneven wire filling and so on.
适当的送丝速度是所述熔化极焊机实现具有非熔化极的焊接效果的必备条件，而电弧长度反馈模块则是确保该焊接效果的条件，利用电弧长度反馈模块反馈的信息，控制系统模块动态微调焊接电流与送丝速度的关系，从而确保所述熔化极焊机始终运行于电弧长度固定的焊接模式中，使其具有非熔化极的焊接效果。 Appropriate wire feeding speed is a necessary condition for the welding machine to achieve the welding effect with non-melting pole, and the arc length feedback module is the condition for ensuring the welding effect, and the information fed back by the arc length feedback module is used to control the system. The module dynamically adjusts the relationship between the welding current and the wire feeding speed, thereby ensuring that the melting electrode welder is always operated in a welding mode in which the arc length is fixed, so that it has a non-melting electrode welding effect.
以下简要说明本发明实施例提供的熔化极焊机的焊接方法，所述焊接方法包括： The welding method of the fusion welding machine provided by the embodiment of the present invention is briefly described below, and the welding method includes:
所述熔化极焊机利用所述高频高压起弧模块，采用高频高压起弧方式进行起弧； The melting pole welding machine uses the high-frequency high-voltage arc starting module to perform arc starting by using a high-frequency high-voltage arcing method;
所述电弧长度反馈模块根据从焊枪中获取的信号计算出焊接时的电弧长度信息，并将该电弧长度信息反馈至所述控制系统模块； The arc length feedback module calculates arc length information at the time of welding based on the signal acquired from the welding torch, and feeds back the arc length information to the control system module;
所述控制系统模块计算出所述熔化极焊机所需的送丝速度，并根据所需的送丝速度发出相应的控制信息至所述送丝控制模块； The control system module calculates a wire feed speed required by the fuser welder, and sends corresponding control information to the wire feed control module according to a desired wire feed speed;
所述送丝控制模块根据接收到的控制信息，控制所述送丝装置的送丝速度，以使所述熔化极焊机在一个焊接周期内的电弧长度相同或基本相同。 The wire feeding control module controls the wire feeding speed of the wire feeding device according to the received control information, so that the arc length of the melting electrode welder in one welding cycle is the same or substantially the same.
其中，所述电弧长度反馈模块在计算电弧长度信息时，通过获取焊枪工作时的电压信号，然后消除电压信号中的干扰信号获得电弧电压信号，最后通过电弧长度与电弧电压的正相关关系，计算出电弧长度信息。优选地，为了获得更加准确的电弧长度数据，所述电弧长度反馈模块在将所述电弧长度信息进行比例、积分或微分的调节处理与修正处理后，再将其反馈至所述控制系统模块。 Wherein, when calculating the arc length information, the arc length feedback module obtains an arc voltage signal by acquiring a voltage signal when the welding torch is working, and then eliminating an interference signal in the voltage signal, and finally calculating a positive correlation between the arc length and the arc voltage. Out arc length information. Preferably, in order to obtain more accurate arc length data, the arc length feedback module feeds back the arc length information to a proportional, integral or differential adjustment process and correction process, and then feeds it back to the control system module.
为了解决传统的熔化极焊机只有单一的直流焊接模式、直流脉冲焊接模式，应用范围较窄的问题，本发明实施例中的熔化极焊机优选设置了交直流变换控制模块。 In order to solve the problem that the conventional fusion welding machine has only a single DC welding mode, a DC pulse welding mode, and a narrow application range, the fusion electrode welding machine in the embodiment of the present invention preferably has an AC/DC conversion control module.
如附图5所示，所述交直流变换控制模块具有输入正端、输入负端、第一输出端以及第二输出端，所述交直流变换控制模块包括第一开关模块、第二开关模块、第三开关模块以及第四开关模块；所述输入正端、第一开关模块的输入端、第一开关模块的输出端、第二开关模块的输入端、第二开关模块的输出端以及所述输入负端依次连接，所述输入正端、第三开关模块的输入端、第三开关模块的输出端、第四开关模块的输入端、第四开关模块的输出端以及所述输入负端依次连接；所述第三开关模块与第四开关模块的相互连接的一端作为所述第一输出端，所述第三开关模块与第四开关模块的相互连接的一端作为所述第二输出端。另外，所述第二输出端与所述第三开关模块与第四开关模块的相互连接的一端之间串联连接有LC串联电路。 As shown in FIG. 5, the AC/DC conversion control module has an input positive terminal, an input negative terminal, a first output terminal, and a second output terminal, and the AC/DC conversion control module includes a first switch module and a second switch module. a third switch module and a fourth switch module; the input positive end, the input end of the first switch module, the output end of the first switch module, the input end of the second switch module, the output end of the second switch module, and The input negative terminals are sequentially connected, the input positive terminal, the input end of the third switch module, the output end of the third switch module, the input end of the fourth switch module, the output end of the fourth switch module, and the input negative end Connecting one end of the third switch module and the fourth switch module as the first output end, and connecting one end of the third switch module and the fourth switch module as the second output end . In addition, an LC series circuit is connected in series between the second output end and one end of the third switch module and the fourth switch module.
优选地，所述第一开关模块、第二开关模块、第三开关模块以及第四开关模块为相同的开关电路，所述开关电路包括一开关功率器件，一电容以及一二极管，所述电容并联连接于所述开关功率器件的漏极与源极之间，或者所述电容并联连接于所述开关功率器件的集电极与发射极之间；所述二极管的正极与所述开关功率器件的漏极或集电极连接，所述二极管的负极与所述开关功率器件的源极或发射极连接；所述开关功率器件的漏极或集电极作为各开关模块的输入端，所述开关功率器件的源极或发射极作为各开关模块的输出端，所述开关功率器件的栅极或基极连接有一用于控制开关功率器件导通或截止的开关信号源。 Preferably, the first switch module, the second switch module, the third switch module and the fourth switch module are the same switch circuit, and the switch circuit comprises a switching power device, a capacitor and a diode, and the capacitors are connected in parallel Connected between the drain and the source of the switching power device, or the capacitor is connected in parallel between the collector and the emitter of the switching power device; the anode of the diode and the drain of the switching power device a pole or a collector connection, a cathode of the diode being connected to a source or an emitter of the switching power device; a drain or a collector of the switching power device as an input terminal of each switching module, the switching power device A source or an emitter is used as an output of each of the switch modules, and a gate or base of the switching power device is connected to a switch signal source for controlling whether the switching power device is turned on or off.
附图6为所述交直流变换控制模块具体的电路原理示图，本实施例中的所述的开关功率器件以MOS管为具体实施例；如附图4所示，所述交直流变换控制模块包括MOS管Q1、Q2、 Q3、 Q4，二极管D1、D2、 D3、 D4，电容C1、C2、C3、C4、C5以及电感L1。其中，电感L1与电容C5串联连接组成所述LC串联电路。各MOS管、二极管以及电容等元件的连接关系如附图4所示，这里不再详述。另外，各MOS管的栅极连接一开关信号源（图4中并未画出），用于控制控制各MOS管的导通或截止。通过控制交直流模块中的各开关功率器件（MOS管Q1、Q2、Q3、Q4）的开关状态（导通或截止），即可使本发明实施例提供的熔化极焊机具有直流、高频直流、直流脉冲、高频直流脉冲、交流、交流高频、交流脉冲、交流高频脉冲等多种焊接模式。 6 is a schematic diagram of a specific circuit of the AC/DC conversion control module. The switching power device in this embodiment uses a MOS transistor as a specific embodiment; as shown in FIG. 4, the AC/DC conversion control The module includes MOS tubes Q1, Q2 Q3, Q4, diodes D1, D2, D3, D4, capacitors C1, C2, C3, C4, C5 and inductor L1. The inductor L1 and the capacitor C5 are connected in series to form the LC series circuit. The connection relationship of components such as MOS transistors, diodes, and capacitors is as shown in FIG. 4 and will not be described in detail herein. In addition, the gate of each MOS transistor is connected to a switching signal source (not shown in FIG. 4) for controlling the on or off of each MOS transistor. By controlling the switching state (on or off) of each switching power device (MOS tube Q1, Q2, Q3, Q4) in the AC/DC module, the fusion welding machine provided by the embodiment of the present invention can have DC and high frequency. DC, DC pulse, high frequency DC pulse, AC, AC high frequency, AC pulse, AC high frequency pulse and other welding modes.
当MOS管Q1、Q4导通，Q2、Q3截止时，则所述交直流变换控制模块两输出端的电压UAB恒为正（直流）；而当MOS管Q2、Q3导通，Q1、Q4截止时，则所述交直流变换控制模块两输出端的电压UAB恒为负（直流）；当以上两种状态轮流切换时，所述交直流变换控制模块两输出端的电压UAB也进行着正负电压极性的变换，从而使得本发明实施例提供的熔化极焊机具有上述多种焊接模式。 When the MOS transistors Q1 and Q4 are turned on, and Q2 and Q3 are turned off, the voltage UAB of the two output terminals of the AC/DC conversion control module is always positive (DC); and when the MOS transistors Q2 and Q3 are turned on, Q1 and Q4 are turned off. The voltage UAB of the two output ends of the AC/DC conversion control module is always negative (DC); when the above two states are alternately switched, the voltage UAB of the two output terminals of the AC/DC conversion control module also performs positive and negative voltage polarity. The transformation so that the fusion welding machine provided by the embodiment of the present invention has the above various welding modes.
另外，通过控制各MOS管的导通或截止的时间，即可实现控制所述熔化极焊机的两输出端的正极接通时间与负极接通时间的时间比，进而可根据具体的焊接材料的需求，控制工件与焊丝的热量需求，以达到最佳的焊接效果，有效提高焊接质量和焊接速度。 In addition, by controlling the turn-on or turn-off time of each MOS transistor, the time ratio between the positive turn-on time and the negative turn-on time of the two output ends of the fusion welding machine can be controlled, and further, according to specific welding materials. Demand, control the heat demand of the workpiece and the wire to achieve the best welding effect, effectively improve the welding quality and welding speed.
上述实施例中提到的内容为本发明较佳的实施方式，并非是对本发明的限定，在不脱离本发明构思的前提下，任何显而易见的替换均在本发明的保护范围之内。 The above mentioned embodiments are a preferred embodiment of the present invention, and are not intended to limit the present invention, and any obvious alternatives are within the scope of the present invention without departing from the inventive concept.

Claims (10)

  1. 一种熔化极焊机， 所述熔化极焊机包括具有同步通信接口的控制系统模块，电流取样模块，电压取样模块，依次连接的电源输入模块、直流 恒压模块、斩波控制模块、恒流反馈模块以及焊枪，焊枪上连接有用于推送焊丝的送丝装置，所述电流取样模块的输入端与所述直流恒压模块的输出端以及焊枪的输入端均连接，所述电压取样模块的输入端与所述直流恒压模块的输出端以及焊枪的输入端均连接，所述电流取样模块的输出端以及电压取样模块的输出端均与所述控制系统模块连接，其特征在于：  a melting electrode welder, The fusion welding machine comprises a control system module with a synchronous communication interface, a current sampling module, a voltage sampling module, a power input module connected in turn, a direct current a constant voltage module, a chopper control module, a constant current feedback module and a welding gun, and a wire feeding device for pushing the welding wire is connected to the welding gun, an input end of the current sampling module and an output end of the DC constant voltage module and an input of the welding gun The terminals of the voltage sampling module are connected to the output end of the DC constant voltage module and the input end of the welding gun, and the output end of the current sampling module and the output end of the voltage sampling module are connected to the control. System module connection, which is characterized by:
    所述熔化极焊机还包括有高频高压起弧模块，电弧长度反馈模块以及送丝控制模块，所述高频高压起弧模块的输入端与焊枪的输入端连接，高频高压起弧模块的输出端与控制系统模块连接；所述电弧长度反馈模块串联连接于所述控制系统模块的同步通信接口与所述焊枪之间，用于焊接时 的电弧长度信息反馈至控制系统模块；所述送丝控制模块串联连接于所述控制系统模块的同步通信接口与所述送丝装置之间，用于接收控制系统模块发出所需的送丝控制信号，并将其转化成相应的控制信息，以控制所述送丝装置的送丝速度和/或送丝量。The fusion welding machine further comprises a high frequency high voltage arc starting module, an arc length feedback module and a wire feeding control module, wherein the input end of the high frequency high voltage arc starting module is connected with the input end of the welding gun, and the high frequency high voltage arc starting module The output end is connected to the control system module; the arc length feedback module is connected in series between the synchronous communication interface of the control system module and the welding gun for welding The arc length information is fed back to the control system module; the wire feed control module is connected in series between the synchronous communication interface of the control system module and the wire feeding device for receiving the wire feeding control required by the control system module The signal is converted to corresponding control information to control the wire feed speed and/or wire feed amount of the wire feeder.
  2. 根据权利要求1所述的熔化极焊机，其特征在于：所述电弧长度反馈模块包括依次连接的电压获取模块、抗干扰模块以及电弧长度计算模块；所述电压获取模块与所述焊枪连接，以获取焊枪工作时的电压信号；所述抗干扰模块用于将所述电压信号中的干扰信号消除，以获得熔化极焊机焊接时的电弧电压信息；所述电弧长度计算模块用于根据获得的所述电弧电压信息计算出电弧长度信息，并将其反馈至所述控制系统模块。 The fusion welding machine according to claim 1, wherein the arc length feedback module comprises a voltage acquisition module, an anti-interference module and an arc length calculation module connected in sequence; the voltage acquisition module is connected to the welding gun, Obtaining a voltage signal when the welding torch is working; the anti-interference module is configured to eliminate the interference signal in the voltage signal to obtain arc voltage information when the welding machine is welded; the arc length calculating module is configured to obtain The arc voltage information calculates arc length information and feeds it back to the control system module.
  3. 根据权利要求2所述的熔化极焊机，其特征在于：所述熔化极焊焊机还包括与控制系统模块连接的人机界面操作及显示模块。 The fusion arc welder of claim 2 wherein said welder welder further comprises a human interface operation and display module coupled to the control system module.
  4. 根据权利要求1～3中任一项所述的熔化极焊机，其特征在于：所述熔化极焊机还包括交直流变换控制模块，该交直流变换控制模块串联连接于所述恒流反馈模块的输出端与所述焊枪的输入端之间。 The fusion welding machine according to any one of claims 1 to 3, wherein the fusion welding machine further comprises an AC/DC conversion control module, wherein the AC/DC conversion control module is connected in series to the constant current feedback The output of the module is between the input of the torch and the input of the torch.
  5. 根据权利要求4所述的熔化极焊机，其特征在于：所述交直流变换控制模块具有输入正端、输入负端、第一输出端以及第二输出端，所述交直流变换控制模块包括第一开关模块、第二开关模块、第三开关模块以及第四开关模块；所述输入正端、第一开关模块的输入端、第一开关模块的输出端、第二开关模块的输入端、第二开关模块的输出端以及所述输入负端依次连接，所述输入正端、第三开关模块的输入端、第三开关模块的输 出端、第四开关模块的输入端、第四开关模块的输出端以及所述输入负端依次连接；所述第三开关模块与第四开关模块的相互连接的一端作为所述第一输出端，所述第三开关模块与第四开关模块的相互连接的一端作为所述第二输出端。 The fusion welding machine according to claim 4, wherein the AC/DC conversion control module has an input positive terminal, an input negative terminal, a first output terminal, and a second output terminal, and the AC/DC conversion control module includes a first switch module, a second switch module, a third switch module, and a fourth switch module; the input positive end, the input end of the first switch module, the output end of the first switch module, the input end of the second switch module, The output end of the second switch module and the input negative end are sequentially connected, and the input positive end, the input end of the third switch module, and the input of the third switch module An output end of the fourth switch module, an output end of the fourth switch module, and the input negative end are sequentially connected; an interconnected end of the third switch module and the fourth switch module is used as the first output end An interconnecting end of the third switch module and the fourth switch module serves as the second output end.
  6. 根据权利要求5所述的熔化极焊机，其特征在于：所述第二输出端与所述第三开关模块与第四开关模块的相互连接的一端之间串联连接有LC串联电路。 The fusion welding machine according to claim 5, wherein an LC series circuit is connected in series between the second output end and the interconnected end of the third switch module and the fourth switch module.
  7. 根据权利要求5所述的熔化极焊机，其特征在于：所述第一开关模块、第二开关模块、第三开关模块以及第四开关模块为相同的开关电路，所述开关电路包括一开关功率器件，一电容以及一二极管，所述电容并联连接于所述开关功率器件的漏极与源极之间，或者所述电容并联连接于所述开关功率器件的集电极与发射极之间；所述二极管的正极与所述开关功 率器件的漏极或集电极连接，所述二极管的负极与所述开关功率器件的源极或发射极连接；所述开关功率器件的漏极或集电极作为各开关模块的输入端，所述开关功率器件的源极或发射极作为各开关模块的输出端，所述开关功率器件的栅极或基极连接有一用于控制开关功率器件导通或截止的开关信号源。 The fusion welding machine according to claim 5, wherein the first switch module, the second switch module, the third switch module, and the fourth switch module are the same switch circuit, and the switch circuit includes a switch a power device, a capacitor and a diode, the capacitor is connected in parallel between the drain and the source of the switching power device, or the capacitor is connected in parallel between the collector and the emitter of the switching power device; a positive pole of the diode and the switching work a drain or collector connection of the device, a cathode of the diode being coupled to a source or an emitter of the switching power device; a drain or collector of the switching power device as an input of each switching module, The source or emitter of the switching power device is used as an output of each switching module, and a gate or base of the switching power device is connected with a switching signal source for controlling whether the switching power device is turned on or off.
  8. 一种应用于权利要求1～7中任一项所述熔化极焊机的焊接方法，其特征在于，所述焊接方法包括：A welding method for use in a fusion welding machine according to any one of claims 1 to 7, wherein the welding method comprises:
    所述熔化极焊机利用所述高频高压起弧模块，采用高频高压起弧方式进行起弧；The melting pole welding machine uses the high-frequency high-voltage arc starting module to perform arc starting by using a high-frequency high-voltage arcing method;
    所述电弧长度反馈模块根据从焊枪中获取的信号计算出焊接时的电弧长度信息，并将该电弧长度信息反馈至所述控制系统模块；The arc length feedback module calculates arc length information at the time of welding based on the signal acquired from the welding torch, and feeds back the arc length information to the control system module;
    所述控制系统模块计算出所述熔化极焊机所需的送丝速度，并根据所需的送丝速度发出相应的控制信息至所述送丝控制模块；The control system module calculates a wire feed speed required by the fuser welder, and sends corresponding control information to the wire feed control module according to a desired wire feed speed;
    所述送丝控制模块根据接收到的控制信息，控制所述送丝装置的送丝速度，以使所述熔化极焊机在一个焊接周期内的电弧长度相同或基本相同 The wire feeding control module controls the wire feeding speed of the wire feeding device according to the received control information, so that the arc length of the melting electrode welder in one welding cycle is the same or substantially the same
  9. 根据权利要求8所述的焊接方法，其特征在于：所述电弧长度反馈模块在计算电弧长度信息时，通过获取焊枪工作时的电压信号，然后消除电压信号中的干扰信号获得电弧电压信号，最后通过电弧长度与电弧电压的正相关关系，计算出电弧长度信息。 The welding method according to claim 8, wherein the arc length feedback module obtains an arc voltage signal by acquiring a voltage signal during operation of the welding torch and then eliminating an interference signal in the voltage signal when calculating the arc length information, and finally The arc length information is calculated by the positive correlation between the arc length and the arc voltage.
  10. 根据权利要求9所述的焊接方法，其特征在于：所述电弧长度反馈模块在将所述电弧长度信息进行比例、积分或微分的调节处理后再将其反馈至所述控制系统模块。 The welding method according to claim 9, wherein the arc length feedback module feeds back the arc length information to a proportional, integral or differential adjustment process and feeds it back to the control system module.
PCT/CN2015/095872 2015-10-14 2015-11-28 Consumable electrode welder and welding method thereof WO2017063253A1 (en)

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CN109128177B (en) * 2018-09-14 2020-09-29 河海大学常州校区 Method for controlling arc length of additive manufacturing arc and flatness of end face of formed part
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