CN109420822B - Pulse arc welding control method - Google Patents
Pulse arc welding control method Download PDFInfo
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- CN109420822B CN109420822B CN201810899870.5A CN201810899870A CN109420822B CN 109420822 B CN109420822 B CN 109420822B CN 201810899870 A CN201810899870 A CN 201810899870A CN 109420822 B CN109420822 B CN 109420822B
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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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Abstract
The invention provides a pulse arc welding control method. The generation of spatter is reduced in pulse arc welding at a small current value. In a pulse arc welding control method in which a welding current (Iw) is increased in an increase period (Tu) from a base current value (Ib) to a peak current value (Ip), the peak current value (Ip) is set in a peak period (Tp), the peak current value (Ip) is decreased in a decrease period (Td1, Td2) from the peak current value (Ip) to the base current value (Ib), the base current value (Ib) is set in a base period (Tb), and welding is performed by turning on the welding current (Iw), the change rate is decreased with time in the increase period (Tu), the decrease period is composed of a 1 st decrease period (Td1) and a 2 nd decrease period (Td2), the welding current (Iw) is linearly decreased in the 1 st decrease period (Td1), the welding current (Iw) is decreased in the 2 nd decrease period (Td2), the absolute value of the change rate is decreased with time, and the absolute value of the change rate of the welding current (Iw) is larger than that in the 1 st decrease period (Td1) in the decrease period (2) .
Description
Technical Field
The present invention relates to a pulse arc welding control method for feeding a welding wire and applying a welding current that increases from a base current value to a peak current value in an increasing period to obtain the peak current value, decreases from the peak current value to the base current value in a decreasing period to obtain the base current value in the base period to perform welding.
Background
Consumable electrode pulsed arc welding is widely used in the welding of steel, stainless steel, and the like. In the pulse arc welding, the welding current is turned on by increasing the current from the base current value to the peak current value in the increasing period, and then decreasing the current from the peak current value to the base current value in the decreasing period, and then changing the current to the base current value in the base period, and the welding is performed by repeating the energization as a 1-pulse cycle. In pulse arc welding, since the 1-pulse cycle is in the 1-droplet transient state, the droplet transient state is stable, the generation of spatters is reduced, and a beautiful bead appearance can be obtained.
Documents of the prior art
Patent document
Patent document 1: JP 2006-75890A
In pulse arc welding, when a thin plate is welded at a low current value of about 150A or less, the arc length is set to be shorter than when welding is performed at medium and high current values. If the arc length is set short, there is a problem that short circuit between the welding wire and the base material is likely to occur and spatter is often generated. In particular, since stainless steel wire is more viscous than steel wire, this tendency becomes remarkable.
Disclosure of Invention
Therefore, an object of the present invention is to provide a pulse arc welding control method capable of reducing the amount of spatter generated in pulse arc welding at a small current value.
In order to solve the above-described problems, the invention according to claim 1 is a pulse arc welding control method for feeding a welding wire and applying a welding current, which increases from a base current value to a peak current value in a rising period, becomes the peak current value in a peak period, decreases from the peak current value to the base current value in a falling period, and becomes the base current value in a base period, the pulse arc welding control method characterized in that the welding current in the rising period rises and the change rate decreases with time, the falling period is composed of a 1 st falling period and a 2 nd falling period, the welding current in the 1 st falling period linearly decreases, the welding current in the 2 nd falling period decreases and the change rate decreases with time, and the absolute value of the change rate of the welding current is larger than that in the 2 nd falling period in the 1 st falling period and welding is performed with the welding current being supplied thereto In (1).
The invention of claim 2 is the pulse arc welding control method according to claim 1, wherein the 1 st falling period is a period from the peak current value to a predetermined reference current value, and the 2 nd falling period is a period from the reference current value to the base current value.
The invention according to claim 3 is the pulse arc welding control method according to any one of claims 1 to 2, characterized in that the time length of the peak period is set to 0.3ms or less.
The invention according to claim 4 is the pulse arc welding control method according to any one of claims 1 to 3, characterized in that an absolute value of a rate of change of the welding current in the 1 st falling period is set to 500A/ms or more.
The invention of claim 5 is characterized in that, in the pulse arc welding control method according to any one of claims 1 to 4, the reference current value is set to be smaller as the peak current value is larger.
The invention of claim 6 is the pulse arc welding control method according to any one of claims 1 to 5, characterized in that the reference current value is set to be smaller as the viscosity of the welding wire is larger.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, the amount of spatter generated can be reduced in pulse arc welding at a small current value.
Drawings
Fig. 1 is a current-voltage waveform diagram illustrating a pulse arc welding control method according to embodiment 1 of the present invention.
Fig. 2 is a block diagram of a welding apparatus for carrying out the pulse arc welding control method according to embodiment 1 of the present invention.
Fig. 3 is a block diagram of a welding apparatus for carrying out the pulse arc welding control method according to embodiment 2 of the present invention.
Fig. 4 is a block diagram of a welding apparatus for carrying out the pulse arc welding control method according to embodiment 3 of the present invention.
Description of reference numerals
1 welding wire
2 base material
3 arc of electricity
4 welding torch
5 feed roller
DV drive circuit
Dv drive signal
EI current error amplifying circuit
Ei current error amplified signal
EV voltage error amplifying circuit
Ev voltage error amplified signal
FC feed control circuit
Fc feed control signal
FR feed speed setting circuit
Fr feed rate setting signal
Current value of base Ib
IBR basic value current setting circuit
Ibr peak current setting signal
ID current detection circuit
Id current detection signal
Ip peak current value
IPR peak current setting circuit
Ipr peak current setting signal
IR current setting circuit
Ir current setting signal
It reference current value
ITR reference current setting circuit
Itr reference current setting signal
ITR3 3 rd reference current setting circuit
Iw welding current
MC power supply main circuit
On start signal
PS welding power supply
RC robot control device
During the Tb base value
1 st falling period of Td1
1 st falling period setting circuit for TD1R
Td1r falling period setting signal
Td2 falling period 2
TD2R falling period setting circuit 2
Td2r falling period setting signal
Tf pulse period (Signal)
Tp peak period
TPR peak period setting circuit
Tpr peak period setting signal
During the Tu rise period
TUR rise period setting circuit
Tur rise period setting signal
VAV voltage averaging circuit
Vav voltage average signal
VD voltage detection circuit
Vd voltage detection signal
VF V/F converter
VR voltage setting circuit
Vr voltage setting signal
Vw welding voltage
WL reactor
WM feed motor
WS welding wire type selection circuit
Ws welding wire type selection signal
Detailed Description
Embodiments of the present invention are described below with reference to the drawings.
[ embodiment 1]
Fig. 1 is a current-voltage waveform diagram illustrating a pulse arc welding control method according to embodiment 1 of the present invention. Fig. a shows a temporal change in welding current Iw, and fig. B shows a temporal change in welding voltage Vw. The operation is described below with reference to this drawing.
In the figure, the period from time t1 to time t2 is an increase period Tu, the period from time t2 to time t3 is a peak period Tp, the period from time t3 to time t4 is a decrease period Td, and the period from time t4 to time t5 is a base period Tb. The period from time t1 to time t5 corresponds to a 1 pulse period Tf. The rise period Tu, peak period Tp, and fall period Td are set to given values. The base period Tb is changed from moment to moment by arc length control described later. As a result, the pulse period Tf also changes from moment to moment. In the present specification, the magnitude of the change rate of the welding current Iw refers to the magnitude of the absolute value of the change rate.
In the increasing period Tu from time t1 to t2, as shown in fig. a, the welding current Iw increases from the base current value Ib to the peak current value Ip, and the rate of change is made smaller with time. The base current value Ib and the peak current value Ip are given values. As shown in fig. B, welding voltage Vw has a waveform similar to the current waveform, and has a voltage value proportional to the arc length.
In peak period Tp from time t2 to time t3, welding current Iw becomes peak current value Ip as shown in (a) of the figure. As shown in fig. B, welding voltage Vw has a peak voltage value proportional to the arc length.
The falling period Td from time t3 to time t4 includes a 1 st falling period Td1 during which the peak current value Ip falls to a predetermined reference current value It, and a 2 nd falling period Td2 during which the reference current value It falls to the base current value Ib. Ib < It < Ip. The rate of change of the welding current Iw is greater in the 1 st falling period Td1 than in the 2 nd falling period Td 2. The welding current Iw in the 1 st falling period Td1 falls linearly. The welding current Iw in the 2 nd falling period Td2 falls, leaving the rate of change smaller with time. As shown in fig. B, welding voltage Vw has a waveform similar to the current waveform, and has a voltage value proportional to the arc length.
In a base period Tb from time t4 to time t5, welding current Iw becomes base current value Ib as shown in fig. a. As shown in fig. B, welding voltage Vw is a base voltage value proportional to the arc length.
The base period Tb (pulse period Tf) is feedback-controlled so that the average value of the welding voltage Vw is equal to a predetermined voltage set value. Since the average value of the welding voltage Vw is proportional to the average arc length, the feedback control controls the arc length to a given value. This control is referred to as arc length control for this reason.
The rise period Tu, the peak period Tp, the fall period Td, and the peak current value Ip are set to predetermined values so that the droplet transient state becomes favorable.
The operation and effect of the present embodiment will be described below. By the operational effects described below, in the present embodiment, high-quality thin plate welding with a small amount of spatter generated can be performed in pulse arc welding at a small current value.
(effect 1) by reducing the change rate of the welding current Iw in the rise period Tu with time, an excessive heat input and an excessive arc pressure are not applied to the base material rapidly. As a result, burn-through of the sheet can be suppressed.
(effect 2) by increasing the rate of change of the welding current Iw in the 1 st falling period Td1, the position of arc generation is shifted to the tip of the welding wire, and the heat input from the arc to the welding wire is reduced, thereby suppressing softening of the welding wire. This prevents the droplets from extending in a long and narrow manner, and the droplets are formed into a shape close to a sphere. As a result, the occurrence of short circuits can be suppressed.
(effect 3) by reducing the change rate of the welding current Iw in the 2 nd lowering period Td2 with time, the arc directivity can be maintained and the arc deflection can be suppressed. When the change rate of the welding current Iw in the 2 nd falling period Td2 is set to be as large as that in the 1 st falling period Td1, the arc directivity is rapidly lost and the arc is easily deflected. This can suppress the arc generation state from becoming unstable.
Further, the welding performance can be improved as follows.
(effect 4) by setting the time length of the peak period Tp to 0.3ms or less, the above-described effect 1 can be more surely achieved. That is, the heat input to the base material and the arc pressure can be made smaller, and burning through of the thin plate can be more reliably suppressed.
(effect 5) by setting the change rate of the welding current Iw in the 1 st falling period Td1 to 500A/ms or more, the above-described effect 2 can be more surely achieved. That is, the shape in which droplets are elongated is reliably suppressed, and the occurrence of short circuits can be further suppressed.
Numerical examples of the above parameters are shown below. Tu 2ms, Tp 0.2ms, Td 2.3ms, Ip 400A, Ib 40A, It 100A.
Fig. 2 is a block diagram of a welding apparatus used in the pulse arc welding control method according to embodiment 1 of the present invention in real time. The welding apparatus is mainly configured by a welding power source PS surrounded by a broken line, a robot controller RC, a robot (not shown), and the like. Each block is described below with reference to the figure.
The welding power source PS is constituted by the following blocks. Power supply main circuit MC receives a 3-phase commercial ac power supply (not shown) such as 200V, performs output control such as inverter control in accordance with a drive signal Dv to be described later, and outputs welding voltage Vw and welding current Iw suitable for welding. Although not shown, the power supply main circuit MC includes: a 1-time rectification circuit for rectifying an alternating current commercial power supply; a capacitor for smoothing the rectified direct current; an inverter circuit for converting the smoothed direct current into a high-frequency alternating current according to a drive signal Dv; the inverter transformer is used for reducing the high-frequency alternating current to a voltage value suitable for welding; and a 2-time rectification circuit for rectifying the high-frequency alternating current with voltage reduction. The reactor WL is inserted between the + side output of the power main circuit MC and the welding torch 4, and smoothes the output of the power main circuit MC.
The voltage detection circuit VD detects the welding voltage Vw and outputs a voltage detection signal VD. The voltage averaging circuit VAV averages (passes through a low-pass filter) the voltage detection signals Vd and outputs a voltage average signal VAV. The voltage setting circuit VR outputs a voltage setting signal VR of a desired value. The voltage error amplifier circuit EV amplifies an error between the voltage setting signal Vr (+) and the voltage average signal Vav (-) and outputs a voltage error amplification signal EV.
The V/F converter VF outputs a pulse period signal Tf, which is a trigger signal having a high level for a short time, at a frequency corresponding to the voltage error amplification signal Ev. The period in which the pulse period signal Tf becomes a short-time high level becomes a 1-pulse period.
The rising period setting circuit TUR outputs a predetermined rising period setting signal TUR. The peak period setting circuit TPR outputs a predetermined peak period setting signal TPR. The 1 st falling period setting circuit TD1R outputs a predetermined 1 st falling period setting signal Tdlr. The 2 nd falling period setting circuit TD2R outputs a predetermined 2 nd falling period setting signal TD2 r.
The peak current setting circuit IPR outputs a predetermined peak current setting signal IPR. The base current setting circuit IBR outputs a predetermined base current setting signal IBR. The reference current setting circuit ITR outputs a predetermined reference current setting signal ITR.
The current setting circuit IR receives the pulse period signal Tf, the rising period setting signal Tur, the peak period setting signal Tpr, the 1 st falling period setting signal Td1r, the 2 nd falling period setting signal Td2r, the peak current setting signal Ipr, the base current setting signal Ibr, and the reference current setting signal Itr as input, and performs the following processing every time the pulse period signal Tf changes to a short-time high level, thereby outputting a current setting signal IR.
1) When the pulse period signal Tf changes to the high level, the current setting signal Ir is output during the rising period Tu determined by the rising period setting signal Tur, and the current setting signal Ir is increased from the value of the base current setting signal Ibr to the value of the peak current setting signal Ipr to decrease the rate of change with time.
2) Next, in the peak period Tp determined by the peak period setting signal Tpr, the peak current setting signal Ipr is output as the current setting signal Ir.
3) Next, a current setting signal Ir linearly decreased from the value of the peak current setting signal Ipr to the value of the reference current setting signal Itr is output during the 1 st falling period Td1 determined by the 1 st falling period setting signal Td1 r.
4) Next, the current setting signal Ir is outputted during the 2 nd falling period Td2 determined by the 2 nd falling period setting signal Td2r, and the current is decreased from the value of the reference current setting signal Itr to the value of the base current setting signal Ibr with the change rate being made smaller with time.
5) Next, in the base period Tb until the pulse period signal Tf becomes high level for a short time again, the base current setting signal Ibr is output as the current setting signal Ir.
The current detection circuit ID detects the welding current Iw and outputs a current detection signal ID. The current error amplifier circuit EI amplifies an error between the current setting signal Ir (+) and the current detection signal Id (-) and outputs a current error amplification signal EI.
The drive circuit DV receives the current error amplification signal Ei and a start signal On from a robot control device RC described later as inputs, performs PWM modulation control based On the current error amplification signal Ei when the start signal On is at a high level (start of welding), outputs a drive signal DV for driving the inverter circuit in the power main circuit MC, and does not output the drive signal DV when the start signal On is at a low level (stop of welding).
The feed rate setting circuit FR outputs a predetermined feed rate setting signal FR. The feed control circuit FC receives the feed speed setting signal Fr and a start signal On from a robot control device RC described later as inputs, and outputs a feed control signal FC for feeding the welding wire 1 at a feed speed determined by the feed speed setting signal Fr to the feed motor WM when the start signal On is high (start of welding), and outputs the feed control signal FC for stopping feeding when the start signal On is low (stop of welding).
The robot control device RC moves a robot (not shown) according to a previously taught task program and outputs a start signal On instructing welding start or welding stop.
[ embodiment 2]
In the invention according to embodiment 2, the reference current value is set to be smaller as the peak current value is larger.
Fig. 3 is a block diagram of a welding apparatus used in the pulse arc welding control method according to embodiment 2 of the present invention in real time. In this figure, the same reference numerals are assigned to the same blocks corresponding to fig. 2, and the description thereof will not be repeated. In this figure, the reference current setting circuit ITR of fig. 2 is replaced with a 2 nd reference current setting circuit ITR 2. The blocks are described below with reference to the figure.
The 2 nd reference current setting circuit ITR2 outputs a reference current setting signal ITR calculated by a predetermined reference current value calculation function having the above-described peak current setting signal Ipr as an input. The reference current value calculation function is defined experimentally in advance, and the larger the value of the peak current setting signal Ipr is, the smaller the value of the reference current setting signal Itr is. For example, Itr 230-Ipr × 0.3.
The current-voltage waveform diagram in fig. 3 showing the pulse arc welding control method according to embodiment 2 of the present invention is the same as that in fig. 1 described above. However, the reference current value It varies depending on the peak current value Ip.
By changing reference current value It in accordance with peak current value Ip, the following effects are obtained in addition to the effects of embodiment 1. In effect 2 of embodiment 1 described above, when the peak current value Ip is increased, the droplet tends to be elongated. Therefore, by reducing the reference current value It as the peak current value Ip is larger, the droplet is more strongly suppressed from being elongated and elongated, and can be formed into a shape close to a sphere. As a result, the occurrence of short circuits can be more reliably suppressed.
[ embodiment 3]
In the invention according to embodiment 3, the reference current value is set to be smaller as the viscosity of the wire is higher.
Fig. 4 is a block diagram of a welding apparatus for carrying out the pulse arc welding control method according to embodiment 3 of the present invention. This figure corresponds to fig. 3, and the same reference numerals are assigned to the same blocks, and their description will not be repeated. In this figure, a wire type selection circuit WS is added to fig. 2, and the 2 nd reference current setting circuit ITR2 of fig. 3 is replaced with a 3 rd reference current setting circuit ITR 3. These blocks are described below with reference to this figure.
The wire type selection circuit WS is a switch selected by a welding operator according to the type of the wire, and outputs a wire type selection signal WS, which becomes 1 when steel is selected and 2 when stainless steel is selected.
The 3 rd reference current setting circuit ITR3 receives the peak current setting signal Ipr and the wire type selection signal Ws as input signals, and outputs the reference current setting signal ITR calculated by the reference current value calculation function when the wire type selection signal Ws is 2 (stainless steel), and outputs a value obtained by adding a predetermined value to the value calculated by the reference current value calculation function when the wire type selection signal Ws is 1 (steel) as the reference current setting signal ITR. For example, the given value is 50A. When the material of the welding wire is stainless steel, the viscosity of the welding wire is higher than when the material is steel. Therefore, the reference current value It is set to be smaller as the viscosity of the wire is larger.
The current-voltage waveform diagram in fig. 3 showing the pulse arc welding control method according to embodiment 3 of the present invention is the same as that in fig. 1 described above. However, the reference current value It varies depending on the peak current value Ip and the viscosity of the wire.
By making reference current value It correspond to peak current value Ip and the change in the viscosity of the wire, the following effects are obtained in addition to the effects of embodiment 2. In effect 2 of embodiment 1 described above, when the viscosity of the wire is increased, the droplets tend to elongate and extend more strongly. Therefore, the droplet is more strongly suppressed from forming a shape extending in a long and narrow direction by reducing the reference current value It as the viscosity of the wire is larger, and can be made to approach a sphere. As a result, the occurrence of short circuits can be more reliably suppressed. When the viscosity of the wire is small, the reference current value It is increased to strongly maintain the arc directivity, and thus the arc generation state can be suppressed from becoming unstable.
Claims (3)
1. A pulse arc welding control method, which comprises the following steps,
feeding a welding wire, and applying a welding current which increases from a base current value to a peak current value during an increasing period and becomes the peak current value during the peak period, and which decreases from the peak current value to the base current value during a decreasing period and becomes the base current value during the base period to perform welding,
the pulse arc welding control method is characterized in that,
the welding current in the rise period is raised, the change rate is reduced along with time in a mode of not giving excessive heat input and excessive arc pressure to the base material rapidly,
the falling period is composed of a 1 st falling period and a 2 nd falling period,
the welding current in the 1 st descending period linearly descends, the welding current in the 2 nd descending period descends, the absolute value of the change rate is reduced along with time in a mode of keeping the directionality of the arc and restraining the arc deviation,
the absolute value of the change rate of the welding current is greater in the 1 st falling period than in the 2 nd falling period,
the 1 st falling period is a period from the peak current value to a predetermined reference current value, the 2 nd falling period is a period from the reference current value to the base current value,
the reference current value is set smaller as the peak current value is larger,
the reference current value is set to be smaller as the viscosity of the welding wire is larger.
2. The pulsed arc welding control method according to claim 1,
the time length of the peak period is set to 0.3ms or less.
3. The pulse arc welding control method according to claim 1 or 2, wherein an absolute value of a change rate of the welding current in the 1 st falling period is set to 500A/ms or more.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2017166574A JP6941410B2 (en) | 2017-08-31 | 2017-08-31 | Pulse arc welding control method |
| JP2017-166574 | 2017-08-31 |
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| Publication Number | Publication Date |
|---|---|
| CN109420822A CN109420822A (en) | 2019-03-05 |
| CN109420822B true CN109420822B (en) | 2022-03-01 |
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| CN201810899870.5A Active CN109420822B (en) | 2017-08-31 | 2018-08-08 | Pulse arc welding control method |
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| JP (1) | JP6941410B2 (en) |
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Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62192264A (en) * | 1986-02-19 | 1987-08-22 | Hitachi Seiko Ltd | Pulse arc welding power source |
| JP2009214148A (en) * | 2008-03-11 | 2009-09-24 | Daido Steel Co Ltd | Consumable-electrode type pulse arc welding method |
| JP5787798B2 (en) * | 2012-03-09 | 2015-09-30 | 株式会社神戸製鋼所 | Solid wire and gas shielded arc welding method using the same |
| JP2014024077A (en) * | 2012-07-25 | 2014-02-06 | Daihen Corp | Pulse arc welding control method |
| US9616514B2 (en) * | 2012-11-09 | 2017-04-11 | Lincoln Global, Inc. | System and method to detect droplet detachment |
| US10835983B2 (en) * | 2013-03-14 | 2020-11-17 | Illinois Tool Works Inc. | Electrode negative pulse welding system and method |
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| CN109420822A (en) | 2019-03-05 |
| JP6941410B2 (en) | 2021-09-29 |
| JP2019042754A (en) | 2019-03-22 |
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