CN1234306A - Fuzzy control method for cooperating type CO2 welding circuit-shorting transition and welding machine thereof - Google Patents
Fuzzy control method for cooperating type CO2 welding circuit-shorting transition and welding machine thereof Download PDFInfo
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Abstract
The present invention relates to a fuzzy control method for CO2 short-circuiting transfer welding and its welding machine. It is characterized by that it adopts a closed-loop control method combining parameters-matched coordinate control and parameters-regulated fuzzy control, on the basis of the real-time detection on short circuiting transfer frequiency of reflecting stability of welding process, according to the coordinate relationship between all welding parameters and short circuiting transfer frequencies, it makes fuzzy treatment to detected data to define the regulating quantity of all parameters to make real-time regulation to make short circuiting transfer frequency keep stable in a certain range to ensure the optimum matching relationship between all parameters. Said invention possesses the advantages of good parameter matching property, strong anti-interference capacity and stable welding course.
Description
A kind of cooperating type CO2 welding circuit-shorting transition fuzzy control method and welding machine belong to welding process and automaton field.
The CO2 welding has obtained using widely and developing in industrial production as a kind of energy-efficient welding method, especially adopts the short circuiting transfer form, can be applied in all position welding, thin plate weldering etc. easily.But since the intrinsic characteristics of short circuiting arc welding also caused splash in the welding process big, the shortcoming that moulding is relatively poor, especially when medium above standard, these shortcomings are particularly outstanding.Experiment shows, rationally whether the welding variables coupling has direct relation to the welding process size of splashing with the appearance of weld quality.Reasonable when the welding variables coupling, it is few then to splash, forming.Otherwise it is bigger then to splash, and moulding is poor.In order to realize the reasonable coupling of welding variables, Welder author has done number of research projects.At first, be to adopt arc voltage and arc current to regulate respectively, this method complicated operation and welder's technical merit had relatively high expectations is difficult to realize the technical abilityization of taking off of welding process.For simplifying the operation course, realize the technical abilityization of taking off of welding process, Finland agree the monolithic processor controlled single knob CO2 welding machine of PRO5000 type than company's production, this welding machine is only regulated a welding parameter, then arc voltage value is just definite thereupon as welding current (wire feed rate), matching relationship curve (seeing shown in Fig. 1 solid line).But in the actual welding process, matching relationship between arc voltage and the welding current is not a single curve, but gang's curve (zones between two dotted lines as shown in Figure 1), promptly after electric current was determined, the value of arc voltage can change in a scope.Concrete which arc voltage value is best, look concrete welding process and extraneous welding condition and determines.The relation curve that existing single knob control CO2 welding machine is adopted is the mean value (shown in solid line among Fig. 1) that adopts the standard interval of arc voltage shown in Figure 1.The shortcoming of the CO2 welding machine of this single knob control is:
1) the optimal parameter matched accuracy is relatively poor.Because the conspiracy relation that adopts is to be based upon on the basis of average matching value, be difficult to the matching effect that reaches best.In order to overcome this shortcoming, the welding machine that has has increased the vernier knob of an arc voltage again when design.Though the problem that this can overcome the parameter matching poor accuracy makes operation become complicated.
2) poor anti jamming capability of welding process.Existing single knob welding machine, the method that all adopts open loop to control.In case after promptly welding variables is determined, just no longer change in welding process, it can't adapt to when change of external conditions the disturbance to welding process.
Purpose of the present invention just is to overcome the defective of above-mentioned prior art, propose that a kind of optimal parameter coupling accuracy is good, antijamming capability is strong, welding process is stable and splash less, the cooperating type CO2 welding circuit-shorting transition fuzzy control method and the welding machine of forming.
For achieving the above object, cooperating type CO2 welding circuit-shorting transition fuzzy control method proposed by the invention, it is the closed loop control method that a kind of fuzzy control that the Collaborative Control and the parameter of parameter matching are regulated combines, in the welding process, detection in real time can reflect the short circuiting transfer frequency situation of change of welding process stability, and be foundation with the conspiracy relation between each welding parameter and the short circuiting transfer frequency, detected short circuiting transfer frequency is carried out Fuzzy processing and fuzzy judgment, to determine the adjustment amount of welding arc voltage, adjust welding arc voltage in real time by control circuit then, make short circuiting transfer frequency keep stable within the specific limits, and guarantee optimum matching relation between each welding parameter and the short circuiting transfer frequency, guarantee welding stability, specifically, it mainly may further comprise the steps:
1) sets up conspiracy relation curve (as shown in Figure 2) between welding parameters such as wire feed rate, welding current, arc voltage and the short circuiting transfer frequency by a large amount of measured datas, and it is deposited in the Control System of Microcomputer, as the foundation of parameter adjustment and control;
2) after welding process begins, at first according to the size of the given signal of wire feed rate, Collaborative Control rule with " wire feed rate is preferential ", according to the conspiracy relation curve between above-mentioned each welding parameter and the short circuiting transfer frequency, determine size with the corresponding arc voltage of this wire feed rate, welding current and short circuiting transfer frequency, each welding parameter of initialization, the frequency reference that the gained short circuiting transfer frequency carries out fuzzy control as the back simultaneously;
3) in the welding process, under Control System of Microcomputer control, detection in real time can reflect the short circuiting transfer frequency of welding process stability, and the short circuiting transfer frequency benchmark that itself and front are determined compared, situation of change according to short circuiting transfer frequency, behind Fuzzy processing and fuzzy judgment, determine the adjustment amount of welding arc voltage, size by the online adjustment arc voltage of control circuit, make to keep the optimum synergistic matching relationship between welding current, arc voltage and the short circuiting transfer frequency, guarantee the stability of welding process.
Design philosophy of the present invention is as follows: experiment shows that when different welding variables couplings, the numerical value of short circuiting transfer frequency also is different.So-called short circuiting transfer frequency is exactly that molten drop is by the number of times of short circuiting transfer transition in the molten bath in the unit interval, and the quality of the quality of the stability of the size of short circuiting transfer frequency and welding process and welding quality, the size of splashing, moulding etc. have very big relation.Therefore, say in some sense that short circuiting transfer frequency is usually as weighing the stable sign of welding process.And confidential relation arranged between the standard parameter of the size of short circuiting transfer frequency and welding process, factors such as welding current, arc voltage, gage of wire all have very big influence to short circuiting transfer frequency and even appearance of weld, the size of splashing, welding process stable etc.Therefore, if on a large amount of technological experiments and expertise basis, and after taking all factors into consideration of the influence of each factor to short circuiting transfer frequency, (relation between these factors has highly non-linear to set up collaborative and fuzzy control relation between each welding parameter and the short circuiting transfer frequency in advance, be difficult to set up precise math model), and it is stored in the Control System of Microcomputer.And when actual welding, under microsystem control, the situation of change that can reflect the short circuiting transfer frequency of welding process stability by real-time detection, with the conspiracy relation between each welding parameter and the short circuiting transfer frequency is foundation, after Fuzzy Processing, determine the adjustment amount of welding arc voltage, and give source of welding current circuit this signal feedback.Like this, by real-time detection and processing to short circuiting transfer frequency, the size of online adjustment arc voltage, thereby form closed-loop control to welding variables, make welding variables and short circuiting transfer frequency keep stable within the specific limits, guarantee the optimum matching relation between them, guarantee the stability of welding process, reach purpose of the present invention.
On above-mentioned control method basis, it is that voltage feedback, interior ring are two closed loop feedback methods of current feedback that the present invention also adopts a kind of outer shroud, and the arc voltage of short-and-medium road of welding process and arc stage and the waveform of welding current are effectively controlled.
The control method that proposes according to the present invention and the welding machine that designs mainly include source of welding current main circuit, wire feeding circuit, welding gun and are the control circuit of control centre with the single-chip microcomputer.Wherein, described is that the control circuit of control centre mainly includes the SCM system that includes control program with the single-chip microcomputer, its input and the short circuiting transfer frequency Acquisition Circuit that the welding arc voltage signal links to each other, output links to each other with SCM system, and the control drive circuit that input links to each other with SCM system, its output links to each other with source of welding current main circuit.Described SCM system mainly includes and adopts the conventional central processor CPU that connects, D/A conversion unit D/A, AD conversion unit A/D, input-output unit I/O, high speed input block HSI, pwm unit PWM, reaches necessary signal sets and peripheral circuit.
Adapt with aforementioned control method of the present invention, in order to improve effect of the present invention better, having adopted an outer shroud in the above-mentioned control drive circuit of the present invention is the voltage feedback, interior ring is the dicyclo feedback circuit of current feedback, it mainly includes voltage signal and handles and sample circuit, the current filtering amplifying circuit, voltage regulator, current regulator and drive circuit, voltage signal is handled and the input of sample circuit links to each other with arc voltage signal, its output links to each other with voltage regulator, the input of current filtering amplifying circuit links to each other with welding current signal, its output links to each other with current regulator, another input of voltage regulator also links to each other with SCM system, and the output of current regulator links to each other with source of welding current main circuit by drive circuit.
Compared with prior art, control method of the present invention and welding machine have the following advantages:
(1) operating process is simple.The present invention only needs to regulate knob of wire feed rate in welding process, just can weld in whole short circuiting transfer scope, thereby simple to operate, and be easy to realize the technical abilityization of taking off of welding process.
(2) coupling of welding variables is reasonable, and the welding machine antijamming capability is strong, the welding process process stabilization, splash less, forming.The present invention is owing to adopt the fuzzy control that the Collaborative Control and the parameter of parameter matching the are regulated closed loop control method that combines that welding process is controlled in real time, whole welding process is carried out under control system control automatically, so when welding condition changes, control system can be adjusted standard parameter automatically, remain optimum matching relation, assurance welding stability between each welding parameter and the short circuiting transfer frequency, thereby guaranteed the stability and the stronger adaptability of welding process.
(3) scope of application of welding machine is wide.The present invention is owing to set in advance different control programs in the control circuit that with the SCM system is control centre, like this, when adopting the welding of different-diameter welding wire, according to wire feed rate, welding current Changing Pattern with gage of wire, select the corresponding work program, just can compensate gage of wire, weld thereby can be fit to multiple gage of wire.
Below in conjunction with drawings and Examples the present invention is described in further details.
Fig. 1 is the typical match curve between CO2 welding circuit-shorting transition arc voltage and the welding current;
Fig. 2 is the collaborative matching relationship curve between the welding variables of the present invention;
Fig. 3 is a welder system theory diagram of the present invention;
Fig. 4 controls the drive circuit schematic diagram for the present invention;
Fig. 5 is a short circuiting transfer frequency Acquisition Circuit schematic diagram of the present invention;
Fig. 6 is collaborative and fuzzy control process schematic diagram for the present invention;
Fig. 7 is a dicyclo feedback procedure schematic diagram of the present invention;
Fig. 8 is a control procedure main program flow chart of the present invention;
Fig. 9 is a fuzzy control subroutine flow chart of the present invention.
Embodiment:
As shown in Figure 3, a specific embodiment welding machine of the present invention mainly is made up of three parts on structure: source of welding current main circuit A, wire feeding circuit C and be the control circuit B of control centre with 8098 single-chip microcomputers.Wherein, it is the full bridge inverter of device for power switching that source of welding current main circuit A adopts with IGBT, it mainly is made of rectification circuit 1, filter circuit 2, switch power device (IGBT) 3, intermediate-frequency transformer 4, secondary commutation circuit 5, filter inductance 6, its operation principle is as follows: three-phase alternating current 380V power supply is behind rectification circuit 1, filter circuit 2, obtain the direct current of 540V at the output of filter circuit 2, be reverse into the medium frequency alternating current of frequency about 20KHz through switch power device 3 again, and then through intermediate-frequency transformer 4 isolate, step-down.Medium frequency alternating current after step-down carries out the secondary rectification through secondary commutation circuit 5 again, and alternating current is become direct current, again behind filter inductance 6, becomes the direct current that can be used for welding at last.Because the operating frequency of above circuit is at 20KHz, output inductor is also very little simultaneously (is generally 20～80UH), adjusts the control that inverse switch frequency or pulsewidth can reach the microsecond level, so response speed is fast, dynamic response performance is good.(3～5ms) the inverter type welder work dozens of cycles in a short circuit process.So, can effectively control arcing in the welding process and short-circuit stage easily by it, thus the control accuracy and the sensitivity that improve the source of welding current.
The stability of welding process is not only relevant with the performance of the source of welding current, and and the stability of wire feed substantial connection is arranged, only guaranteed welding wire can be sent to uniformly, could produce the droplet transfer clocklike.Because the present invention reaches the purpose of regulating welding current by regulating wire feed rate, so require wire feed rate can regulate in certain scope.For reaching above-mentioned requirements, present embodiment wire feeding circuit C adopts the degenerative regulative mode of armature voltage, it mainly includes wire-feed motor 11, wire-feeding control circuit 12 and the feedback circuit 10 that tests the speed, the output of wire-feed motor 11 links to each other with welding gun 8, its input links to each other with wire-feeding control circuit 12, and the input of the feedback circuit 10 that tests the speed links to each other with the wire-feed motor armature voltage, its output links to each other with wire-feeding control circuit 12.In addition, 9 be workpiece among the figure.By above circuit, not only can realize the stable of armature voltage, can also the offset supply internal resistance and the change in rotational speed that causes of net voltage fluctuation, thus guarantee the requirement of stablizing and satisfy welding procedure of wire feed rate.
Among Fig. 3, present embodiment control circuit B mainly includes 8089 SCM systems 20 that include control program, its input links to each other with the welding arc voltage signal and short circuiting transfer frequency Acquisition Circuit 19 that output links to each other with SCM system high speed input block HSI, with and input link to each other with SCM system pwm unit PWM and control drive circuit 13 that output links to each other with source of welding current main circuit switch power device 3.Wherein, described SCM system 20 mainly includes single-chip microcomputer internal circuit such as central processor CPU, D/A conversion unit D/A, AD conversion unit A/D, input-output unit I/O, high speed input block HSI, pwm unit PWM and wire feed rate given circuit 15, arc voltage given circuit 16, display system circuit 17, gage of wire is selected peripheral circuits such as circuit 18.Except that routine connects, more than each parts annexation as follows: the output of wire feed rate given circuit 15 and arc voltage given circuit 16 links to each other with the input of AD conversion unit A/D respectively, gage of wire selects circuit 18 outputs to link to each other with the input of high speed input block HSI, and the input of display system circuit 17 links to each other with the output of output unit I/O.
For better to short-circuit stage and arc stage to voltage, current waveform control effectively, as shown in Figure 4, it is the voltage feedback that present embodiment Control of Voltage drive circuit 13 has adopted an outer shroud, interior ring is the dicyclo feedback circuit of current feedback, its primary structure as previously mentioned, mainly including voltage signal handles and sample circuit 21, current filtering amplifying circuit 22, voltage regulator 23, current regulator 24 and drive circuit 25, wherein, voltage signal is handled and the input of sample circuit 21 links to each other with arc voltage signal, its output links to each other with voltage regulator 23, the input of current filtering amplifying circuit 22 links to each other with welding current signal by a Hall element (I-LEM) 7, its output links to each other with current regulator 24, another input of voltage regulator 23 also links to each other with SCM system pwm unit PWM, and the output of current regulator 24 links to each other with source of welding current main circuit by drive circuit 25.In addition, another input of drive circuit 25 also links to each other with an overcurrent overheat under-voltage protecting circuit 14.The design principle of above circuit is as follows: according to the characteristics of CO2 arc welding short-circuiting, need control current waveform in short-circuit stage and arc stage respectively, and keep certain arc voltage, make the arcing process stabilization.Based on above-mentioned thought, adopted two kinds of negative-feedbacks of electric current and voltage among the present invention, and corresponding adjuster is set has regulated electric current and voltage, carry out tandem between the two and connect.The input of current regulator is used as in the output of voltage regulator, goes to control the output of voltage again with the output of current regulator.On structure, current regulator is called interior ring inside, and voltage regulator is called outer shroud outside, so just forms voltage, current double closed-loop control system.In the welding process, short-circuit stage, interior ring works separately, and makes it as a follower preferably, and current waveform changes with given current waveform; Arc stage, dicyclo works, and feedback voltage is compared with specified rate, obtains the given side that new given electric current is sent into current regulator, adjusts electric current output, with the pilot arc voltage constant, and keeps certain arc length.Like this, both can realize that arc length was stable, and can control electric current output in time according to arc voltage again, thereby can comparatively accurately control respectively short circuit and arcing current waveform.Experimental result also shows, the inner and outer rings parameter rationally is set, and can easily obtain the stable output of short-circuit stage and arc stage.
For preventing the influence of instantaneous short-circuit to short circuiting transfer frequency, improve the signal detection precision, the above-mentioned short circuiting transfer frequency Acquisition Circuit 19 of present embodiment adopts structure as shown in Figure 5, it includes respectively by resistance R 1, R2, capacitor C 1, the filtering that voltage-stabiliser tube Z1 constitutes, mu balanced circuit 26, shaping circuit 27 by Schmidt trigger U1 (4584) formation, mainly by OR-NOT circuit U2 (4001), time base circuit U4 (NE555), resistance R 3, R4, capacitor C 3, C4, the monostable noise filtering circuit 28 that diode D2 and adjustable potentiometer VR1 constitute, and mainly by transistor G1 (8050), optocoupler U3 (TTL117) and resistance R 5, the amplification that R6 constitutes, isolate, sample circuit 29, wherein filtering, the input of mu balanced circuit 26, output connects the input of welding arc voltage output and shaping circuit 27 respectively, the output of shaping circuit 27 inserts OR-NOT circuit U2 in the monostable sound filtering circuit 28 respectively, the input of time base circuit U4, another input of OR-NOT circuit U2 links to each other the output of OR-NOT circuit U2 and amplification with the output of time base circuit U4, isolate, the input of sample circuit 29 links to each other.Its operation principle is as follows: filtering, mu balanced circuit 26 are with the interference filtering of arc voltage signal and be stabilized in 15V, and then through the shaping by Schmidt trigger U1, change arc voltage signal into square-wave signal that peak value is 15V.The input signal of time base circuit U4 is the output signal of Schmidt trigger U1, and the output of the output of time base circuit U4 and Schmidt trigger U1 simultaneously is again as the input of OR-NOT circuit U2.The output signal of OR-NOT circuit U2 is through amplifying and isolating the back obtains treated arc voltage on sample resistance R6 signal, and the high speed input block HSI that at last this signal is input to single-chip microcomputer carries out frequency collection.After the foregoing circuit processing, the instantaneous short-circuit of short circuit duration below 2ms can be filtered out, what obtain is the frequency values that can reflect the normal short circuit of welding process stability, thereby can prevent the influence of instantaneous short-circuit to short circuiting transfer frequency, improves the signal detection precision.
Whole welding process of the present invention is all carried out under the SCM system programme-control, below in conjunction with control method of the present invention, and with reference to figure 6, present embodiment welding machine control procedure is described in detail:
1. the initialization of program and each welding parameter.Welding machine at first carries out the initialization of program and the setting of each welding parameter initial amount after starting.Wherein, each welding parameter initial amount adopts the Collaborative Control rule of " wire feed rate is preferential " to be determined, promptly at first determine wire feed rate by wire feed rate given circuit 15, after 8098 Chip Microcomputer A/D processing unit carries out data acquisition, with collaborative matching relationship curve shown in Figure 2 is foundation, the wire-feed motor control signal is outputed to control circuit for wire feeder 12 through the D/A unit, the size of control wire feed rate.Simultaneously, arc voltage control signal through the PWM accumulator, is outputed to control drive circuit 13 as voltage given through PWM again.Simultaneously, be foundation with conspiracy relation curve shown in Figure 2 again, through the query processing of single-chip computer control system internal database, determine the short circuiting transfer frequency value (a reference value of frequency when this frequency values will as back carry out fuzzy control) corresponding with this wire feed rate.So far, finish the setting of each welding parameter initial amount, under the collaborative coupling of each parameter, begin welding process.
2. the fuzzy control of parameter adjusting.In the welding process, be input to the high speed input block HSI of single-chip microcomputer after by short circuiting transfer frequency Acquisition Circuit 23 the welding arc voltage signal being handled, short circuiting transfer frequency is gathered in real time.The short circuiting transfer frequency that collects and given short circuiting transfer frequency are compared processing, calculate the deviation of present frequency and the situation of change of deviation variation rate, and then according to the situation of change of the rate of change of deviation that calculates frequency and deviation, by Fuzzy Processing and fuzzy judgment, determine the adjustment amount of the arc voltage of this moment, set-point addition through PWM accumulator and original arc voltage, output to control drive circuit 16 through PWM then, the size of control arc voltage, the numerical value of online adjustment arc voltage, make it and welding current (wire feed rate) between reach best matching relationship, guarantee the stability of welding process.
3. the Waveform Control of welding process.In the above process, adopt the mode of dicyclo feedback that the arc voltage of short circuit and arc stage and the waveform of welding current are controlled by aforementioned control drive circuit simultaneously, its operation principle as shown in Figure 7, among the figure, voltage given signal Ug and the voltage signal Uf that obtains through executed arc voltage feedback are as the input of voltage regulator, the output signal Ig of voltage regulator is as the input of interior circular current adjuster, the signal If of another input signal of current regulator for obtaining through current feedback, and the output signal of current regulator will be exported as voltage control signal.Like this, interior ring adopts current feedback, is traditional constant-current source, because its good dynamic characteristic makes output current and the basically identical that gives current waveform.And outer shroud adopts the voltage feedback, and making whole output characteristics is constant-voltage characteristic.At this moment, the dynamic response of whole circuit mainly shows as the response speed of outer shroud, and the parameter that changes inner and outer ring promptly can change the response speed of entire circuit.Thereby welding current and arc voltage to arc stage in the welding process and short-circuit stage are effectively controlled, and reach to improve appearance of weld and reduce the purpose of splashing.
The present embodiment welding machine provides the gage of wire φ 1.0mm of two kinds of specifications and φ 1.2mm to be available for users to select.Gage of wire is selected and can be selected circuit 18 to select by gage of wire.When gage of wire selects circuit 18 to be output as high level " 1 ", select φ 1.2mm welding wire; When being output as " 0 " low level, then select the welding wire of φ 1.0mm.Single-chip computer control system will select the output state handle gage of wire value corresponding with it of circuit 18 to send display system 17 according to gage of wire.After gage of wire is determined, control system then will be by detecting wire feed rate given circuit 15 the size of given signal, again according to detected result by looking into database, corresponding with it wire feed rate set-point is outputed to the size that wire-feeding control circuit 12 is controlled wire feed rate by D/A conversion unit D/A.Find the arc voltage set-point corresponding simultaneously, output to control drive circuit 13 control electric power output voltages by pwm unit PWM with this wire feed rate.In this process, also send display system 17 to show wire feed rate set-point and arc voltage set-point.
The main program of above control procedure and fuzzy control subroutine flow chart are seen Fig. 8, shown in Figure 9 respectively.Wherein, its main program flow is described by the above-mentioned welding machine course of work, repeats no more.Now fuzzy control subprogram flow process is done a simple declaration: among Fig. 9, after entering the fuzzy control subprogram, at first according to size setting and the corresponding frequency departure of this frequency reference, the rate of change of frequency departure and the basic domain e[-xe of voltage adjustment amount of the resulting frequency reference value in front, xe], c[-xc, xc], u[-xu, xu], start software timer then and interrupt sampling, frequency departure e (k) and the deviation variation rate c (k) that this moment is calculated in the back finished in sampling, and whether the value of judging them is in the domain scope of setting.If when exceeding the domain of setting, then handle, otherwise still handle by former calculated value by the maximum of setting.After having determined frequency departure and deviation variation rate, again by to looking into the fuzzy control state table after its quantification treatment, obtain the voltage change that will export, output goes to control the output of arc voltage then, turns back to main program at last.
In the above process, the fuzzy control state table is to finish on the CO2 welding circuit-shorting transition fuzzy controller of off-line design.Basic fuzzy controller is to carry out work by certain control law, and these control laws are on a large amount of technological experiments and expert's experiential basis, and taken all factors into consideration and obtained after the influence relation of various factors to short circuiting transfer frequency, it mainly solves the problem of following three aspects: 1, the accurately obfuscation of amount is the language value of linguistic variable fuzzy subset on certain suitable domain promptly.2, the design of FUZZY ALGORITHMS FOR CONTROL.It constitutes fuzzy control rule by one group of fuzzy condition statement, and calculates the fuzzy relation of fuzzy control rule decision.3, the fuzzy judgment of output information, and finish by fuzzy quantity to the accurately conversion of amount.The type of fuzzy controller has multiple, the present invention selects the fuzzy controller of the single output of two inputs, it with the rate of change of the deviation of short circuiting transfer frequency and deviation as input, the adjustment amount of output arc voltage behind Fuzzy Processing and fuzzy judgment, set-point addition through PWM accumulator and arc voltage, export the set-point of new arc voltage then through PWM, thereby guarantee the collaborative matching relationship between welding variables.
The above is a best specific embodiment of the present invention.Obviously, scope of the present invention is not limited thereto, it can also have some constructional variant, for example adopted the mode that voltage signal is directly regulated in the present embodiment, realize the optimum Match of each standard parameter, certainly, the mode by direct adjusting current signal can reach purpose of the present invention too.Similarly constructional variant is also a lot, if these constructional variant are those skilled in the art can be according to content of the present invention, need not make performing creative labour and can draw, all should belong within the scope of the present invention.
In order to be illustrated more clearly in effect of the present invention, the welding machine to present embodiment carries out the actual welding experiment below.The important technological parameters and the experimental result of this welding machine are as follows:
1, important technological parameters
| Specified input voltage | 380±20％ | The voltage- | 17～37V |
| Rated current | 315A | The electric current adjustable range | 60～315A |
| Rated duty cycle | 60％ | The wire feed rate adjustable range | 1～16m/min |
2, the test experiments result of welding process spatter loss coefficient is as follows:
Method of testing is by the weight method of MIG/MAG arc-welding machine industry standard (JB/T8748-1998) regulation of mechanical industry office of People's Republic of China (PRC) issue on May 28th, 1998.
1. experiment condition:
Test specimen specification 500*30*4
The H08Mn2SiA of gage of wire and welding wire trade mark Φ 1.0mm, Φ 1.2mm
Fusion length is greater than 250mm
2. standard parameter and spatter loss coefficient
Experimental result sees Table 1 respectively, shown in the table 2.Wherein, adopt the welding wire of Φ 1.0mm in the table 1, adopt the welding wire of Φ 1.2mm in the table 2.
Table 1
| Welding current (A) | Arc voltage (V) | Dry extension of electrode (mm) | Throughput (l/min) | Speed of welding (m/min) | Spatter loss coefficient (%) |
| ????65 | ????17.0 | ????12 | ????15 | ????0.2 | ????2.5 |
| ????80 | ????18.3 | ????12 | ????15 | ????0.2 | ????2.1 |
| ????88 | ????19.1 | ????12 | ????15 | ????0.2 | ????1.5 |
| ????120 | ????19.5 | ????12 | ????15 | ????0.2 | ????1.87 |
| ????165 | ????20.4 | ????12 | ????15 | ????0.2 | ????1.7 |
| ????210 | ????22.5 | ????12 | ????15 | ????0.2 | ????1.56 |
Table 2
| Welding current (A) | Arc voltage (V) | Dry extension of electrode (mm) | Throughput (l/min) | Speed of welding (m/min) | Spatter loss coefficient (%) |
| ????85 | ????18.3 | ????15 | ????15 | ????0.2 | ????3.5 |
| ????120 | ????19.1 | ????15 | ????15 | ????0.2 | ????3.2 |
| ????140 | ????19.7 | ????15 | ????15 | ????0.2 | ????3.6 |
| ????170 | ????20.3 | ????15 | ????15 | ????0.2 | ????3.17 |
| ????200 | ????20.8 | ????15 | ????15 | ????0.3 | ????3.3 |
| ????250 | ????26.7 | ????15 | ????15 | ????0.3 | ????3.6 |
As seen from the table, splashing of this welding machine has tangible reduction than traditional CO2 welding machine, and welding process shows that its parameter matching is good, antijamming capability is strong, welding process is stable, has reached purpose of the present invention.
Claims (7)
1. cooperating type CO2 welding circuit-shorting transition fuzzy control method, it is characterized in that: it is the closed loop control method that a kind of fuzzy control that the Collaborative Control and the parameter of parameter matching are regulated combines, in the welding process, detection in real time can reflect the short circuiting transfer frequency situation of change of welding process stability, and be foundation with the conspiracy relation between each welding parameter and the short circuiting transfer frequency, detected short circuiting transfer frequency is carried out Fuzzy processing and fuzzy judgment, to determine the adjustment amount of welding arc voltage, adjust welding arc voltage in real time by control circuit then, make short circuiting transfer frequency keep stable within the specific limits, and guarantee optimum matching relation between each welding parameter and the short circuiting transfer frequency, guarantee welding stability, specifically, it mainly may further comprise the steps successively:
1) sets up conspiracy relation curve between welding parameters such as wire feed rate, welding current, arc voltage and the short circuiting transfer frequency by a large amount of measured datas, and it is deposited in the Control System of Microcomputer, as the foundation of parameter adjustment and control;
2) after welding process begins, at first according to the size of the given signal of wire feed rate, Collaborative Control rule with " wire feed rate is preferential ", according to the conspiracy relation curve between above-mentioned each welding parameter and the short circuiting transfer frequency, determine size with the corresponding arc voltage of this wire feed rate, welding current and short circuiting transfer frequency, each welding parameter of initialization, the frequency reference that the gained short circuiting transfer frequency carries out fuzzy control as the back simultaneously;
3) in the welding process, under Control System of Microcomputer control, detection in real time can reflect the short circuiting transfer frequency of welding process stability, and the short circuiting transfer frequency benchmark that itself and front are determined compared, situation of change according to short circuiting transfer frequency, behind Fuzzy processing and fuzzy judgment, determine the adjustment amount of welding arc voltage, size by the online adjustment arc voltage of control circuit, make to keep the optimum synergistic matching relationship between welding current, arc voltage and the short circuiting transfer frequency, guarantee the stability of welding process.
2. cooperating type CO2 welding circuit-shorting transition fuzzy control method according to claim 1, it is characterized in that: it adopts a kind of outer shroud is that voltage feedback, interior ring are two closed-loop feedback manner of current feedback, and the arc voltage and the arc current waveform of short-circuit stage, arc stage control effectively.
3. a control method according to claim 1 and the welding machine that designs, it includes source of welding current main circuit, wire feeding circuit, welding gun, reaching with the single-chip microcomputer is the control circuit of control centre, it is characterized in that: described is that the control circuit of control centre mainly includes the SCM system (20) that includes control program with the single-chip microcomputer, its input links to each other with the welding arc voltage signal, the short circuiting transfer frequency Acquisition Circuit (19) that output links to each other with SCM system, and input links to each other with SCM system, the control drive circuit (13) that its output links to each other with source of welding current main circuit, wherein, described SCM system (20) mainly includes and adopts the conventional central processor CPU that connects, D/A conversion unit D/A, AD conversion unit A/D, input-output unit I/O, high speed input block HSI, pwm unit PWM, and necessary signal sets and peripheral circuit.
4. welding machine according to claim 3, it is characterized in that: in the described control drive circuit (13), adopting an outer shroud is the voltage feedback, interior ring is the dicyclo feedback circuit of current feedback, it mainly includes voltage signal and handles and sample circuit (21), current filtering amplifying circuit (22), voltage regulator (23), current regulator (24) and drive circuit (25), voltage signal is handled and the input of sample circuit (21) links to each other with arc voltage signal, its output links to each other with voltage regulator (23), the input of current filtering amplifying circuit (22) links to each other with welding current signal, its output links to each other with current regulator (24), another input of voltage regulator (23) also links to each other with SCM system (20), and the output of current regulator (24) links to each other with source of welding current main circuit by drive circuit (25).
5. welding machine according to claim 3, it is characterized in that: described source of welding current main circuit adopts one to be the full bridge inverter of device for power switching with IGBT, and it is formed by connecting in turn by rectification circuit (1), filter circuit (2), switch power device (3), intermediate-frequency transformer (4), secondary commutation circuit (5), filter inductance circuit (6) respectively.
6. welding machine according to claim 3, it is characterized in that: described wire feeding circuit adopts the degenerative regulative mode of armature voltage, it mainly includes wire-feed motor (11), wire-feeding control circuit (12) and the feedback circuit that tests the speed (10), the output of wire-feed motor (11) links to each other with welding gun (8), its input links to each other with wire-feeding control circuit (12), and the input of the feedback circuit that tests the speed (10) links to each other with the wire-feed motor armature voltage, its output links to each other with wire-feeding control circuit (12).
7. welding machine according to claim 3, it is characterized in that: described short circuiting transfer frequency Acquisition Circuit includes respectively by resistance R 1, R2, capacitor C 1, the filtering that voltage-stabiliser tube Z1 constitutes, mu balanced circuit (26), the shaping circuit (27) that constitutes by Schmidt trigger U1, by OR-NOT circuit U2, time base circuit U4, resistance R 3, R4, capacitor C 3, C4, the monostable noise filtering circuit (28) that diode D2 and adjustable potentiometer VR1 constitute, and mainly by transistor G1, optocoupler U3 and resistance R 5, the amplification that R6 constitutes, isolate, sample circuit (29), wherein filtering, the input of mu balanced circuit (26), output connects the input of welding arc voltage output and shaping circuit (27) respectively, the output of shaping circuit (27) inserts OR-NOT circuit U2 in the monostable sound filtering circuit (28) respectively, the input of time base circuit U4, another input of OR-NOT circuit U2 links to each other the output of OR-NOT circuit U2 and amplification with the output of time base circuit U4, isolate, the input of sample circuit (29) links to each other.
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