CN102665995A - Resistance welding method, resistance-welded member, resistance welder, control apparatus for resistance welder, control method and control program for resistance welder, resistance welding evaluation method, and resistance welding evaluation program - Google Patents
Resistance welding method, resistance-welded member, resistance welder, control apparatus for resistance welder, control method and control program for resistance welder, resistance welding evaluation method, and resistance welding evaluation program Download PDFInfo
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- CN102665995A CN102665995A CN2010800524257A CN201080052425A CN102665995A CN 102665995 A CN102665995 A CN 102665995A CN 2010800524257 A CN2010800524257 A CN 2010800524257A CN 201080052425 A CN201080052425 A CN 201080052425A CN 102665995 A CN102665995 A CN 102665995A
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
- B23K11/257—Monitoring devices using digital means the measured parameter being an electrical current
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
- B23K11/258—Monitoring devices using digital means the measured parameter being a voltage
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Abstract
In a resistance welding method, by controlling the power amount from a melting start time onward, the weld quality may be stabilized efficiently, even when a disturbance is present, because of the correlation between the amount of power input from the melting atart time and a resulting nugget. The resistance welding method includes: pressing an electrode (11a, 11b) against a workpiece (Wa, Wb); inputting power to the workpiece (Wa, Wb) through the electrode (11a, 11b) to subject the workpiece (Wa, Wb) to Joule heating; detecting the melting start time, which is the time at which at least a portion of the faying portion of the workpiece (Wa, Wb) starts to melt when subjected to Joule heating; calculating a first power amount input into the workpiece (Wa, Wb) from the melting start time; and determining whether the first power amount has reached a first set value; and continuing the Joule heating until the first power amount reaches the first set value.
Description
Technical field
The present invention relates to such as the relevant method of the resistance welded of spot welding, electric resistance welding fitting, resistance welding machine, the control device that is used for resistance welding machine, the control method that is used for resistance welding machine and control program, resistance welded appraisal procedure and resistance welded appraisal procedure.
Background technology
Because welding low-cost and can when engaging multiple material, adopt welding usually so as to guaranteeing the simplification of intensity.Spot welding is a type of resistance welded, and it for example is generally used for a plurality of positions (point) in body of a motor car etc. and locates to weld efficiently overlapping steel plate (a plurality of workpiece).Usually, spot welding through make big electric current at short notice from the electrode that is clipped in each workpiece outside through workpiece so that the fusing of the junction surface on each inboard of each workpiece and solidify engage.
Incidentally, spot welding is that with difference such as the welding of other type of arc-welding the junction makes to be difficult to directly observe the welding position in the inboard of workpiece.In addition, in batch production process, it is unpractical that the operator uses the situations of spot check spot welding at length such as anchor clamps.Therefore, the whole bag of tricks has been proposed to equate to stablize welding quality through the size that makes the nugget (fusing of workpiece and the part of solidifying) that during spot welding is handled, forms.For example, publication number is that the Japanese patent application (JP-A-62-64483) of 62-64483 has been described this problem.
JP-A-62-64483 has described and has applied the resistance welding technology of welding current till the energy that is applied reaches the target total energy value.Yet in the welding place of reality, welding is under the various situations that are difficult to expect (interference), to carry out.For example, if with two steel plates as the workpiece of resistance welded in addition, then the gap possibly separated steel plate, steel plate possibly tilt, and the wearing and tearing that possibly become of the tip portion of pushing down the electrode of steel plate.When existing these to disturb, the alignment condition of steel plate (especially table of joint area) changes.As a result, joule's heat energy that produces in the junction surface and thermal discharge change owing to disturbing, and make the heat that in welding process, effectively uses change.According to the welding procedure of in JP-A-62-64483, describing, the words that the gross energy that only being primarily focused on switches on certainly begins to import workpiece (total electric weight) is not upward taken interference into account are to be difficult to stablize welding quality.
Summary of the invention
The electric resistance welding fitting that the invention provides a kind of method for resistance welding and obtain through said method for resistance welding; Through said method for resistance welding; Even interference has taken place in the aspects such as contact condition when at welding work pieces in fact the time between situation, workpiece and the electrode of junction surface (joint between the workpiece), also can the steady resistance welding quality.The present invention also provides a kind of resistance welding machine that is suitable for realizing this method for resistance welding, and the control method, control device and the control program that are used for resistance welding machine.The present invention further provides resistance welded appraisal procedure and resistance welded appraisal procedure.
Because to address the above problem is research and the repetition test that purpose is done, the inventor has obtained new discovery, promptly; Even when the existing various interference of welding; Begin fusing in case stand joule workpiece of heating, these disturb just basic not influence, therefore; Through advancing resistance welded according to input energy (input amount of power) and regulating input energy (input amount of power), can form desired nugget.Through this discovery is studied, the inventor has realized each item invention relevant with resistance welded, will describe these inventions below.
Scheme of the present invention provides a kind of method for resistance welding, comprising: make electrode push down workpiece; Through being imported through said electrode, electric power make said workpiece stand a joule heating in the said workpiece; Detect the initial time point of fusing, the initial time point of said fusing is the time point (that is, detecting processing) that at least a portion at the junction surface of said workpiece begins to melt; Through carrying out integration and calculate first amount of power (, computing) to when said fusing is initial, lighting the total electricity of importing said workpiece via said electrode; Whether the welding desired value of judging the welding situation at said first amount of power or indication and the corresponding junction surface of said first amount of power reaches first setting value (that is first determination processing) at least; And when said fusing is initial, light proceed said joule heating up to said first amount of power or said welding desired value reach at least said first setting value (; Heat treated), wherein can stablize formation through the junction surface fusing and solidify the nugget that obtains.
According to above-mentioned method for resistance welding; After the resistance welded of workpiece has begun; Perhaps in other words; In order workpiece to be carried out joule heating after making electrifying electrodes, at first, detect the time point (melting initial time point) that at least a portion at the junction surface of workpiece begins to melt when carrying out joule heating.Then, utilize the initial time point of fusing to calculate the energy (input amount of power) of input workpiece as starting point.Through concentrating on first amount of power, promptly light the amount of power of input when initial from melting, even exist under the situation of various interference, also can suitably control the size of the nugget that forms in the junction surface of workpiece.More specifically; Through carrying out joule heating up to through carrying out first amount of power that integration obtains or reach predetermined set value (first setting value) at least, even also can stablize welding quality in the welding place that has various interference through first amount of power being converted into welding desired value that nugget size (nugget size) obtains etc. to melting the input amount of power of lighting when initial certainly.
Be noted that in this manual, term " reaches setting value at least " and comprises that object value is included in the situation in the particular range.Therefore, setting value can reach value (lower limit) for higher limit (final goal value) or minimum.Under situation of the present invention; When the welding desired value of first power value that calculates or correspondence reaches first setting value; Heat treated can stop, and perhaps just continues heat treated as long as first power value or welding desired value remain on to surpass within the certain limit of first setting value.In addition, " welding desired value " can be the arbitrary value of the situation of accurately indicating resistance welded, and its representative illustration is a nugget size.In addition, for the not restriction of method of calculating " amount of power " according to this specification.The concrete numerical value of each amount of power of describing in this manual itself is inessential, as long as they are used as the relevant accurate indexs such as diameter with the initial time point of the fusing of workpiece, the nugget that forms.
In method for resistance welding according to the present invention,, be important to detection or the regulation (estimation) that melts initial time point in order to realize the stability of the welding quality of workpiece based on melting first amount of power that initial time point calculates certainly.Basically, the junction surface of melting initial time point and be workpiece becomes the point of liquid phase from solid phase, therefore, the variation of physical characteristic value that can be through concentrating on workpiece, the variation such as the temperature of melt portions, volume etc. detects the initial time point of fusing.Even the inventor has had been found that when near fusing object and electrode, having various interferences, no matter is which kind of disturbs, also can both be accurately and the new method that melts initial time point of detection easily.More specifically; The inventor has been found that; Can detect the initial time point of fusing (in other words through carrying out following two processing; The formation that aforementioned detection is handled): the second amount of power computing, it is through carrying out integration and calculate second amount of power according to light elapsed time when initial from switching on the total electricity of input workpiece, and the initial time point of said energising is to begin the time point to said electrifying electrodes in order the junction surface to be carried out joule heating; And second determination processing; It judges that the initial time point of said fusing is that said second amount of power reaches the initial amount of power of fusing or the time point of second setting value set based on the initial amount of power of said fusing at least, the amount of power that the initial amount of power of said fusing is imported till in fact beginning to melt at least a portion up to said junction surface and confirmed in advance according to when said energising is initial, lighting elapsed time.The reason of doing like this is following.
When " interference " made contact condition between configuration state, workpiece and the electrode of workpiece to be welded etc. depart from their initial imagination situation (status of criterion), the actual initial time point of fusing changed.This fact is to investigate the test result (see figure 2) that is obtained through the diameter that carries out integration the input amount of power of calculating and the nugget that forms to beginning to switch on from electrode to obtain proving conclusively.Therefore, at first sight, seem to be difficult to exist under the situation of not specifying interference with the initial time point of pinpoint accuracy detection fusing.Yet, under various interference after the initial time point of fusing of investigation workpiece, find until section and between the input amount of power (melting initial amount of power) of the initial time point of fusing, the have dependency relation conduction time of the initial time point of fusing.In other words, find that it is to be expressed by the function of energising beginning back elapsed time (section conduction time at initial stage) that workpiece begins to melt required cumulative power amount (melting initial amount of power).More specifically, when workpiece began to melt after the short time period after the energising, the input amount of power was less, and when workpiece began to melt after long-time section after the energising, the input amount of power increased.Like this, learn the initial amount of power of fusing with conduction time at initial stage section have dull increasing and concern.Therefore; At least reach and according to the point that begins the definite initial amount of power of fusing of elapsed time (section conduction time at initial stage) from energising equally through detecting according to begin amount of power (second amount of power) that elapsed time (section conduction time at initial stage) calculates from energising; Can confirm that workpiece begins fusing at this point; Therefore can this point be judged to be the initial time point of fusing, and need not to specify the type of interference.
Incidentally, conduction time at initial stage, section can be described below with the reason that the initial amount of power of fusing has above-mentioned relation simply.When interference existed, the contact resistance and the current density at junction surface changed, and made the heat (heat generation rate) that produces in the inherent melt portions of time per unit correspondingly change.Therefore, when contact resistance and current density made the heat generation rate at junction surface also big more greatly, for example, the temperature at junction surface raise and fusing rapidly.On the contrary, make heat generation rate also hour, the temperature at junction surface is raise and fusing when contact resistance and current density are less.
In the present invention, needn't select the current value and the magnitude of voltage of the electrifying electrodes that is used for during resistance welded, making contact workpiece.Before first amount of power reaches first setting value according to settings such as expectation nugget sizes,, can suitably adjust the current value and the magnitude of voltage that put on workpiece for each solder joint.Therefore, can comprise that according to heat treated of the present invention heating adjustment handles, said heating adjustment is handled and is used for being based on the heating situation that result of determination that said first determination processing obtains is adjusted workpiece.This can be applied to the detection of the initial time point of fusing of workpiece similarly.When detecting the initial time point of fusing, be important up to section conduction time that workpiece begins to melt, according to second amount of power that conduction time, section calculated and according to the relation between the initial amount of power of fusing that conduction time, section was confirmed.Therefore, can suitably adjust current value and the magnitude of voltage that puts on workpiece in the computing interval of second amount of power and for each solder joint.
Be noted that the control method of the resistance welding machine that will explain below content described herein can suitably be applied to, the control device of resistance welding machine, resistance welding machine, the control program of resistance welding machine, resistance welded appraisal procedure, resistance welded appraisal procedure etc.In this case, " processing " that in the formation of the invention described above, is comprised should be interpreted as " step " or " unit " as required.
Through adopting above-mentioned method for resistance welding, can obtain that weld defect is suppressed and the welding quality stabilized products.Therefore, the present invention not only can be understood that method for resistance welding, and can be understood that to have the electric resistance welding fitting of stable shape of nugget etc., and this is irrealizable in correlation technique.
The present invention also can be construed as realizing the resistance welding machine and the control device thereof of above-mentioned method for resistance welding.More specifically; The present invention can be for being used for the control device of resistance welding machine; Said resistance welding machine has electrode and supply unit; The outer surface of said electrode contact workpiece, said supply unit are supplied with electric current to said electrode to be used for that the joule heating is carried out at the junction surface of said workpiece, and said control device comprises: melt initial time point detecting unit; It detects the initial time point of fusing, the time point that the initial time point of said fusing begins to melt at least a portion at said junction surface when standing by the electric power from said electrode input workpiece joule to heat; The first amount of power computing unit, it is through carrying out integration and calculate first amount of power when said fusing is initial, lighting the total electricity of importing said workpiece via said electrode; First identifying unit, whether its welding desired value of judging the welding situation at said first amount of power or indication and the corresponding junction surface of said first amount of power reaches first setting value at least; And heating unit, it is lighted when said fusing is initial and carries out said joule heating and reach said first setting value at least up to said first amount of power or said welding desired value.
In addition, the present invention can be resistance welding machine, and said resistance welding machine comprises: electrode, and it pushes down workpiece; Supply unit, it supplies with heating current to said electrode to be used for that the joule heating is carried out at the junction surface of said workpiece; And be used to control the above-mentioned control device of importing the amount of power of said workpiece from said supply unit.
In addition, the present invention can be construed as the control method or the control program of above-mentioned resistance welding machine.More specifically; The present invention can be for being used for the control method of resistance welding machine; Said resistance welding machine has electrode and supply unit; The outer surface of said electrode contact workpiece, said supply unit are supplied with heating current to said electrode to be used for that the joule heating is carried out at the junction surface of said workpiece, and said control method may further comprise the steps: melt initial time point and detect step; Wherein detect the initial time point of fusing, the initial time point of said fusing is the time point that at least a portion at said junction surface begins to melt when standing the joule heating by the electric power from said electrode input workpiece; The first amount of power calculation procedure is wherein through carrying out integration and calculate first amount of power when said fusing is initial, lighting the total electricity of importing said workpiece via said electrode; First determination step judges wherein whether the welding desired value of the welding situation at said first amount of power or indication and the corresponding junction surface of said first amount of power reaches first setting value at least; And heating steps, wherein when said fusing is initial, light and carry out said joule heating and reach said first setting value at least up to said first amount of power or said welding desired value.
The present invention can also be for being used for the control program of resistance welding machine, and said control program makes computer carry out this control method that is used for resistance welding machine.
In addition, the present invention can be understood that resistance welded appraisal procedure and resistance welded appraisal procedure.More specifically; The present invention can be the resistance welded appraisal procedure that may further comprise the steps: melt initial time point and detect step; Wherein detect the initial time point of fusing, the initial time point of said fusing is the time point that at least a portion at the junction surface of workpiece when the electric power of importing through the electrode of pushing down workpiece certainly carries out the joule heating begins to melt; The first amount of power calculation procedure is wherein through carrying out integration and calculate first amount of power melting the total electricity of lighting when initial via electrode input workpiece certainly; And estimating step, wherein estimate the welding situation at junction surface based on said first amount of power.
Except above-mentioned resistance welded appraisal procedure; The present invention can be the resistance welded appraisal procedure that may further comprise the steps: the second amount of power calculation procedure; Wherein through the total electricity of the electrode input workpiece of pushing down workpiece is certainly carried out integration and calculates second amount of power according to light elapsed time when initial from switching on, the initial time point of said energising is in order to utilize the electric power from said electrode input that the junction surface of workpiece is carried out joule heating and begun the time point to said electrifying electrodes; And second determination step; Judge that wherein the initial time point of fusing is that second amount of power reaches the initial amount of power of fusing or the time point of second setting value set based on the initial amount of power of said fusing at least; The initial amount of power of said fusing confirmed for the amount of power till in fact at least a portion at said junction surface begins to melt, imported and according to when said energising is initial, lighting elapsed time in advance, wherein can detect the initial time point of said fusing that at least a portion of the workpiece that carries out resistance welded begins to melt.After the resistance welded appraisal procedure stated can incorporate in " melt initial time point and detect step " of aforementioned resistance welding assessment method.
And the present invention can make computer carry out the resistance welded appraisal procedure of these resistance welded appraisal procedures for being used to.
Be noted that; Whether above-mentioned appraisal procedure can for assessing the appraisal procedure of welding situation in preset range according to the welding desired value of the welding situation at first amount of power that calculates or indication junction surface, wherein said welding desired value is confirmed through said first amount of power.In addition, appraisal procedure is more preferably for assessing the nugget appraisal procedure of the size of the nugget that when melt portions melts and solidifies, forms based on first amount of power.
Description of drawings
In detailed description of illustrative embodiments of the present invention, characteristic of the present invention, advantage and technology and industrial significance are described below with reference to accompanying drawings, wherein similar mark is represented similar parts, and wherein:
Fig. 1 shows contingent various interference in the resistance welded process;
Fig. 2 by illustrate from input amount of power that the energising that is present in the workpiece under the various interference begins and the curve map of the correlation between the diameter of formation nugget;
Fig. 3 illustrates section and be applied to the curve map of the correlation between the input amount of power of the workpiece that is present under various interference conduction time;
Fig. 4 by illustrate when the fusing of workpiece is initial, light the input amount of power that is applied to workpiece and the curve map of the correlation between the diameter of formation nugget;
Fig. 5 illustrates the sketch map of mash welder according to an embodiment of the invention;
Fig. 6 is near the sketch map the junction surface that illustrates on the workpiece; And
Fig. 7 is the flow chart of the welding method that mash welder adopted according to an embodiment of the invention.
The specific embodiment
Now the present invention will be described at length under the background of embodiments of the invention.Following explanation mainly concentrates on according to method for resistance welding of the present invention; But the content of explaining not only can suitably be applied to method for resistance welding, and can be applicable to electric resistance welding fitting, resistance welding machine, is used for the control device of resistance welding machine, the control method that is used for resistance welding machine, the control program that is used for resistance welding machine, resistance welded appraisal procedure and resistance welded appraisal procedure.The present invention has further comprised one or more formations of selecting through the formation of hereinafter being quoted certainly as required and has added the structure that is obtained in the above-mentioned formation to.Can be concomitantly or at random select structure to be added, and do not consider type.Be noted that, will be according to the differences such as performance of theme, requirement about which embodiment for the decision of the best.
At first, will be to describing as resistance welded and the interference of understanding important required content of the present invention.In resistance welded, through the electrifying electrodes of pushing down workpiece is formed joint.Owing to being present in various types of resistance in junction surface heat (Joule heat) that has a resistance.Then, the temperature at the junction surface of workpiece raises according to the heat difference, and said heat difference is to obtain through deducting the thermal discharge that is produced from the resistance heating amount.The part of the heat that has a resistance is radiated workpiece itself, electrode etc.Then, junction surface fusing, and the junction surface is cooled and solidifies up to the junction surface.For example, can make one group of metallic plate stand resistance welded.At first, wait this group plate that pushes as workpiece to make its tight contact through electrode.Make electrifying electrodes then, and (joint) produces Joule heat between the contact surface of adjacent panel.Therefore, near the preferential fusing in the zone of contact surface.When energising was accomplished, workpiece was cooled so that melted portion is solidified, thereby formed nugget.Then, resistance welded finishes.
Reason near the preferential fusing in zone of the contact surface of workpiece to be joined during resistance welded is that the contact resistance in this zone is higher than the resistance in other part.Yet contact resistance receives the influence of the contact condition between the workpiece to a great extent, in addition, in the welding place of reality, the deviation (interference) with desirable contact condition (status of criterion) often takes place.Therefore, though such as the current value that applies, conduction time situation such as section remain unchanged, the form of the welding at the junction surface that obtains also can change.Certainly, if during soldering, import the required heat of fusion bond portion in real time, even then when exist disturbing, also can wait and stablize welding through accurately calculating thermal discharge.Yet in fact such energising heating is difficult to realize.Therefore, in the resistance welded of routine, junction surface irregular and import excessive amount of power and make and be difficult to form efficiently stable weld part.
Yet before the junction surface of workpiece began fusing, the influence of interference continued to diminish or do not exist basically, and after the junction surface of workpiece began fusing, the influence of interference was insignificant.Therefore, through concentrating on the point that workpiece begins to melt, can make the amount of power of input workpiece optimum according to expectation welding parameter (for example, nugget size), the result can form stable welding.Yet; These necessary conditions; Be the initial time point of fusing of workpiece and, change, only therefore be difficult to come accurately to judge or specify the initial time point of fusing of workpiece based on the amount of power that begins to import workpiece from energising according to the type of disturbing by the amount of power of the initial time point of fusing input.
For example, if the interference shown in the pattern III among Fig. 1 exists, then the contact area at junction surface is littler than the contact area of the interference shown in the pattern IV, so contact resistance is bigger.Even the total current value through electrode is identical under two kinds of situation; Resistance in the junction surface is bigger under former instance, and the feasible density that flows through the electric current at junction surface increases, and (in other words the result produces heat apace through the junction surface; Heat generation rate is bigger), cause the temperature at junction surface to raise rapidly.In addition, because the temperature rising, with the also rising rapidly of resistivity of temperature correlation.As a result, under former instance, melt, make and reduced the heat release of waste and the amount of power of till fusing begins, importing than under latter instance, earlier beginning.
In amount of power computing according to the present invention, amount of power is based on value through the electric current of the electrode of pushing down workpiece and waits and calculate.Amount of power is judged as the integrated value of electric current, voltage and time, but amount of power can be confirmed through transformation for mula.Electric current through electrode can be for direct current or alternating current, and when applying alternating current, amount of power can be calculated based on virtual value.
Compare through the amount of power that will in the amount of power computing, calculate or with corresponding desired value of said amount of power and setting value and to carry out according to determination processing of the present invention.According to comparison other is that amount of power or desired value come suitably to select setting value.The size (nugget size) of representational desired value for melting and solidify the nugget that forms through the junction surface that makes workpiece.Because nugget does not form before workpiece begins fusing, so will preferably directly compare according to input amount of power that conduction time, section calculated on demand with section is confirmed according to conduction time the initial amount of power of fusing or based on the setting value that melts initial amount of power.
Do not limit for the shape of workpiece, material etc.Representational workpiece can be overlapping steel plate.For example, be that 0.05% to 0.2% soft steel plate stands resistance welded usually with weight content (C) with approximate 0.5mm to 3mm thickness and carbon.Alternatively, suitable workpiece also can be by processing such as the material of high strength (high-tensile strength) steel, galvinized steel, stainless steel, aluminium (Al), Al alloy, copper (Cu), Cu alloy, nickel (Ni) and Ni alloy.In addition, workpiece can be formed by the combination of different materials structure.Acquisition has required amount of power in the junction surface of expectation form etc. and changes according to workpiece material.The mode that the setting value of therefore, comparing with the amount of power that during resistance welded, calculates, the initial amount of power of fusing etc. are arranged according to workpiece material and form, workpiece, electrode applied pressure etc. and different.
The shape of electrode, material etc. are not limited.Electrode is processed by copper bar or copper post usually.If electrode is cylindrical, then cooling agent preferably be fed to electrode inside with cooling electrode, thereby suppress wearing and tearing.The end surfaces of the outer surface that contacts with workpiece of electrode is generally circle or tapered conical.If resistance welded is advantageously carried out, then the nugget of weld part forms and the identical shape in electrode tip surface usually, so that nugget is a circular.In this case, the size of nugget is represented by its diameter (nugget size).In this manual, for ease, the size of nugget refers to nugget size.
Supply unit can be AC power or dc source.Under the situation that is AC power, can be single phase poaer supply, three phase mains etc.In addition, supply unit can be constant-current supply or constant voltage source.If the use constant-current supply then increases in the amount that workpiece is heated to the Joule heat that is produced when stablizing higher temperature.As a result, form the fusing through workpiece more reliably and solidify the nugget of acquisition, the therefore preferred constant-current supply that uses.Be noted that, be supplied to the favourable current value etc. of workpiece from electrode according to the nugget size of workpiece material, expectation, conduction time section etc. and different.
To describe specific embodiment of the present invention now.The resistance welded (spot welding) of execution on the cutting model of the workpiece that constitutes by two overlapping steel plates under the various interference (said workpiece), and use high-speed camera that soldering is photographed.Like this, observe the forming process of the nugget that forms by spot welding.More specifically, spot welding is carried out through setting five representative mode I to V as shown in Figure 1 in (1).In pattern I, in Fig. 1, two overlapping steel plates are pressed onto together by electrode so that the junction surface established law of the central axial line of electrode and workpiece to.In pattern II, with respect to the status of criterion of pattern I, workpiece is from 3 ° of inclined.In pattern III, the periphery at the junction surface forms the gap.More specifically, have the position of the distance piece of 1mm thickness between the either side 15mm
of the welding central authorities that are positioned at overlapping steel plate.In pattern IV; Round-shaped on the tip end surface of electrode (surface of contact workpiece) increases to
here from
, and de is the diameter of a circle that forms on the tip of electrode.The tip end surface that should be noted in the discussion above that electrode is connected with all sides of electrode through the curved surface with 40mm radius of curvature.In pattern V, flow to except when the point that has been soldered beyond the preceding pad wherein is welded in the previous processing and accomplishes from the electric current of electrode supply.
In above-mentioned corresponding modes, set after workpiece and the electrode, workpiece is carried out spot welding.At this moment, the integrated value of electric power of calculating the input workpiece is with as importing amount of power Q.In addition, measure the diameter D that is formed on the final nugget in the workpiece according to input amount of power Q.Then, in curve map, draw input amount of power Q and nugget size D, as shown in Figure 2.The workpiece that stands spot welding is made up of two with 2mm thickness overlapping cold rolling soft steel plates (JIS:SPC270).The electrode that is adopted is cylindrical, and when cooling electrode is inner, carries out spot welding.The point of electrode as stated formalizes.In addition, when making electrode push down each outside of workpiece, carry out spot welding.The pressure that is applied on the workpiece by electrode is set to 3430N.60 cycles, single-phase alternating current are as power supply.The effective current value is set to 11kA.Control the application time section of heating current with the unit of Ct cycle time (1/60sec).
The input amount of power Q that here calculates is the integrated value that is applied to the voltage * time at (between the two ends of workpiece) between the electric current * electrode of electrode.Therefore, input amount of power Q also is the function of time.Fig. 3 shows for above-mentioned various patterns elapsed time (section conduction time) and the relation of importing between the amount of power Q after the energising beginning.Be noted that in Fig. 3 conduction time, section was to be represented by the number in energising cycle (one-period time Ct:1/60sec).In addition, the point (fusing starting point) that workpiece begins to melt in aforementioned various patterns utilizes Fig. 2 to be estimated and be added on Fig. 3.The fusing starting point is designated as on the cutting model can confirm the correct time that molten material flows.
Through connecting five fusing starting points that obtain in the various patterns, obtain fusing virgin curve (heavy line by among Fig. 3 is represented).On the contrary, be illustrated in during the actual spot weld operation conduction time section and the input amount of power between curve (conduction time section-input amount of power curve) and the joining between the fusing virgin curve of relation as melting starting point.Therefore, the fusing starting point is to be provided by the joining between conduction time section-input amount of power curve and the fusing virgin curve, and need not to consider the existence or the appointment interference type that disturb.In addition, section conduction time of this moment is used as the initial time point of fusing, and the input amount of power of this moment is as the initial amount of power of fusing.More specifically; For each section conduction time (number in energising cycle); The fusing initial amount of power of the input amount of power that calculates with related section storage conduction time compared; And do not consider jamming pattern, and will import amount of power meet or exceed the fusing initial amount of power point be judged to be the fusing initial time point.
Fig. 4 shows nugget size D and the first amount of power Q1 when corresponding workpiece carries out spot welding, and (=relation between Q-Qm), the first amount of power Q1 calculates through deducting the initial amount of power Qm of fusing from input amount of power Q (amount of power that calculates when the energising beginning).In other words, Fig. 4 shows each the bar curve along continuous straight runs shown in Fig. 2 to move with the fusing corresponding amount of initial amount of power Qm.It is obvious that from Fig. 4, and the relation between the first amount of power Q1 after the fusing beginning and the diameter D of the nugget that forms keeps constant basically, and no matter is which kind of jamming pattern.In other words, in case workpiece begins fusing, the diameter D of the nugget that obtains is confirmed by the first amount of power Q1 basically, can ignore from the influence of disturbing.
Fig. 5 shows the mash welder 100 that is used as the embodiment of resistance welding machine according to of the present invention.Mash welder 100 comprises hinged welding manipulator 20, is used to control the control device 30 and the supply unit 40 of welding manipulator 20.
Spot-welding gun 10 constitutes with servomotor 13 by falling L shaped rifle arm 12.Pair of electrodes 11 (travelling electrode 11a and comparative electrode 11b) is arranged on the rifle arm 12.
Travelling electrode 11a is driven so that move and move away from workpiece W towards workpiece W by servomotor 13.Therefore, thus travelling electrode 11a and comparative electrode 11b cooperating are with expectation pressure clamp clamping of workpieces W, the thickness direction coaxial arrangement of comparative electrode 11b and workpiece W.In addition, travelling electrode 11a and comparative electrode 11b are the closed end cylinder that is formed by copper alloy, and through making circulate coolant cool off travelling electrode 11a and comparative electrode 11b through the inside of each electrode 11.
Then, mash welder 100 starts and moves the welding manipulator 20 by control device 30 controls, so that spot-welding gun 10 places each pad place continuously.The electrode 11 that is arranged on the spot-welding gun 10 is driven by the servomotor 13 that control device 30 is controlled subsequently, to pass through setting pressure clamping work pieces W.Under this state, predetermined constant current is supplied to workpiece W from supply unit 40.Through repeating this operation, suitably workpiece W (weldment) is carried out spot welding at each pad.
Fig. 6 is the sketch map through the weld part of spot welding formation.If spot welding is advantageously carried out, then workpiece W melts and solidifies, so that nugget N is formed on the inside at the junction surface of the workpiece W (workpiece Wa and workpiece Wb) that is made up of for example soft steel plate.Be noted that as junction surface Y, and nugget N is surrounded by junction surface Y usually by electrode 11 heating and the part pushed down.In addition, the maximum gauge of nugget N is set to nugget size.
The initial time point detecting unit of the fusing of observation circuit comprises: the second amount of power computing unit; It calculates the interior second amount of power Q2 (t) via electrode 11 input workpiece W of section t conduction time in the early stage, and conduction time at initial stage, section t was section conduction time that self-electrode 11 makes workpiece W begin to have switched on; And second identifying unit; It judges whether the second amount of power Q2 (t) has reached fusing initial amount of power X2 (t) (second setting value) (in other words; Whether be Q2 >=X2), melt initial amount of power X2 (t) and be the section t and definite conduction time at initial stage that in fact begins to melt according to workpiece W.
The flow chart of the control method that Fig. 7 is adopted for the control device 30 of control point welding machine 100.Through carrying out control method shown in Figure 7, realized each processing according to method for resistance welding of the present invention, the result produces resistance welded workpiece W.At first, in step S11, set and import various welding conditions (setting step).More specifically, set and import material and the thickness of slab of workpiece Wa, Wb; The quantity of pad and position; The core shape of electrode 11 a, 11b; Be applied to the pressure of workpiece W by electrode 11; The current magnitude I1 that during spot welding, uses; Cycle time Ct; With the first corresponding setting value X1 of expectation nugget size; Melt initial amount of power X2 (t), it is the function of section t conduction time at initial stage; Or the like.As long as the initial amount of power X2 of fusing (t) obtains from fusing virgin curve shown in Figure 3; Its (that is, melting initial amount of power X2 (t)) just can take and the empirical equation of the relevant initial amount of power X2 of fusing (t) of section t conduction time at initial stage or the form of numeric data (array data).
In step S12, operation welding manipulator 20 and spot-welding gun 10 are so that the outside of the end of electrode 11a, 11b (electrode cores) contact workpiece W.Electrode 11 is based on the setting of step S11 and push down workpiece W (step of exerting pressure).In step S13,, make electrifying electrodes in order to carry out spot welding.In other words, heating current I1 is supplied to electrode, and spot welding begins (heating steps, heat treated) thus.
In step S14, according to the second amount of power Q2 (t) (the second amount of power calculation procedure, the second amount of power computing) that calculates input workpiece W from section conduction time (section conduction time at the initial stage) t that energising begins.More specifically, if electric current is an alternating current, then based on the effective current through electrode 11 supply and effective voltage thereof each of power-on servicing cycle time Ct calculate the second amount of power Q2 (t).Therefore be noted that the one-period of the alternating current that 1Ct equals to supply is being under the 60 Hz situation about exchanging for example, 1Ct=1/60sec.
In step S15, initial amount of power X2 of fusing (t) that will be corresponding with Ct cycle time that calculates the second amount of power Q2 (t) therein and the second amount of power Q2 (t) that in step S14, calculates compare (second determination step, second determination processing).If the second amount of power Q2 (t) is lower than fusing initial amount of power X2 (t), in other words, if the second amount of power Q2 (t) does not reach fusing initial amount of power X2 (t) as yet, then the heating of step S13 energising continues.Yet when the second amount of power Q2 (t) had reached the initial amount of power X2 of fusing (t), program advanced to step S16, the initial time point t0 of fusing designated (melt initial time point and detect step, melt initial time point and detect processing) in this step.
In step S17, S14 is similar with step, according to section conduction time (fusing section conduction time: t-t0) calculate the first amount of power Q1 (the first amount of power calculation procedure, the first amount of power computing) that imports workpiece W from the initial time point t0 of fusing.In step S18, will compare (first determination step, first determination processing) from the first amount of power Q1 of the initial time point t0 of fusing calculating and corresponding to the first setting value X1 that expects nugget size.
If the first amount of power Q1 is less than the first setting value X1, then the energising of workpiece W continues.Yet when the first amount of power Q1 had reached the first setting value X1, program advanced to step S19, and the energising of workpiece W stops in this step, and electrode 11 separates with workpiece W, and the spot welding in this position finishes (heating steps, heat treated).
Although the flow process at Fig. 7 is not shown, when step S17 and S18 have repeated pre-determined number or predetermined amount of time (number cycle time) at least, can makes amendment or adjust (heating set-up procedure, the heating adjustment is handled) the condition of heating energising.
Can utilize step S14 to S18 among Fig. 7 to assess the situation of spot welding.Can compare assessment welding quality separately through the value and the first setting value X1, shown in step S18 (estimation steps, appraisal procedure) with the first amount of power Q1.In addition, through be ready to the first amount of power Q1 be associated with nugget size D such as database shown in Figure 4, can estimate the diameter D (nugget estimation steps) of formed nugget in the weld part based on the first amount of power Q1 that integration is in fact calculated.
In addition, can detect the initial time point of fusing through the step S13 to S16 of execution graph 7.In other words, can judge the initial time point of fusing through the initial amount of power X2 of fusing (t) in the value of the second amount of power Q2 (t) and each section is compared conduction time, shown in step S15 (estimation steps, appraisal procedure).
Claims (13)
1. method for resistance welding, it is used for forming nugget through making the junction surface fusing and solidifying, and this method for resistance welding comprises:
Make electrode push down workpiece;
Through being input to through said electrode, electric power make said workpiece stand a joule heating in the said workpiece;
Detect the initial time point of fusing, the initial time point of said fusing is the time point that at least a portion at the junction surface of said workpiece begins to melt;
Calculate first amount of power, said first amount of power is for lighting the integrated value of importing the electric power of said workpiece via said electrode when said fusing is initial;
Judge whether said first amount of power or indication and the welding desired value of the welding situation at the corresponding said junction surface of said first amount of power reach first setting value at least; And
When said fusing is initial, light and proceed said joule heating and reach said first setting value at least up to said first amount of power or said welding desired value.
2. method for resistance welding according to claim 1, wherein said detection melt initial time point and further comprise:
Through the total electricity of importing said workpiece is carried out integration and calculates second amount of power according to light elapsed time when initial from switching on, the initial time point of said energising is to begin the time point to said electrifying electrodes in order said junction surface to be carried out joule heating; And
Judge that the initial time point of said fusing is that said second amount of power reaches the initial amount of power of fusing or the time point of second setting value set based on the initial amount of power of said fusing at least, the amount of power that the initial amount of power of said fusing is imported till in fact beginning to melt at least a portion up to said junction surface and confirmed in advance according to when said energising is initial, lighting elapsed time.
3. method for resistance welding according to claim 1, wherein, said joule of heating of said workpiece comprises based on said first amount of power or said welding desired value whether reaching the heating parameters that said first setting value is revised said workpiece at least.
4. a warp uses the workpiece according to each the described method for resistance welding welding in the claim 1 to 3.
5. control device that is used for resistance welding machine; Said resistance welding machine comprises electrode and supply unit; The outer surface of said electrode contact workpiece, said supply unit are supplied with electric current to said electrode to be used for that the joule heating is carried out at the junction surface of said workpiece, and said control device comprises:
Melt initial time point detecting unit, it detects the initial time point of fusing, and the initial time point of said fusing is the time point that at least a portion at said junction surface when standing the joule heating begins to melt;
The first amount of power computing unit, it is through carrying out integration and calculate first amount of power when said fusing is initial, lighting the total electricity of importing said workpiece via said electrode;
First identifying unit, whether its welding desired value of judging the welding parameter at said first amount of power or indication and the corresponding said junction surface of said first amount of power reaches first setting value at least; And
Heating unit, it is lighted when said fusing is initial and carries out said joule heating and reach said first setting value at least up to said first amount of power or said welding desired value.
6. resistance welding machine comprises:
Electrode, it pushes down workpiece;
Supply unit, its supply electric current to said electrode is to be used for that the joule heating is carried out at the junction surface of said workpiece; And
Control device according to claim 5.
7. control method that is used for resistance welding machine; Said resistance welding machine comprises electrode and supply unit; The outer surface of said electrode contact workpiece, said supply unit supply electric current to said electrode is to be used for that the joule heating is carried out at the junction surface of said workpiece, and said method comprises:
Detect the initial time point of fusing, the initial time point of said fusing is the time point that at least a portion at said junction surface begins to melt when standing the joule heating by the electric power of importing said workpiece from said electrode;
Through carrying out integration and calculate first amount of power to when said fusing is initial, lighting the total electricity of importing said workpiece via said electrode;
Whether the welding desired value of judging the welding situation at said first amount of power or indication and the corresponding said junction surface of said first amount of power reaches first setting value at least; And
When said fusing is initial, light and proceed said joule heating and reach said first setting value at least up to said first amount of power or said welding desired value.
8. control program that is used for resistance welding machine, said control program control computer is carried out the control method that is used for resistance welding machine according to claim 7.
9. resistance welded appraisal procedure comprises:
Make electrode push down workpiece;
Through being input to through said electrode, electric power make said workpiece stand a joule heating in the said workpiece;
Detect the initial time point of fusing, the initial time point of said fusing is the time point that at least a portion at the junction surface of workpiece begins to melt;
Through carrying out integration and calculate first amount of power to when said fusing is initial, lighting the total electricity of importing said workpiece via said electrode; And
Estimate the welding parameter at said junction surface based on said first amount of power.
10. resistance welded appraisal procedure according to claim 9; The said welding parameter of wherein being estimated is the size of nugget; Said nugget forms when the fusing of said junction surface and when solidifying, and the said size of said nugget (N) is based on that said first amount of power estimates.
11. according to claim 9 or 10 described resistance welded appraisal procedures, wherein said detection is melted initial time point and is further comprised:
Through the total electricity of importing said workpiece is carried out integration and calculates second amount of power according to light elapsed time when initial from switching on, the initial time point of said energising is to begin the time point to said electrifying electrodes in order said junction surface to be carried out joule heating; And
Judge that the initial time point of said fusing is that said second amount of power reaches the initial amount of power of fusing or the time point of second setting value set based on the initial amount of power of said fusing at least, the initial amount of power of said fusing is confirmed for the amount of power till in fact at least a portion at said junction surface begins to melt, imported and according to when said energising is initial, lighting elapsed time in advance.
12. a resistance welded appraisal procedure comprises:
Total electricity through the electrode of pushing down workpiece certainly being imported said workpiece carries out integration and calculates second amount of power according to light elapsed time when initial from switching on, and the initial time point of said energising is in order to utilize the electric power from said electrode input that the junction surface of said workpiece is carried out joule heating and begun the time point to said electrifying electrodes; And
Judge that the initial time point of fusing is that said second amount of power reaches the initial amount of power of fusing or the time point of second setting value set based on the initial amount of power of said fusing at least; The initial amount of power of said fusing is confirmed for the amount of power till in fact at least a portion at said junction surface begins to melt, imported and according to when said energising is initial, lighting elapsed time in advance
Wherein detect the initial time point of said fusing that at least a portion of the said workpiece of pending resistance welded begins to melt.
13. control computer and carry out resistance welded appraisal procedure for one kind according to each the described resistance welded appraisal procedure in the claim 9 to 12.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2009262730A JP5052586B2 (en) | 2009-11-18 | 2009-11-18 | Resistance welding method, resistance welding member, resistance welding machine and control device thereof, resistance welding machine control method and control program thereof, resistance welding evaluation method and evaluation program, and detection method at the start of resistance welding melting |
| JP2009-262730 | 2009-11-18 | ||
| PCT/IB2010/003119 WO2011061623A2 (en) | 2009-11-18 | 2010-11-16 | Resistance welding method, resistance-welded member, resistance welder, control apparatus for resistance welder, control method and control program for resistance welder, resistance welding evaluation method, and resistance welding evaluation program |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN102665995A true CN102665995A (en) | 2012-09-12 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2010800524257A Pending CN102665995A (en) | 2009-11-18 | 2010-11-16 | Resistance welding method, resistance-welded member, resistance welder, control apparatus for resistance welder, control method and control program for resistance welder, resistance welding evaluation method, and resistance welding evaluation program |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US20120248086A1 (en) |
| EP (1) | EP2501514A2 (en) |
| JP (1) | JP5052586B2 (en) |
| CN (1) | CN102665995A (en) |
| WO (1) | WO2011061623A2 (en) |
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| CN106457453A (en) * | 2014-06-12 | 2017-02-22 | 杰富意钢铁株式会社 | Resistance spot welding device and resistance spot welding method |
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| CN112262012A (en) * | 2018-06-29 | 2021-01-22 | 杰富意钢铁株式会社 | Resistance spot welding method and method for manufacturing welded member |
| CN112775528A (en) * | 2020-12-22 | 2021-05-11 | 上海电力大学 | Method for automatically evaluating rigidity of resistance spot welding clamp |
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| JP6112209B2 (en) * | 2013-09-12 | 2017-04-12 | 新日鐵住金株式会社 | Resistance spot welding method and manufacturing method of welded structure |
| US10406626B2 (en) * | 2013-09-12 | 2019-09-10 | Nippon Steel Corporation | Resistance spot welding method and welded structure |
| US20170072513A1 (en) * | 2014-02-24 | 2017-03-16 | Howon Co., Ltd. | Hybrid welder |
| JP6471841B1 (en) * | 2017-08-18 | 2019-02-20 | Ｊｆｅスチール株式会社 | Resistance spot welding method and manufacturing method of welded member |
| KR102415945B1 (en) * | 2018-06-29 | 2022-06-30 | 제이에프이 스틸 가부시키가이샤 | Resistance spot welding method and manufacturing method of a welded member |
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| CN111037079A (en) * | 2018-10-11 | 2020-04-21 | 罗伯特·博世有限公司 | Method for checking quality in resistance welding of workpieces |
| CN111037079B (en) * | 2018-10-11 | 2022-12-20 | 罗伯特·博世有限公司 | Method for testing quality in resistance welding of workpieces |
| CN112775528A (en) * | 2020-12-22 | 2021-05-11 | 上海电力大学 | Method for automatically evaluating rigidity of resistance spot welding clamp |
| CN112775528B (en) * | 2020-12-22 | 2022-09-27 | 上海电力大学 | Method for automatically evaluating rigidity of resistance spot welding clamp |
Also Published As
| Publication number | Publication date |
|---|---|
| JP5052586B2 (en) | 2012-10-17 |
| US20120248086A1 (en) | 2012-10-04 |
| JP2011104628A (en) | 2011-06-02 |
| EP2501514A2 (en) | 2012-09-26 |
| WO2011061623A2 (en) | 2011-05-26 |
| WO2011061623A3 (en) | 2011-11-03 |
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