CN115397597A - Welding power supply, welding system, control method for welding power supply, and program - Google Patents
Welding power supply, welding system, control method for welding power supply, and program Download PDFInfo
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- CN115397597A CN115397597A CN202180028768.8A CN202180028768A CN115397597A CN 115397597 A CN115397597 A CN 115397597A CN 202180028768 A CN202180028768 A CN 202180028768A CN 115397597 A CN115397597 A CN 115397597A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
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- Plasma & Fusion (AREA)
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- Arc Welding Control (AREA)
Abstract
The welding power supply includes: a feeding control unit that controls feeding of the welding wire such that a leading end of the welding wire is fed while being accompanied by periodic switching in forward feeding and backward feeding; and a current control unit which changes the welding current corresponding to the front end position of the welding wire. The feeding control means controls the time taken for the tip of the welding wire to reach the farthest point from the base material from the closest point to the base material to be shorter than the time taken for the tip of the welding wire to reach the closest point from the farthest point. The current control means controls the welding wire so that a low current period in which the welding current is reduced from a predetermined current value is provided during a period in which the tip of the welding wire is fed in the reverse direction.
Description
Technical Field
The invention relates to a welding power supply, a welding system, a control method of the welding power supply, and a program.
Background
A welding power supply for supplying a welding current to a welding wire as a consumable electrode is known, which includes a control unit for changing the welding current in accordance with a tip position of the welding wire at which a distance from a surface of a base material periodically varies when the tip of the welding wire is fed to the base material while periodically switching a period of forward feeding and a period of reverse feeding, and the control unit controls such that a low current period in which the welding current is reduced below a predetermined current value is provided while the tip of the welding wire is fed in the reverse direction (see, for example, patent document 1).
Documents of the prior art
Patent literature
Patent document 1: JP 2020-49506A
Disclosure of Invention
Problems to be solved by the invention
The method comprises the following steps: a low current period is provided in a period in which the tip of the welding wire is fed back to the base material while periodically switching between a period in which the tip of the welding wire is fed forward and a period in which the tip of the welding wire is fed back, thereby reducing scattering of spatters caused by droplet detachment. In such a technique, there is a limit to the possibility of droplet separation during a period in which the tip of the welding wire is fed in the reverse direction, that is, during a low current period, in a configuration in which the welding wire is fed at a feed speed of the welding wire that changes in a sine wave shape. That is, there is a limit to make sputtering less likely to scatter.
The present invention has an object to make spatter less likely to scatter in a technique in which a low-current period is provided during which a tip of a welding wire is fed back to a base material while periodically switching between a period of being fed forward and a period of being fed back, as compared with a technique in which a welding wire is fed at a wire feed speed that changes in a sine wave shape.
Means for solving the problems
In accordance with a related object, the present invention provides a welding power supply for supplying a welding current to a wire as a consumable electrode and separating a droplet in an open arc state without short-circuiting the wire with a molten pool, the welding power supply comprising: a feeding control unit that controls feeding of the welding wire so that a tip of the welding wire is fed to the base material while being periodically switched between a period of being fed forward and a period of being fed backward; and a current control unit that changes a welding current in accordance with a tip position of the welding wire whose distance from the surface of the base material periodically varies, wherein the feed control unit controls a time taken for the tip of the welding wire to reach a farthest point, which is a position farthest from the base material, from a closest point, which is a position closest to the base material, to be shorter than a time taken for the tip of the welding wire to reach the closest point from the farthest point, and the current control unit controls the welding current to be set to a low current period in which the welding current is reduced below a predetermined current value while the tip of the welding wire is fed in reverse.
The feeding control means may control the feeding speed amplitude of the welding wire in a period in which the tip of the welding wire is fed backward to be larger than the feeding speed amplitude of the welding wire in a period in which the tip of the welding wire is fed forward.
The current control means may control the low current period so as to start when the tip position of the welding wire that periodically fluctuates is located closer to the base material side than a position 1/2 of the wave height defined by the closest point and the farthest point. In this case, the current control means may control the low-current period to start within a range from a leading end position of the welding wire at a time point when the leading end of the welding wire is switched from the period of being fed forward to the period of being fed backward to a leading end position of the welding wire at a time point when the command value of the feeding speed of the welding wire switched to be fed backward is maximum. The current control means controls the low-current period to end in a range from a tip position of the welding wire at a time point when the command value of the feed speed of the welding wire switched to the reverse feed is maximum to a tip position of the welding wire at a time point when the tip of the welding wire is switched from the period of being fed in the reverse direction to the period of being fed in the forward direction.
Further, the present invention provides a welding system for performing arc welding by supplying a welding current to a wire as a consumable electrode and separating a droplet in an open arc state without short-circuiting the wire with a molten pool, the welding system comprising: a feeding control unit that controls feeding of the welding wire so that a tip of the welding wire is fed to the base material while being periodically switched between a period of being fed forward and a period of being fed backward; and a current control means for changing a welding current in accordance with a tip position of the welding wire whose distance from the surface of the base material periodically varies, wherein the feed control means controls the time taken for the tip of the welding wire to reach a farthest point, which is a position farthest from the base material, from a closest point, which is a position closest to the base material, to be shorter than the time taken for the tip of the welding wire to reach the closest point from the farthest point, and the current control means controls the welding current to be set to a low current period in which the welding current is reduced to a predetermined current value while the tip of the welding wire is reversely fed.
Further, the present invention provides a method for controlling a welding power supply that supplies a welding current to a welding wire as a consumable electrode and separates a droplet in an open arc state without short-circuiting the welding wire with a molten pool, the method comprising: controlling the feeding of the welding wire so that the tip of the welding wire is fed to the base material while being periodically switched between a period of being fed forward and a period of being fed backward; and changing the welding current in accordance with a tip position of the welding wire at which a distance from the surface of the base material periodically varies, wherein in the step of controlling the feeding, control is performed such that a time taken for the tip of the welding wire to reach a farthest point, which is a position farthest from the base material, from a closest point, which is a position closest to the base material, is shorter than a time taken for the tip of the welding wire to reach the closest point from the farthest point, and in the step of changing the welding current, control is performed such that a low current period in which the welding current is reduced below a predetermined current value is provided while the tip of the welding wire is being fed in reverse.
Furthermore, the present invention provides a program for causing a computer of a welding system to realize functions of supplying a welding current to a wire as a consumable electrode to perform arc welding and separating a droplet in an open arc state without short-circuiting the wire with a molten pool, the functions including: controlling the feeding of the welding wire so that the front end of the welding wire is fed to the base material along with the periodical switching of the period of forward feeding and the period of reverse feeding; the function of controlling the feeding is controlled such that the time taken for the tip of the welding wire to reach the farthest point, which is the position farthest from the base material, from the closest point, which is the position closest to the base material, is shorter than the time taken for the tip of the welding wire to reach the closest point from the farthest point, and the function of controlling the welding current is controlled such that a low current period in which the welding current is reduced below a predetermined current value is provided while the tip of the welding wire is fed in the reverse direction.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, in the technique of providing the low current period during which the tip of the welding wire is fed backward to the base material while periodically switching the period during which the welding wire is fed forward and the period during which the welding wire is fed backward, spatters are less likely to be scattered than in the case of using the configuration in which the welding wire is fed at the wire feed speed that changes in a sine wave shape.
Drawings
Fig. 1 is a configuration diagram illustrating an example of an arc welding system according to the present embodiment.
Fig. 2 is a block diagram illustrating a configuration example of a control system portion of the welding power supply.
Fig. 3 is a waveform diagram illustrating a temporal change in the wire feed speed.
Fig. 4 is a waveform diagram illustrating a temporal change in the leading end position of the welding wire.
Fig. 5 is a flowchart illustrating an example of control of the welding current in the present embodiment.
Fig. 6 is a timing chart showing an example of control of the current setting signal for specifying the current value of the welding current.
Fig. 7 is a graph showing the waveform of the wire feeding speed, the welding current, and the welding voltage, and the droplet separation timing of patent document 1.
Fig. 8 is a graph showing the waveform of the wire feeding speed, the welding current, and the welding voltage, and the droplet separation timing according to the present embodiment.
Fig. 9 is a graph showing the measurement results of the droplet detachment timing of patent document 1.
Fig. 10 is a graph showing measurement results of droplet detachment timing according to the present embodiment.
Fig. 11 is a graph showing the results of measuring the time from the start of the current suppression period to the departure in patent document 1.
Fig. 12 is a graph showing the results of measuring the time from the start of the current suppression period to the time of departure in the present embodiment.
Detailed Description
Embodiments of the present invention are described in detail below with reference to the accompanying drawings.
< problems to be solved by the present embodiment >
The problem to be solved by the present embodiment is 2.
The 1 st problem is that sputtering is liable to scatter.
In the technique of patent document 1, in carbon dioxide gas welding (open arc welding) without short circuit, the wire feed rate and the welding current are appropriately controlled, and a droplet (molten metal) is separated and transited to a welding base metal during a low current period.
It is important here that the droplet is positively detached by pulling back the welding wire in a state where the droplet is easily detached. The ease of droplet detachment is affected by the droplet size (weight), surface tension, arc reaction force, and the like. For example, the larger the droplet size, the easier the droplet is to detach, and the smaller the droplet size, the more difficult the droplet is to detach.
In an automatic welding machine using a robot, a "self-holding function of an arc length" for holding the arc length constant is used to obtain a stable welding result. By "self-sustaining function of the arc length" is meant the following function: the welding power source is made to have "constant voltage characteristics", and when the arc length is made longer, the welding current is slightly reduced (the melting of the wire is slowed) to operate in a direction of shortening the arc length, and when the arc length is made shorter, the welding current is conversely increased (the melting of the wire is accelerated) to operate in a direction of lengthening the arc length. In patent document 1, when the arc length is increased and the welding current is decreased due to some external factors during welding, droplet growth in the droplet growth period is slowed and the droplet size is reduced, and the droplet may not be separated in the current suppression period in which it is desired to separate the droplet. If the droplet is released during the current non-suppression period, there is a problem that sputtering is easily scattered.
The 2 nd problem is a point at which the contact tip is easily worn.
In arc welding, a welding current is supplied to a welding wire by a power supply member made of a copper alloy called a "contact tip" attached to a tip of a welding torch. Joule heat caused by the passage of a large current is generated in the contact portion between the contact tip and the welding wire, and the contact tip is easily softened. If the softened contact tip is moved while the welding wire is in contact with the surface thereof, the welding wire is gradually scraped off and is continuously worn. When the wire feeding portion of the contact tip is worn, the feeding of the wire to the welding wire becomes unstable, a predetermined welding current does not flow any more, the deposition amount changes, and a problem such as deposition of the contact tip and the welding wire occurs. The contact tip is more likely to be worn away as the welding current increases, and is more likely to be worn away as the wire feed speed increases.
In patent document 1, there is a problem that a peak period of a welding current and a peak period of a wire feeding speed overlap each other, and a welding wire is passed through a contact tip softened by a large current at a high speed, so that the contact tip is easily worn.
Therefore, in the present embodiment, when the droplet is separated in the open arc state without short-circuiting the wire and the molten pool, spatters are less likely to scatter, and the contact tip is less likely to wear. Such an embodiment will be described in detail below.
< Overall Structure of System >
Fig. 1 is a configuration diagram illustrating an example of an arc welding system 10 according to the present embodiment.
The arc welding system 10 includes a welding robot 120, a robot controller 160, a welding power supply 150, a feeding device 130, and a shielding gas supply device 140.
The welding power supply 150 is connected to the welding electrode via a positive cable, and is connected to an object to be welded (hereinafter also referred to as "base material" or "workpiece") 200 via a negative cable. This connection is performed in the opposite polarity, and when welding is performed in the positive polarity, the welding power source 150 is connected to the base material 200 via a positive cable, and is connected to the welding electrode via a negative cable.
The welding power source 150 and the feeding device 130 of the consumable electrode (hereinafter also referred to as "welding wire") 100 are also connected by a signal line, and the feeding speed of the welding wire can be controlled.
Welding robot 120 includes welding torch 110 as an end effector. Torch 110 has a current-carrying mechanism (contact tip) for carrying current to welding wire 100. Welding wire 100 generates an arc from the tip by the current supplied from the contact tip, and welds base material 200 to be welded by the heat of the arc.
Further, the welding torch 110 includes a shielding gas nozzle (a mechanism for ejecting shielding gas). The shielding gas may be carbon dioxide gas, argon + carbon dioxide gas (CO) 2 ) And the like. Further, carbon dioxide gas is more preferable, and in the case of a mixed gas, a system in which 10 to 30% of carbon dioxide gas is mixed with Ar is preferable. The shielding gas is supplied from the shielding gas supply device 140.
The welding wire 100 used in the present embodiment may be either a flux-free (flux) -containing solid welding wire or a flux-added welding wire containing a flux. The material of welding wire 100 is also not limited. For example, the material may be mild steel, stainless steel, aluminum, or titanium. Further, the diameter of the welding wire 100 is also not particularly limited. In the case of the present embodiment, it is preferable that the upper limit of the diameter is 1.6mm and the lower limit is 0.8mm.
The robot controller 160 controls the operation of the welding robot 120. The robot controller 160 holds teaching data for specifying the operation mode, the welding start position, the welding end position, the welding conditions, the weaving operation, and the like of the welding robot 120 in advance, and instructs the welding robot 120 to control the operation of the welding robot 120. Further, the robot controller 160 gives an instruction to the welding power supply 150 to control the power supply in the welding job in accordance with the teaching data.
The arc welding system 10 here is an example of a welding system. The welding power source 150 is also an example of a control unit that changes the welding current.
< construction of welding Power supply >
Fig. 2 is a block diagram illustrating an example configuration of a control system portion of the welding power supply 150.
The control system portion of the welding power supply 150 is implemented, for example, by a computer executing a program.
The current setting portion 36 is included in the control system portion of the welding power supply 150. The current setting unit 36 in the present embodiment includes: a function of setting various current values that define a welding current flowing through welding wire 100; a function of setting a start time and an end time of a period in which the current value of the welding current is suppressed (current suppression period setting unit 36A); and a wire tip position conversion unit 36B that obtains information on the tip position of the welding wire 100.
In the present embodiment, the current setting unit 36 sets a peak current Ip, a base current Ib, and a steady-state current Ia for droplet detachment. In the case of the present embodiment, the welding current is basically controlled by 2 values of the peak current Ip and the base current Ib. Therefore, a time t1 at which the period in which the current value is suppressed starts represents a time at which the base current Ib starts (base current start time), and a time t2 at which the period in which the current value is suppressed ends represents a time at which the base current Ib ends (base current end time) (refer to fig. 6).
The main power supply circuit of welding power supply 150 includes an ac power supply (here, a three-phase ac power supply) 1, a primary 1-side rectifier 2, a smoothing capacitor 3, a switching element 4, a transformer 5, a primary 2-side rectifier 6, and a reactor 7.
Ac power input from an ac power supply 1 is full-wave rectified by a primary-side rectifier 2, and is further smoothed by a smoothing capacitor 3 to be converted into dc power. Then, the dc power is converted into high-frequency ac power by inverter control by the switching element 4, and then converted into 2-side power via the transformer 5. The ac output of the transformer 5 is full-wave rectified by the secondary-side rectifier 6, and further smoothed by the reactor 7. The output current of the reactor 7 is supplied to the welding nozzle 8 as an output from the power supply main circuit, and the welding wire 100 as a consumable electrode is energized.
Feeding of wire 100 by feeding motor 24 is controlled by control signal Fc from feeding drive unit 23. The average value of the feed rate was approximately the same as the melting rate. In the present embodiment, the feeding of welding wire 100 by feeding motor 24 is also controlled by welding power source 150.
The target value of the voltage applied between the welding nozzle 8 and the base material 200 (voltage setting signal Vr) is supplied from the voltage setting unit 34 to the current setting unit 36.
The voltage setting signal Vr is also supplied to the voltage comparing section 35, and is compared with the voltage detection signal Vo detected by the voltage detecting section 32. The voltage detection signal Vo is a measured value.
The voltage comparing unit 35 amplifies the difference between the voltage setting signal Vr and the voltage detection signal Vo, and outputs the amplified signal to the current setting unit 36 as a voltage error amplified signal Va.
The current setting unit 36 controls the welding current so that the length of the arc 9 (i.e., the arc length) is constant. In other words, the current setting portion 36 performs constant voltage control by control of the welding current.
The current setting unit 36 resets the value of the peak current Ip, the value of the base current Ib, the period during which the peak current Ip is given, or the value of the peak current Ip and the value of the base current Ib based on the voltage setting signal Vr and the voltage error amplification signal Va, and outputs the current setting signal Ir corresponding to the reset period or value to the current error amplification unit 37.
In the present embodiment, the period during which the peak current Ip is given is a period other than the period during which the base current Ib is given. In other words, the period during which the peak current Ip is given is a period during which the current is not suppressed (current non-suppression period). The period for giving the peak current Ip is an example of the 1 st period.
On the other hand, the period during which the base current Ib is given is also referred to as a current suppression period. The current suppression period is an example of the low current period, and is also an example of the 2 nd period.
The current error amplifier 37 amplifies the difference between the current setting signal Ir given as the target value and the current detection signal Io detected by the current detector 31, and outputs the amplified signal as a current error amplified signal Ed to the inverter driver 30.
The inverter driving unit 30 corrects the driving signal Ec of the switching element 4 by the current error amplification signal Ed.
The average feeding speed Fave of the fed wire 100 is also given to the current setting section 36. Average feed speed Fave is output by average feed speed setting unit 20 based on teaching data stored in a storage unit, not shown.
The current setting unit 36 determines the peak current Ip, the base current Ib, the steady-state current Ia, the time t1 when the base current Ib starts, and the time t2 when the base current Ib ends, based on the given average feed speed Fave.
In the present embodiment, as shown in fig. 2, the average feed speed Fave is input to the current setting unit 36, but the signal input to the current setting unit 36 may be used by replacing the average feed speed Fave with a value related to the average feed speed Fave as a set value. For example, when a database of the average feed speed and the average current value at which welding can be performed optimally for the average feed speed is stored in a storage unit, not shown, the average current value may be used as a set value by replacing it with the average feed speed Fave.
The average feed speed Fave is also supplied to the amplitude feed speed setting section 21 and the feed speed command setting section 22.
The amplitude feed rate setting unit 21 here determines the values of the amplitude Wf and the period Tf, which are basic feed conditions, based on the input average feed rate Fave. The amplitude Wf is the magnitude of change with respect to the average feed speed Fave, and the period Tf is the time of change in amplitude as a repeating unit.
The wire feeding in patent document 1 is a feeding method as follows: a period (forward feeding period) in which the feeding speed is higher than the average feeding speed Fave and a period (reverse feeding period) in which the feeding speed is lower than the average feeding speed Fave are alternately present, and the time width of the forward feeding period and the time width of the reverse feeding period are the same.
In contrast, in the present embodiment, the forward/reverse speed ratio setting unit 38 sets PFR (%) which is a ratio of the reverse feed period to the period Tf, and supplies the PFR to the amplitude feed speed setting unit 21.
Here, in the amplitude feed rate setting section 21, the amplitude feed rate Ff during forward feeding and the amplitude feed rate Ff during reverse feeding are calculated based on the amplitude Wf, the period Tf, and the forward-reverse feed ratio PFR. The amplitude feed speed Ff during reverse feed is given by the following equation. Here, t denotes the time instant.
[ mathematical formula 1]
Further, the amplitude feeding speed Ff during the forward feeding is given by the following equation.
[ mathematical formula 2]
As described above, the amplitude feed rate setting unit 21 generates and outputs different amplitude feed rates Ff during the forward feed period and the backward feed period.
The feed speed command setting unit 22 outputs a feed speed command signal Fw based on the amplitude feed speed Ff and the average feed speed Fave.
In the present embodiment, the feed speed command signal Fw is represented by the following expression.
Fw = Ff + Fave … formula 3
The feed speed command signal Fw is output to the phase deviation detection unit 26, the feed error amplification unit 28, and the current setting unit 36.
The feed error amplification unit 28 amplifies the difference between the feed speed command signal Fw, which is the target speed, and the feed speed detection signal Fo, which is the actual feed speed of the welding wire 100 by the feed motor 24, and outputs a speed error amplification signal Fd, which is corrected by the error, to the feed drive unit 23.
The feed driving section 23 generates a control signal Fc based on the speed error amplification signal Fd and supplies the control signal Fc to the feed motor 24.
Here, feed speed converter 25 converts the amount of rotation of feed motor 24 and the like into feed speed detection signal Fo of wire 100.
The phase deviation detecting unit 26 in the present embodiment compares the feed speed command signal Fw with the feed speed detection signal Fo as a measurement value, and outputs a phase deviation time T θ d. The phase deviation detection unit 26 may measure the feeding operation of the feed motor 24 to determine the phase deviation time T θ d when the parameter (the period Tf, the amplitude Wf, and the average feed speed Fave) for the predetermined amplitude feeding is changed.
The phase deviation time T θ d is given to the wire tip position conversion unit 36B of the current setting unit 36. Wire tip position conversion unit 36B calculates the tip position of wire 100 with reference to base material 200 based on feed speed command signal Fw and phase shift time T θ d, and supplies the information of the calculated tip position to current suppression period setting unit 36A.
Here, current suppression period setting unit 36A sets a period for suppressing the welding current (i.e., a period for controlling current setting signal Ir to be equal to base current Ib) based on information of the tip position of wire 100 or based on information of the tip position of wire 100 and feed speed command signal Fw.
Here, current setting unit 36 is an example of a feeding control unit that controls feeding of wire 100 and a current control unit that changes the welding current in accordance with the tip position of wire 100.
< example of controlling welding Current >
An example of controlling the welding current of the welding power source 150 is described below.
The welding current is controlled by a current setting unit 36 constituting the welding power source 150. As described above, the current setting unit 36 in the present embodiment implements control by executing a program.
Fig. 3 is a waveform diagram illustrating a temporal change in the feed speed command signal Fw. The horizontal axis is time (phase) and the vertical axis is velocity. The vertical axis is in meters per minute or revolution. Among them, numerical values are an example. For example, when the diameter of the welding wire 100 (see fig. 1) is set to 1.2mm, the average feed speed Fave is 12 to 25 m/min. However, in order to maintain the later-described droplet (globule) transition or spray transition, the feed speed is desirably 8 meters per minute or more, although it depends on the projection length of the welding wire 100. For example, when the projection length of the welding wire 100 is 25mm, the welding current is about 225A. The critical area for short circuit transitions and droplet transitions is about 250A.
In fig. 3, a speed faster than the average feed speed Fave is characterized by a positive value, and a speed slower than the average feed speed Fave is characterized by a negative value. A period in which the feeding speed is higher than the average feeding speed Fave is referred to as a forward feeding period, and conversely, a period in which the feeding speed is lower than the average feeding speed Fave is referred to as a reverse feeding period. Further, welding wire 100 (see fig. 1) is fed out so as to be close to base material 200 (see fig. 1).
In patent document 1, the time width of the forward feed period and the time width of the backward feed period are equal to each other, and the velocity amplitude of the forward feed period and the velocity amplitude of the backward feed period are equal to each other, so that the velocity waveform is a sine wave having a period Tf and an amplitude Wf.
In the case of the present embodiment, the feed rate command signal Fw is different in the time width of the forward feed period and the time width of the backward feed period, and is different in the velocity amplitude Wf _ f of the forward feed period and the velocity amplitude Wf _ r of the backward feed period.
That is, if the proportion of the reverse feed time in the 1-cycle feed is PFR (%), the cycle and velocity amplitude of the forward feed period and the cycle and velocity amplitude of the reverse feed period can be defined as follows.
During forward feed: half waves of a sine wave with period ((100-PFR). Times.Tf)/50 and velocity amplitude Wf _ f PFR. Times.wf/50.
During the reverse feeding: the period is PFR Tf/50 and the velocity amplitude Wf _ r is the half-wave of a ((100-PFR) Wf/50 sine wave.
Here, wf is a velocity amplitude when the PFR is 50, that is, when the velocity waveform is a sine wave as in patent document 1.
In the present embodiment, PFR < 50 is assumed. Thereby, the velocity amplitude Wf _ f becomes smaller than the velocity amplitude Wf, and the velocity amplitude Wf _ r becomes larger than the amplitude Wf. The average feed speed Fave can be regarded as the wire melting speed Fm.
In other words, the feeding speed amplitude Wf _ r of the welding wire during the period in which the tip of the welding wire is fed in the reverse direction is preferably controlled to be larger than the feeding speed amplitude Wf _ f of the welding wire during the period in which the tip of the welding wire is fed in the forward direction.
Fig. 4 is a waveform diagram illustrating a temporal change in the tip position (wire tip position) of the welding wire 100 (see fig. 1). The horizontal axis represents time (phase), and the vertical axis represents a distance (height) from the surface of the base material 200 (base material surface) upward in the normal direction.
In fig. 4, the distance (height) when wire 100 is fed at average feed speed Fave is defined as a reference distance, and a distance larger than the reference distance is defined by a positive value, and a distance smaller than the reference distance is defined by a negative value.
As shown in fig. 4, the period in which the tip position of wire 100 approaches the base material surface with the elapse of time is the forward feeding period, and the period in which the tip position of wire 100 moves away from the base material surface with the elapse of time is the reverse feeding period.
Fig. 4 represents time points corresponding to a position (lowermost point) where the tip position of welding wire 100 is closest to the surface of the base material at T0 and T4, and represents time points corresponding to a position (uppermost point) where the tip position of welding wire 100 is farthest from the surface of the base material at T2. Here, the lowermost point is an example of the closest point, and the uppermost point is an example of the farthest point.
The time points corresponding to the reference distance are T1 and T3. T1 is a time point from the position (lowermost point) at which the tip end of welding wire 100 is closest to the base material surface to the middle of the position (uppermost point) at the farthest distance. T3 is a time point from a position farthest from the parent material surface in the front end position of the welding wire 100 to the middle of the closest position. As shown in fig. 4, the difference between the tip position of wire 100 and the positions at reference points T1 and T3 is an amplitude.
Fig. 5 is a flowchart illustrating an example of control of the welding current in the present embodiment. The control shown in fig. 5 is executed in the current setting portion 36 (refer to fig. 2). The symbol S in the figure is a step.
The control shown in fig. 5 corresponds to a change (1 cycle) in the leading end position of wire 100. Therefore, in fig. 5, a state where time T is time T0 is set as step 1.
The average feed speed Fave is equal to the wire melting speed Fm. Therefore, the tip position of welding wire 100 can be obtained by integrating the difference between feed speed command signal Fw and wire melting speed Fm (≈ Fave).
Therefore, current setting unit 36 sets the tip position of wire 100 based on the following equation.
Welding wire tip position = (Fw-Fave) · dt … formula 4
The change in the front end position calculated in equation 4 corresponds to fig. 4.
In the case where feed motor 24 (see fig. 2) is used for feeding wire 100, a phase deviation may occur between the command and the actual feed speed (i.e., feed speed detection signal Fo). Therefore, current setting unit 36 corrects base current start time T1 calculated in accordance with the tip position of wire 100 calculated from average feed speed Fave and feed speed command signal Fw, by phase deviation time T θ d supplied from phase deviation detecting unit 26. Specifically, the value of the base current start time t1 is reset as follows.
T1= T1+ T θ d … formula 5
Similarly, the current setting unit 36 corrects the base current end time T2 calculated from the average feed speed Fave and the feed speed command signal Fw by the phase shift time T θ d.
T2= T2+ T θ d … formula 6
Here, the case where the base current start time t1 and the base current end time t2 are controlled has been described from the viewpoint of the feed speed, but the same is also true from the viewpoint of the position control.
Fig. 6 is a timing chart showing an example of control of the current setting signal Ir for specifying the current value of the welding current. The horizontal axis is time, and the vertical axis is the current detection signal Io. Time points T0, T1, T2, T3, and T4 in the figure correspond to time points T0, T1, T2, T3, and T4 in fig. 4, respectively. Here, time points T0, T1, T2, T3, and T4 are determined based on the tip position of wire 100, which is calculated based on average feed speed Fave and feed speed command signal Fw.
As shown in fig. 6, base current start time T1 exhibits a phase later than time T0 at which the tip of wire 100 is positioned at the lowermost point (i.e., the time at which the forward feeding period is switched to the reverse feeding period). In fig. 6, the maximum value of the base current start time t1 is represented by t 1'.
Returning to the description of fig. 5.
When the tip position of wire 100 is the lowest point (i.e., time point T0), current setting unit 36 determines whether or not time T at which measurement is started from time point T0 is equal to or greater than base current start time T1 (step 2).
While the determination result in step 2 is negative (False), the current setting unit 36 outputs the peak current Ip as the current setting signal Ir (step 3). This period corresponds to the current non-suppression period in fig. 6.
The supply period of peak current Ip immediately before switching to base current Ib is a period in which the melting of wire 100 advances by peak current Ip and a droplet formed at the tip end of the wire grows significantly. The tip position of welding wire 100 is also in the period of approaching the base material surface. This period is also a period during which short circuits are likely to occur and sputtering associated with short circuits is likely to occur.
Therefore, in the present embodiment, the peak current Ip is supplied until the time t1 elapses, thereby preventing or suppressing the occurrence of short circuit. In other words, the supply of welding current is controlled so that short circuit does not occur.
In the case of the present embodiment, the preferable range of the peak current Ip is 300A to 650A. The base current Ib preferably ranges from 10A to 250A.
In addition, during a period in which there is a possibility of short-circuiting, it is desirable to supply the peak current Ip even after the start of the reverse feeding period. This period is approximately between time points T0 and T1. Therefore, the end of the period (current non-suppression period) to which the peak current Ip is supplied is desirably performed between time points T0 to T1. That is, at time T0 and in the vicinity thereof, a state of so-called "submerged arc" in which the droplet at the tip of the wire is located at a position surrounded by the molten pool pushed open by the force of the arc is a state in which short-circuiting is likely to occur, and therefore, by ending the period during which the peak current Ip is supplied between time T0 and time T1, the depression action on the surface of the molten pool and the rising action of the droplet due to the arc can be maintained, and the occurrence of short-circuiting at the time of "submerged arc" can be prevented.
Therefore, it is desirable to set time T1 such that switching to base current Ib is performed at a time point slightly elapsed from time point T0 at which the tip of welding wire 100 is located at the lowermost point (for example, at a time point of 1 to 2 of 9 minutes 1 to 3 minutes from time point T0 to time point T1).
In other words, it is preferable to control the low current period to start when the tip position of the welding wire that periodically fluctuates is located closer to the base material side than the position 1/2 of the wave height defined by the closest point and the farthest point.
Returning to the description of fig. 5.
When the determination result in step 2 becomes positive (True), the current setting unit 36 starts outputting the base current Ib as the current setting signal Ir (step 4). As described above, at the time point when switching to base current Ib is started, the feeding of wire 100 has already been switched to the reverse feeding, and the tip of wire 100 starts moving in the direction away from the surface of the base material.
When the peak current Ip is large, the droplet detached from the tip of the welding wire 100 differs depending on the transition form that varies depending on the shielding gas and the current domain used, but for example, when the droplet is in transition, the droplet is in a shape of a large particle larger than the diameter of the welding wire 100, and when the droplet is in transition, the droplet is in a shape of a small particle.
Further, when carbon dioxide gas is used as the protective gas, the arc is constricted, and the arc reaction force is concentrated on the bottom portion of the droplet (the portion facing the surface of the molten bath), so that the force for raising the droplet becomes large, and the droplet is transferred. In addition, when the shielding gas is argon gas or a gas having a high mixing ratio of argon, the spray transition is performed.
Since the droplet near time T0 at which the tip of wire 100 is located at the lowest point is located near the molten pool, the arc length becomes short. Further, the time point T0 is switched to the reverse feeding period. That is, the tip of welding wire 100 is pulled up and moved. An inertial force in the forward feeding direction (the direction toward base material 200 (see fig. 1)) acts on the entire growing droplet, and the droplet moves in the opposite direction (the direction away from base material 200) with respect to wire 100, so that the droplet changes to an overhanging shape, and detachment is further promoted.
Further, by switching the current value of the welding current to the base current Ib during the period in which the deviation is predicted, the arc reaction force can be reduced as compared with the period in which the peak current Ip is supplied. As a result, the force for raising the droplet becomes weaker, and the droplet is more likely to have an overhanging shape.
Further, as described above, since the droplet at the tip of the wire is buried in the "submerged arc" of the molten pool during the period from T0 to T1, a shearing force due to a pinching force or the like acts largely on the droplet, and detachment is further promoted.
As described above, by separating the droplet from the tip of welding wire 100 during the period in which the welding current is suppressed (current suppressing period), reduction in spatter can be expected.
Returning to the description of fig. 5.
The current setting unit 36 (see fig. 2) that switches the current setting signal Ir to the base current Ib determines whether or not the time T is equal to or longer than the base current end time T2 (step 5). In fig. 6, the maximum value of the base-value current end time t2 is shown by t 2'.
While the determination result in step 5 is negative (False), the current setting unit 36 outputs the base current Ib as the current setting signal Ir (step 4).
After the supply of base current Ib is started, the tip of wire 100 is moved so as to be raised to the uppermost point (position where the tip is farthest from base material 200) with the detachment of the droplet.
After the droplet is detached, in order to melt wire 100 to form a droplet, it is necessary to end the supply period of base current Ib (current suppression period) and switch to a period of supplying peak current Ip (current non-suppression period).
Therefore, the supply of the base current Ib is desirably ended between time points T1 to T2.
On the other hand, if the switching from the base current Ib to the peak current Ip is too fast, the droplet growth becomes too much, and the following problem occurs: when the welding wire 100 is positioned at the lowermost point, short-circuiting tends to occur, the enlarged droplet is excessively raised, and the enlarged droplet is unlikely to be detached.
Therefore, it is more preferable that the end of the supply period of the base current Ib (base current end time T2) is, for example, between 1/3 of time from the time point T1 to the time point T2 and the time point T2.
When the determination result in step 5 becomes positive (True), the current setting unit 36 starts outputting the peak current Ip as the current setting signal Ir (step 6).
Next, the current setting unit 36 determines whether or not the time T measured from the time T0 is the time T4 (step 7).
While the determination result in step 7 is negative (False), the current setting unit 36 outputs the peak current Ip as the current setting signal Ir (step 6).
On the other hand, if the determination result in step 7 is affirmative (True), the current setting unit 36 returns to step 1.
By the above control, the current setting signal Ir has a pulse waveform in which the peak current Ip and the base current Ib are periodically repeated.
< effects of the present embodiment >
The effects of the present embodiment will be described below while comparing with patent document 1.
The following effects are based on laboratory experimental results.
Under the welding conditions, the forward and reverse feed frequency was set to 100Hz, the forward and reverse amplitude was set to 4.8mm, a solid wire (MG-50R, manufactured by Kobe Steel) having a diameter of 1.2mm was used as the wire 100, and the feed speed (wire feed speed) of the wire 100 was set to an average of 16m/min, and flat bead welding was used as the welding method.
Fig. 7 is a graph showing the waveform of the wire feeding speed, the welding current, and the welding voltage, and the droplet separation timing of patent document 1. The wire feed speed is given as a sine wave centered on the average wire feed speed (thin dashed line) as indicated by the thin solid line. Here, the wire feed speed is a command value, and the average wire feed speed is a detection value. In addition, a thick solid line indicates a welding current, and a thick broken line indicates a welding voltage. Here, the welding current is a command value, and the welding voltage is a detection value. Further, the droplet detachment timing is shown at ↓.
Fig. 8 is a graph showing the waveform of the wire feeding speed, the welding current, and the welding voltage, and the droplet detachment timing in the present embodiment. As shown by the thin solid line, the wire feed speed is centered on the average wire feed speed (thin broken line), and the speed amplitude becomes smaller on the upper side (forward feed side) and larger on the lower side (reverse feed side). Further, the time width of the forward feeding is longer than that of the reverse feeding. Here, the wire feed speed is a command value, and the average wire feed speed is a detection value. In addition, a thick solid line indicates a welding current, and a thick broken line indicates a welding voltage. Here, the welding current is a command value and the welding voltage is a detected value. Further, the droplet detachment timing is shown at ↓.
In fig. 7 and 8, the time from the time point T0 when the wire feeding speed is switched from the forward feeding to the reverse feeding (i.e., the timing when the wire feeding speed intersects the average wire feeding speed) to the droplet detachment timing is measured. The measurement target period is 5 seconds from 3 seconds of the start of welding out of 10 seconds of welding.
Fig. 9 is a graph showing the measurement results of the droplet detachment timing of patent document 1. That is, the graph is for the case of PFR = 50. In this graph, the distribution of off-timing extends approximately uniformly from 3.2msec to 4.8 msec.
Fig. 10 is a graph showing measurement results of droplet detachment timing according to the present embodiment. A graph of the case of PFR =45 is shown here. In the graph, the distribution of the deviation timing is shifted from 3.0msec to 4.0msec, and the deviation after 4.0msec is reduced from patent document 1.
Next, fig. 11 and 12 are graphs showing the results of measuring the time from the start of the current suppression period to the departure. Fig. 11 is a graph of patent document 1, and fig. 12 is a graph of the present embodiment.
As is clear from fig. 11, in patent document 1, the deviation is later than the current suppression period, and the deviation is more frequent in the current non-suppression period.
On the other hand, as is clear from fig. 12, in the present embodiment, many droplets are separated during the current suppression period, and the rate of separation during the current non-suppression period is reduced.
As described above, in the present embodiment, since the wire feed speed at the time of drawing back is higher than that in the technique of patent document 1, it is verified that the probability of droplet detachment during current suppression is higher than that in the technique of patent document 1. Regarding the effect of reducing the spattering, it is assumed that the spattering is reduced by the present embodiment because it can be confirmed by observation with a high-speed camera that the spattering is scattered when the droplet is detached during the current non-suppression period.
In the present embodiment, the maximum speed of the wire feeding speed at the time of feeding is smaller than that of the technique of patent document 1. It is known that, in general, as the wire feeding speed increases, the wear of the contact tip increases, and therefore, an effect of reducing the wear of the contact tip can be expected.
Further, in the present embodiment, according to fig. 12, the timing of droplet detachment is earlier than that of the technique of patent document 1, and the droplet detachment distribution is concentrated. As can be seen from this, it is not necessary to unnecessarily maintain the current suppression period long, and it is only necessary to set the deviation timing by observing the distribution. Therefore, the current suppressing period can be set shorter than the technique of patent document 1.
Here, since the cycle Tf of the wire feeding is fixed, the current non-suppression period can be extended. The current non-suppression period is a droplet growth period, but if the current value can be extended, even if the current value in the current non-suppression period is reduced, desired droplet growth can be performed. Since it is generally known that the wear of the contact tip advances as the welding current increases, it is expected that the reduction of the current during the current non-suppression period contributes to the reduction of the wear of the contact tip.
< other embodiment >
The embodiments of the present invention have been described above, but the technical scope of the present invention is not limited to the scope described in the above embodiments. It is apparent from the description of the claims that modifications and improvements can be made to the above-described embodiments, and the scope of the technique of the present invention is also included.
For example, in the above description of the embodiment, the case where amplitude feed rate setting unit 21 (see fig. 2), feed rate command setting unit 22 (see fig. 2), current setting unit 36 (see fig. 2), forward/reverse speed ratio setting unit 38 (see fig. 2), and the like are incorporated in welding power supply 150 (see fig. 2) has been described, but these may be incorporated in robot controller 160. In this case, these functional units are realized by the robot controller 160 by, for example, a CPU (Central Processing Unit) not shown reading a program stored in a ROM (Read Only Memory) not shown into a RAM (Random Access Memory) not shown and executing the program.
As described above, the present invention is not limited to the above-described embodiments, and it is also a matter of course that the present invention is intended to be included in the scope of claims by combining the respective configurations of the embodiments with each other and by modifying and applying the same by a person skilled in the art based on the description of the specification and a technique known in the art.
This application is based on Japanese patent application No. 8/17/2020 (Japanese patent application No. 2020-137245), the contents of which are incorporated herein by reference.
Description of reference numerals
An arc welding system, 23.. Feed drive, 36.. Current setting, 36A.. Current suppression period setting, 36B.. Wire tip position conversion, 100.. Consumable electrode (wire), 110.. Welding torch, 120.. Welding robot, 130.. Feed device, 140.. Shielding gas supply device, 150.. Welding power supply, 160.. Robot controller, 200.. Parent metal.
Claims (8)
1. A welding power supply for supplying a welding current to a welding wire as a consumable electrode and separating a droplet in an open arc state without short-circuiting the welding wire with a molten pool,
the welding power supply is characterized by comprising:
a feeding control unit that controls feeding of the welding wire so that a tip of the welding wire is fed to the base material while being periodically switched between a period of being fed forward and a period of being fed backward; and
a current control means for changing the welding current in accordance with a tip position of the welding wire at which a distance from a surface of the base material periodically varies,
the feeding control means controls the time taken for the tip of the welding wire to reach the farthest point, which is the position farthest from the base material, from the closest point, which is the position closest to the base material, to be shorter than the time taken for the tip of the welding wire to reach the closest point from the farthest point,
the current control means controls the welding current to be lower than a predetermined current value during a period in which the tip of the welding wire is fed in the reverse direction.
2. Welding power supply according to claim 1,
the feeding control means controls the feeding speed amplitude of the welding wire during a period in which the tip of the welding wire is fed in the reverse direction to be larger than the feeding speed amplitude of the welding wire during a period in which the tip of the welding wire is fed in the forward direction.
3. Welding power supply according to claim 1,
the current control means controls the low current period to start when the tip position of the welding wire that periodically fluctuates is located closer to the base material side than a position 1/2 higher than a wave defined by the closest point and the farthest point.
4. Welding power supply according to claim 3,
the current control means controls the low-current period to start within a range from a leading end position of the welding wire at a time point when the leading end of the welding wire is switched from a period of being fed forward to a period of being fed backward to a leading end position of the welding wire at a time point when a command value of a feeding speed of the welding wire switched to be fed backward is maximum.
5. Welding power supply according to claim 3,
the current control means controls the low-current period to end in a range from a leading end position of the welding wire at a time point when a command value of a feeding speed of the welding wire switched to the reverse feeding is maximum to a leading end position of the welding wire at a time point when the leading end of the welding wire is switched from a period of being reversely fed to a period of being forwardly fed.
6. A welding system for performing arc welding by supplying a welding current to a wire as a consumable electrode and separating a droplet in an open arc state without short-circuiting the wire with a molten pool,
the welding system is characterized by comprising:
a feeding control unit that controls feeding of the welding wire such that a tip of the welding wire is fed to the base material with periodic switching between a period of forward feeding and a period of reverse feeding; and
a current control means for changing the welding current in accordance with a tip position of the welding wire at which a distance from a surface of the base material periodically varies,
the feeding control means controls so that the time taken for the tip of the welding wire to reach the farthest point, which is the position farthest from the base material, from the closest point, which is the position closest to the base material, is shorter than the time taken for the tip of the welding wire to reach the closest point from the farthest point,
the current control means controls the welding current to be lower than a predetermined current value during a period in which the tip of the welding wire is fed in the reverse direction.
7. A method for controlling a welding power source for supplying a welding current to a welding wire as a consumable electrode and separating a droplet in an open arc state without short-circuiting the welding wire with a molten pool,
the control method of the welding power supply is characterized by comprising the following steps:
controlling the feeding of the welding wire so that the tip of the welding wire is fed to the base material while being periodically switched between a period of being fed forward and a period of being fed backward; and
changing the welding current according to a tip position of the welding wire whose distance from the surface of the base material periodically varies,
in the step of controlling the feeding, the time taken for the tip of the welding wire to reach the farthest point, which is the position farthest from the base material, from the closest point, which is the position closest to the base material, is controlled to be shorter than the time taken for the tip of the welding wire to reach the closest point from the farthest point,
in the step of varying the welding current, the welding current is controlled so that a low current period in which the welding current is reduced from a predetermined current value is provided while the tip of the welding wire is fed in a reverse direction.
8. A program for causing a computer of a welding system to realize functions of supplying a welding current to a wire as a consumable electrode to perform arc welding and separating a droplet in an open arc state without short-circuiting the wire with a molten pool, the functions comprising:
controlling the feeding of the welding wire so that the tip of the welding wire is fed to the base material with periodic switching between a period of forward feeding and a period of reverse feeding; and
changing the welding current according to a tip position of the welding wire in which a distance from a surface of the base material periodically varies,
the function of controlling the feeding is controlled so that the time taken for the tip of the welding wire to reach the farthest point from the farthest point to the closest point is shorter than the time taken for the tip of the welding wire to reach the farthest point from the farthest point,
the function of changing the welding current is controlled so that a low current period in which the welding current is reduced from a predetermined current value is provided during a period in which the tip of the welding wire is fed in a reverse direction.
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| Application Number | Priority Date | Filing Date | Title |
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| JP2020137245A JP7309671B2 (en) | 2020-08-17 | 2020-08-17 | Welding power source, welding system, control method and program for welding power source |
| JP2020-137245 | 2020-08-17 | ||
| PCT/JP2021/027044 WO2022038947A1 (en) | 2020-08-17 | 2021-07-19 | Welding power supply, welding system, control method for welding power supply, and program |
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| CN106925863A (en) * | 2015-11-09 | 2017-07-07 | 株式会社达谊恒 | Arc welding control method |
| CN109715336A (en) * | 2016-09-15 | 2019-05-03 | 松下知识产权经营株式会社 | Arc-welding apparatus and arc welding control method |
| CN110049842A (en) * | 2017-01-16 | 2019-07-23 | 株式会社达谊恒 | The striking control method of forward and reverse feeding arc welding |
| JP2019171419A (en) * | 2018-03-28 | 2019-10-10 | 株式会社神戸製鋼所 | Control method and controller of gas shield arc welding |
| JP2020049506A (en) * | 2018-09-26 | 2020-04-02 | 株式会社神戸製鋼所 | Welding power source, welding system, control method of welding power source, and program |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2022038947A1 (en) | 2022-02-24 |
| KR20230037623A (en) | 2023-03-16 |
| JP7309671B2 (en) | 2023-07-18 |
| CN115397597B (en) | 2024-03-05 |
| JP2022033399A (en) | 2022-03-02 |
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