CN102126077B - Plasma metal inert gas arc welding method - Google Patents
Plasma metal inert gas arc welding method Download PDFInfo
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Abstract
In a plasma metal insert gas arc welding method which causes a metal insert gas arc (3a) and a plasma arc (3b) to generate from a welding torch (WT), even a welding torch height (Lp) changes, a stable fused drop transition state of the metal insert gas arc can be kept. For this purpose, a plasma welding current (Iwp) is applied between a plasma electrode (1b) and a mother plate (2) for generating the plasma arc (3b). Additionally, a peak current in a peak period and a reference current in a reference period are applied between a welding wire (1a) and the mother plate (2). Furthermore, the peak period and/or the peak current is changed according to the heated length of the welding wire (1a), which is heated by the plasma arc (3b). Thus, even the welding torch height (=Lp) is changed, the unit pulse condition can be optimized correspondingly, and the stability of the fused drop transition state can be always kept.
Description
Technical field
The present invention relates to a kind of plasma metal inert gas arc welding (plasma MIG welding) method, it produces Metallic Inert Gas (MIG:Metal Inert Gas) electric arc and plasma-arc with a welding torch simultaneously, welds.
Background technology
In the prior art, motion the plasma metal inert gas arc welding method (reference example is as patent documentation 1) that combines of article on plasma welding method and metal inert gas arc welding method.In this plasma metal inert gas arc welding method, by be disposed at logical between plasma electrode in welding torch and mother metal on plasma welding current, plasma-arc is produced.Simultaneously, plasma electrode is arranged to hollow shape, through carrying out the welding wire that feeding is powered via being configured in the power supply chip (chip) in above-mentioned plasma electrode in above-mentioned hollow shape inside, and by leading to metal inert gas arc welding electric current between welding wire and mother metal, Metallic Inert Gas electric arc is produced.Therefore, Metallic Inert Gas electric arc is the state being surrounded by plasma-arc.Welding wire is as the electrode performance function that Metallic Inert Gas electric arc is produced, and its front end melting becomes molten drop, the joint of auxiliary mother metal.Therefore, plasma metal inert gas arc welding method uses in high efficiency welding, the high-speed welding of thin plate etc. of slab.
About above-mentioned metal inert gas arc welding electric current, in order to suppress to splash the generation of (sputter) and stably supply with molten drop, the general impulse waveforms that use direct current more.Therefore, metal inert gas arc welding method is general Metallic Inert Gas electric arc pulse welding method.Comprising Metallic Inert Gas electric arc pulse welding method in interior consumption electrode type arc welding method, the electric arc length in welding is being maintained in to an appropriate value very important, therefore will carry out the long control of electric arc.Above-mentioned Plasma Welding electric current uses direct current or DC pulse waveform.In explanation afterwards, in the time only having recorded electric arc length, its electric arc that refers to Metallic Inert Gas electric arc is long.Below, describe about above-mentioned plasma metal inert gas arc welding method.
Figure 10 is the oscillogram that represents plasma metal inert gas arc welding method of the prior art.Represent metal inert gas arc welding electric current I wm with figure (A), represent metal inert gas arc welding voltage Vwm with figure (B), represent Plasma Welding electric current I wp with figure (C), represent Plasma Welding voltage Vwp with figure (D).Below, describe with reference to FIG..
Shown in figure (A), logical upper by the peak point current Ip in Tp during peak value (peak) and the background current Ib in Tb forms during base value (base) metal inert gas arc welding electric current I wm.Between this peak period, during Tp and base value, Tb is impulse duration Tf altogether.And the energising of metal inert gas arc welding electric current I wm is corresponding therewith, shown in figure (B), between the peak period, in Tp, between welding wire and mother metal, applies crest voltage Vp, and in Tb, apply base value voltage Vb during base value.
In Metallic Inert Gas electric arc pulse welding, in order to obtain good welding quality, carry out electric arc length to be maintained in long control of electric arc of appropriate value.Conventionally, this electric arc is long to be controlled, and utilizes metal inert gas arc welding voltage Vwm and electric arc to grow up and causes the relation being directly proportional, and the control impuls cycle, so that the mean value of metal inert gas arc welding voltage Vwm equals predefined voltage setting value.The mean value of metal inert gas arc welding voltage Vwm, makes metal inert gas arc welding voltage Vwm generate by low pass filter.The long mode of controlling of this electric arc is called frequency modulation(PFM) mode.In this case, Tp, peak point current Ip and background current Ib between the peak period are set as to setting, it becomes pulse parameter.More than peak point current Ip is set in to critical value, between itself and peak period, Tp combines, the unit of being known as (unit) impulsive condition.This unit pulse condition is set as carrying out 1 time the droplet transfer in 1 pulse period.Background current Ib is set as to the little current value of the tens of A left and right that is less than critical value.According to the material of welding wire, diameter, feed speed etc., unit pulse condition and background current Ib are set as to appropriate value.
On the other hand, shown in figure (C), article on plasma welding current Iwp implements constant current control, becomes the DC waveform of predefined steady state value.In addition, shown in figure (D), between plasma electrode and mother metal, apply Plasma Welding voltage Vwp.Therefore, plasma-arc is produced by the energising of the Plasma Welding electric current I wp of steady state value.
Patent documentation 1:JP JP 2008-229641 communique
In plasma metal inert gas arc welding, between 1 welding torch and mother metal, produce two electric arcs of Metallic Inert Gas electric arc and plasma-arc simultaneously.And Metallic Inert Gas electric arc is to produce under the state being surrounded by plasma-arc.Therefore, the welding wire of Metallic Inert Gas electric arc will be heated from plasma-arc.According to the thickness of mother metal, joint geometry, operability etc., the distance between welding torch front end and mother metal (torch height) is set as to appropriate value.Therefore,, even if torch height is by welding position difference or in welding, also can change.If this torch height changes, the distance between the distance between plasma electrode front end and mother metal and power supply chip front end and mother metal will change, and the length of being heated of pretending the length of the part of being heated from plasma-arc for welding wire will change.The length variations if this is heated, changes thereby the heat from plasma-arc to welding wire can change preheat mode, therefore the temperature rise of the extension of welding wire will change.Consequently, droplet transfer state will change, and also can produce from 1 pulse period, 1 droplet transfer state and depart from the situation that becomes unsure state.
Summary of the invention
The length variations of being heated of the length of the part of being heated from plasma-arc as welding wire, the object of the invention is to for this reason, a kind of plasma metal inert gas arc welding method is provided, even if also can maintain stable droplet transfer state.
In order to solve above-mentioned problem, the invention of claim 1 is a kind of plasma metal inert gas arc welding method, its by be disposed between plasma electrode in welding torch and mother metal, apply Plasma Welding voltage and logical on plasma welding current, thereby plasma-arc is produced, and, described plasma electrode is arranged to hollow shape, through carrying out the welding wire that feeding is powered via being configured in the power supply chip in described plasma electrode in described hollow shape inside, and by between described power supply chip and mother metal, apply metal inert gas arc welding voltage and logical on background current in during peak point current in using between the peak period and base value as the metal inert gas arc welding electric current of 1 pulse period, thereby Metallic Inert Gas electric arc is produced,
Wherein, make between the described peak period and/or described peak point current changes according to the length of being heated of the length of the part of being heated from described plasma-arc as described welding wire.
The invention of claim 2, the plasma metal inert gas arc welding method of recording according to claim 1, is characterized in that, described in the length of being heated be the distance between front end and the described mother metal of described plasma electrode.
The invention of claim 3, the plasma metal inert gas arc welding method of recording according to claim 2, it is characterized in that, according to using described Plasma Welding electric current and described Plasma Welding voltage as input and predefined function, calculate the distance between front end and the described mother metal of described plasma electric.
The invention of claim 4, the plasma metal inert gas arc welding method of recording according to claim 1, it is characterized in that, described in the length of being heated be that distance between front end and the described mother metal of described plasma electrode deducts the value that the electric arc of described Metallic Inert Gas electric arc obtains long.
The invention of claim 5, the plasma metal inert gas arc welding method of recording according to claim 4, it is characterized in that, according to using the mean value of the feed speed of welding wire and described metal inert gas arc welding voltage as input and predefined function, calculate described electric arc long.
According to the present invention, by making between the peak period in metal inert gas arc welding electric current according to the length of being heated of welding wire and/or peak point current variation, can compensate the variation of the preheat mode of the welding wire of the variation of following the length of being heated.Therefore, though the variations such as torch height, thus the length variations of being heated of welding wire also can maintain the state of 1 droplet transfer of 1 pulse period, therefore welded condition is by all-the-time stable.
Further, according to the invention of claim 4 and claim 5, the value that the length of being heated is obtained as the distance between plasma electrode front end and mother metal deducts the electric arc length of Metallic Inert Gas electric arc is calculated.Therefore, change even if the electric arc of Metallic Inert Gas electric arc is long, also can correctly calculate the length of being heated.Consequently, can compensate more accurately the variation of the preheat mode of the welding wire of the variation of following the length of being heated.
Brief description of the drawings
Fig. 1 is the pie graph of the welder of the plasma metal inert gas arc welding method for implementing embodiments of the present invention 1.
Fig. 2 is be heated length L h and the figure of the relation between Tp and peak point current Ip between the peak period when being illustrated in Plasma Welding electric current I wp and being 50A.
Fig. 3 is be heated length L h and the figure of the relation between Tp and peak point current Ip between the peak period when being illustrated in Plasma Welding electric current I wp and being 100A.
Fig. 4 is be heated length L h and the figure of the relation between Tp and peak point current Ip between the peak period when being illustrated in Plasma Welding electric current I wp and being 150A.
Fig. 5 is the figure that represents the arc characteristic of plasma-arc.
Fig. 6 is the module map of the metal inert gas arc welding power ps M of the welder of pie graph 1.
Fig. 7 is the module map of the Plasma Welding power ps P of the welder of pie graph 1.
Fig. 8 is the figure that represents the arc characteristic of the Metallic Inert Gas electric arc of embodiments of the present invention 2.
Fig. 9 is the module map of the metal inert gas arc welding power ps M of the formation welder of embodiments of the present invention 2.
Figure 10 is the oscillogram that represents the plasma metal inert gas arc welding method of prior art.
Symbol description:
1a: welding wire
1b: plasma electrode
2: mother metal
3a: Metallic Inert Gas electric arc
3b: plasma-arc
4: power supply chip
51: plasma nozzle
52: protective gas nozzle
61: center gas
62: plasma gas
63: protective gas
7: feed rolls
EI: current error amplifying circuit
Ei: current error amplifying signal
EV: voltage error amplifying circuit
Ev: voltage error amplifying signal
FC: feeding control circuit
Fc: feeding control signal
FR: feed speed initialization circuit
Fr: feed speed setting signal
Fw: feed speed
Ib: background current
IBR: background current initialization circuit
Ibr: background current setting signal
ID: current detection circuit
Id: current detection signal
Ip: peak point current
IPR: peak point current initialization circuit
Ipr: peak point current setting signal
IPR2: the second peak point current initialization circuit
IRC: current settings control circuit
Irc: current settings control signal
Iwm: metal inert gas arc welding electric current
Iwp: Plasma Welding electric current
IWPR: Plasma Welding current setting circuit
Iwpr: Plasma Welding current settings signal
La: the electric arc of Metallic Inert Gas electric arc is long
LAR: the long initialization circuit of Metallic Inert Gas electric arc
Lar: the long setting signal of Metallic Inert Gas electric arc
Lh: the length of being heated
LHC: the length computation of being heated circuit
Lhc: length signals is heated
Lp: the distance between torch height, plasma electrode front end and mother metal
Lpa: the electric arc of plasma-arc is long
LPC: plasma electrode front end mother metal spacing counting circuit
Lpc: plasma electrode front end mother metal spacing signal
Lw: the distance between power supply chip front end and mother metal
Lx: stretch out length
PM: electric power main circuit
PSM: metal inert gas arc welding power supply
PSP: Plasma Welding power supply
Tb: during base value
Tf: pulse period (signal)
TP: timing (Timer) circuit between the peak period
Tp: between the peak period (signal)
TPR: initialization circuit between the peak period
Tpr: setting signal between the peak period
TPR2: initialization circuit between the second peak period
VAV: average voltage counting circuit
Vav: average voltage value signal
Vb: base value voltage
VD: voltage detecting circuit
Vd: voltage detection signal
VF: voltage/frequency translation circuit
Vp: crest voltage
VR: voltage setting circuit
Vr: voltage setting signal
Vwm: metal inert gas arc welding voltage
Vwp: Plasma Welding voltage
WM: feed motor
WT: welding torch
Detailed description of the invention
Below, with reference to accompanying drawing, describe about embodiments of the present invention.
[embodiment 1]
Fig. 1 is the pie graph of the welder of the plasma metal inert gas arc welding method for implementing embodiments of the present invention 1.Below, with reference to FIG., describe about each construct.
This welder comprises by the welding torch WT of dotted line, metal inert gas arc welding power ps M and Plasma Welding power ps P.Welding torch WT is configured in the structure in concentric shafts by plasma nozzle 51, plasma electrode 1b and power supply chip 4 protective gas nozzle 52 is interior.From the gap between protective gas nozzle 52 and plasma nozzle 51, supply with the protective gas 63 of mist of such as argon gas, argon gas and carbon dioxide etc.Between plasma nozzle 51 and plasma electrode 1b, supply with the plasma gas 62 of mist of such as argon gas, argon gas and carbon dioxide etc.Between plasma electrode 1b and power supply chip 4, supply with mist Deng center (center) gas 61 of for example argon gas, argon gas and carbon dioxide.
Plasma electrode 1b is formed as hollow shape.In the hollow shape of this plasma electrode 1b, insulate and configure power supply chip 4.Then, carry out feeding welding wire 1a from the through hole being arranged on this power supply chip 4.Power supply chip 4 carries out conducting to welding wire 1a.But insulate between welding wire 1a and plasma electrode 1b.Welding wire 1a carrys out feeding by the rotation of the feed rolls taking feed motor WM as drive source (feed roll) 7.Plasma electrode 1b is made up of for example copper or copper alloy, indirectly carries out water cooling by the cooling water in the path through outside figure.Plasma nozzle 51 is made up of for example copper or copper alloy, makes the stream of cooling water process by formation, carries out directly cooling.Conventionally, under the state being kept by robot (diagram is omitted) at welding torch WT, make it to move relative to mother metal 2.Between the front end of welding wire 1a and mother metal 2, produce Metallic Inert Gas electric arc 3a.Between plasma electrode 1b and mother metal 2, produce by plasma gas 62 and carry out the contained plasma-arc 3b of heat.Therefore, Metallic Inert Gas electric arc 3a is the state being surrounded by plasma-arc 3b.Thereby, the effect that plasma-arc 3b has the shape of contained Metallic Inert Gas electric arc 3a to expand.
As shown in the figure, the distance between the front end of plasma electrode 1b and mother metal 2 is Lp (mm), and the distance between the front end of power supply chip 4 and mother metal 2 is Lw (mm), and the electric arc length of Metallic Inert Gas electric arc 3a is La (mm).And Lp < Lw, La < Lp.Therefore, the electric arc of plasma-arc 3b is long is above-mentioned Lp (mm).In addition, welding wire 1a stretch out long Lx=Lw-La.As shown in the figure, because a part for the extension of welding wire 1a is surrounded by plasma-arc 3b, the temperature rise therefore be heated.This effect is known as pre-heat effect.The length of the part that in addition, welding wire 1a is heated from plasma-arc 3b is known as the length L h that is heated.About the length L h that is heated, be correctly Lh=Lp-La (situation of embodiment 2).In the situation that simplifying, can regard the length L h=Lp that is heated (situation of embodiment 1) as.The heat that welding wire 1a is subject to from plasma-arc 3b changes according to Plasma Welding electric current I wp and the length L h that is heated.Even if Plasma Welding electric current I wp is identical value, if the length L h that is heated changes, heat also can change.At this, if torch height is defined as to the distance L p between front end and the mother metal 2 of above-mentioned plasma electrode 1b, if torch height changes, the distance L w between front end and the mother metal of above-mentioned power supply chip 4 also can change.,, if torch height changes, the length L of being heated h also can change.Consequently, the temperature of the extension of welding wire 1a can change, thereby can produce, droplet transfer state is influenced becomes unsettled situation.In order to prevent this situation, in the present embodiment, according to the variation of the length L h that is heated, as shown in the aftermentioned of Fig. 2～Fig. 4, make unit pulse condition (Tp and peak point current Ip between the peak period) be varied to appropriate value.Like this, even thereby torch height changes the length L h that is heated to be changed, also can maintain stable droplet transfer state.
Metal inert gas arc welding power ps M is for by applying via power supply chip 4 power supply that metal inert gas arc welding voltage Vwm leads to metal inert gas arc welding electric current I wm between welding wire 1a and mother metal 2.From metal inert gas arc welding power ps M, feed motor WM is sent to feeding control signal Fc, thereby control the feed speed of welding wire 1a.In the time that metal inert gas arc welding power ps M applies metal inert gas arc welding voltage Vwm, make welding wire 1a in "+" side.Metal inert gas arc welding power ps M is the power supply of constant voltage characteristic, it is controlled, so that metal inert gas arc welding voltage Vwm equals the value of predefined voltage setting signal Vr (diagram is omitted).In addition, metal inert gas arc welding electric current I wm, according to the feed speed of welding wire 1a, decides its value.
Plasma Welding power ps P is for by applying the power supply that Plasma Welding voltage Vwp leads to plasma welding current Iwp between plasma electrode 1b and mother metal 2.In the time applying Plasma Welding voltage Vwp from Plasma Welding power ps P, make plasma electrode 1b in "+" side.Plasma Welding power ps P is the power supply of constant current characteristic, it is controlled, so that Plasma Welding electric current I wp is setting.
Predefined Plasma Welding current settings signal Iwpr is outputed to metal inert gas arc welding power ps M and Plasma Welding power ps P by Plasma Welding current setting circuit IWPR.This plasma welding current setting signal Iwpr is the signal for setting above-mentioned Plasma Welding electric current I wp.Plasma Welding current setting circuit IWPR, for robot welding in the situation that, is arranged in robot controller.
The oscillogram of metal inert gas arc welding electric current I wm, metal inert gas arc welding voltage Vwm, Plasma Welding electric current I wp and Plasma Welding voltage Vwp is identical with above-mentioned Figure 10.As mentioned above, in the present embodiment, change according to the length L h that is heated of welding wire 1a as Tp between the peak period of unit pulse condition and peak point current Ip.This point unlike the prior art.Below, describe about this point.
Fig. 2 represents to be heated length L h and the figure as the relation between Tp between the peak period of unit pulse condition and peak point current Ip.With the transverse axis of the figure length L h (mm) that represents to be heated, represent to use the scope of 15 more～25mm in practicality.The longitudinal axis has represented Tp between the peak period (ms) and peak point current Ip (A).In same figure, solid line represents the variation of Tp between the peak period, and dotted line represents the variation of peak point current Ip.The same figure is the situation of Plasma Welding current value I wp=50A.For welding wire uses the aluminum-alloy wire of diameter 1.2mm, the situation of feed speed=9m/min.Background current Ib is the steady state value of 30A.
As shown in the figure, in the time being heated length L h=15mm, be set as Tp=1.0ms and peak point current Ip=340A between the peak period.Along with being heated, length L h is elongated, and between the peak period, Tp and peak point current Ip all diminish.This be due to, because being heated, length L h is longer, the heat that welding wire is subject to from plasma-arc is larger, therefore can be little by unit pulse condition is established, maintain 1 pulse period, 1 droplet transfer state.And, if be heated length L h=20mm, be set as Tp=0.8ms and peak point current Ip=330A between the peak period.The length L of being heated if become h=25mm, Tp=0.6ms and peak point current Ip=320A between the peak period.
Fig. 3 is be heated length L h and the figure as the relation between Tp between the peak period of unit pulse condition and peak point current Ip while being illustrated in Plasma Welding current value I wp=100A.With the transverse axis of the figure length L h (mm) that represents to be heated, represent to use the scope of 15 more～25mm in practicality.The longitudinal axis has represented Tp between the peak period (ms) and peak point current Ip (A).In same figure, solid line represents the variation of Tp between the peak period, and dotted line represents the variation of peak point current Ip.Corresponding with above-mentioned Fig. 2 with figure, the welding condition except Plasma Welding current value I wp is identical.
As shown in the figure, in the time being heated length L h=15mm, be set as Tp=1.0ms and peak point current Ip=310A between the peak period.Along with being heated, length L h is elongated, and between the peak period, Tp and peak point current Ip all diminish.This be due to, because being heated, length L h is longer, the heat that welding wire is subject to from plasma-arc is larger, therefore can be little by unit pulse condition is established, maintain 1 pulse period, 1 droplet transfer state.And, if be heated length L h=20mm, be set as Tp=0.8ms and peak point current Ip=300A between the peak period.The length L of being heated if become h=25mm, Tp=0.6ms and peak point current Ip=290A between the peak period.In addition, if will compare with above-mentioned Fig. 2 with figure, Tp and peak point current Ip between the peak period in the time that the length L h that is heated is same value, with in figure with Fig. 2 comparison, be relatively little value.This be due to, in order to make Plasma Welding current value I wp in same figure become large, the heat that welding wire is subject to from plasma-arc will become greatly, therefore in order to maintain 1 pulse period, 1 droplet transfer state, reduced Tp and peak point current Ip between the peak period.
Fig. 4 is be heated length L h and the figure as relation between Tp between the peak period of unit pulse condition and peak point current Ip while being illustrated in Plasma Welding current value I wp=150A.With the transverse axis of the figure length L h (mm) that represents to be heated, represent to use the scope of 15 more～25mm in practicality.The longitudinal axis has represented Tp between the peak period (ms) and peak point current Ip (A).In same figure, solid line represents the variation of Tp between the peak period, and dotted line represents the variation of peak point current Ip.Corresponding with above-mentioned Fig. 2 and Fig. 3 with figure, the welding condition except Plasma Welding current value I wp is identical.
As shown in the figure, in the time being heated length L h=15mm, be set as Tp=1.0ms and peak point current Ip=290A between the peak period.Along with being heated, length L h is elongated, and between the peak period, Tp and peak point current Ip all diminish.This be due to, because being heated, length L h is longer, the heat that welding wire is subject to from plasma-arc is larger, therefore can be little by unit pulse condition is established, maintain 1 pulse period, 1 droplet transfer state.And, if be heated length L h=20mm, be set as Tp=0.8ms and peak point current Ip=280A between the peak period.The length L of being heated if become h=25mm, Tp=0.6ms and peak point current Ip=270A between the peak period.In addition, if will compare with figure and above-mentioned Fig. 2 and Fig. 3, Tp and peak point current Ip between the peak period in the time that the length L h that is heated is same value, with in figure being relatively little value.This be due to, in order to make Plasma Welding current value I wp in same figure become large, the heat that welding wire is subject to from plasma-arc will become greatly, therefore in order to maintain 1 pulse period, 1 droplet transfer state, reduced Tp and peak point current Ip between the peak period.
In Fig. 2～Fig. 4, the variation of the length L h that is heated relatively above-mentioned Tp between the peak period is called to computing function between the peak period.In addition, peak point current Ip is heated the relatively variation of length L h is called peak point current and calculates function.These functions are set appropriate value for according to the material of Plasma Welding current value I wp, welding wire, diameter, feed speed etc.This setting is carried out by experiment.In addition, in Fig. 2～Fig. 4, the situation that two parameters (Tp and peak point current Ip between the peak period) of unit pulse condition all change according to predefined function has been described in the time that the length L h that is heated changes.But, also can only make one of them variation in unit pulse condition.This is because the heat that welding wire is subject to from plasma-arc in the time that the length L h that is heated changes also can change, therefore unit pulse condition is changed, compensates the variation to the heat of welding wire.Therefore, there is no need all to change for this compensates to make two aspects of unit pulse condition, and only need a wherein side to change.That is, corresponding with the variation of the length L h that is heated, make Tp and/or peak point current Ip variation between the peak period.
Next, describe about the detection method of the length L h that is heated.In the present embodiment, as mentioned above, owing to regarding the length L h that is heated as distance L p between plasma electrode front end and mother metal, therefore the detection of the length L h that is heated is equivalent to detect the distance L p between plasma electrode front end and mother metal.As this detection method, there are two kinds of methods shown below.
(1) method sending from robot controller
Having used in the welding of robot, in the time of teaching sealing wire, be that the mode of appropriate value is carried out according to making torch height.As mentioned above, because torch height is the distance L p between plasma electrode front end and mother metal, therefore in the time of teaching, make to write this value in operation sequence.And, in the time welding, send these data (distance between plasma electrode front end and mother metal) to source of welding current PSM from robot controller.
(2) method of calculating according to Plasma Welding voltage Vwp and Plasma Welding electric current I wp
Plasma-arc is non-consumable electrode type electric arc, therefore the distance L p between the long Lpa of the electric arc of plasma-arc and plasma electrode front end and mother metal is consistent.If the long Lpa of electric arc is set to Plasma Welding current value I wp, with the proportional relation of Plasma Welding magnitude of voltage Vwp.This proportional relation is known as arc characteristic.Therefore, in welding, detect Plasma Welding voltage Vwp, can calculate the corresponding with it long Lpa of electric arc according to arc characteristic.In this method, calculate the long Lpa of electric arc of plasma-arc according to Plasma Welding current value I wp and Plasma Welding magnitude of voltage Vwp, the long Lpa of electric arc equals the distance L p between plasma electrode front end and mother metal, further, the length L h that equals to be heated of the distance L p between plasma electrode front end and mother metal.Therefore, can calculate the length L h that is heated according to arc characteristic.In Fig. 1, this calculating is carried out in Plasma Welding power ps P, therefore plasma electrode front end mother metal spacing signal Lpc outputs to metal inert gas arc welding power ps M from Plasma Welding power ps P.
Fig. 5 is the figure that represents the arc characteristic of above-mentioned plasma-arc.Represent Plasma Welding voltage Vwp (V) with the transverse axis of figure, the longitudinal axis represents the long Lpa of the electric arc of plasma-arc (mm).In same figure, situation when solid line has represented Plasma Welding current value I wp=50A, situation when dotted line has represented Iwp=100A, situation when chain-dotted line has represented Iwp=150A.
As shown in the figure, Vwp is larger for Plasma Welding magnitude of voltage, and long Lpa is longer for electric arc.In addition, in the time that Plasma Welding magnitude of voltage Vwp is same value, wp is larger for Plasma Welding current value I, and long Lpa is shorter for electric arc.For example, in the time of Plasma Welding current value I wp=100A, the in the situation that of Plasma Welding magnitude of voltage Vwp=31A, the long Lpa of electric arc is 20mm.Like this, can calculate the long Lpa of electric arc of plasma-arc, and because the long Lpa of electric arc equals the distance L p between plasma electrode front end and mother metal, therefore study carefully its result, can calculate the distance L p between plasma electrode front end and mother metal.Below, the arc characteristic shown in same figure is called to plasma electric arc length computing function.The long computing function of this electric arc is using Plasma Welding current value I wp and Plasma Welding magnitude of voltage Vwp as input, and exports the long Lpa of electric arc of plasma-arc.The long computing function of this plasma-arc is set as appropriate value according to the shape of the kind of plasma gas 62 and protective gas 63, plasma electrode 1b etc.This setting is carried out by experiment.In same figure, in the time of Plasma Welding current value I wp=70A, carry out interpolation according to the arc characteristic of the arc characteristic of Iwp=50A and Iwp=100a, calculate plasma electric arc length Lpa.
Fig. 6 is the module map that forms the metal inert gas arc welding power ps M of above-mentioned Fig. 1.With figure, as mentioned above, be the situation from Plasma Welding power ps P input plasma electrode front end mother metal spacing signal Lpc.Below, describe about each module with reference to FIG..
Electric power main circuit PM is using the source power supplies such as 3 phase 200V (diagram is omitted) as input, carry out the output control of inversion control etc. according to current error amplifying signal Ei described later, output metal inert gas arc welding voltage Vwm and metal inert gas arc welding electric current I wm.This electric power main circuit PM, though diagram is omitted, it is by forming below: a rectification circuit, it carries out rectification to source power supply; Capacitor, it makes the direct current after rectification level and smooth; Inverter (inverter) circuit, the DC converting after level and smooth is become high-frequency ac by it; It becomes to be applicable to the magnitude of voltage of arc welding by high-frequency ac step-down contravariant transformer (inverter transformer); Secondary rectification circuit, its high-frequency ac after to step-down carries out rectification; Reactor (reactor), it makes the direct current after rectification level and smooth; And drive circuit, it carries out PWM modulation control according to current error amplifying signal Ei described later, and drives inverter circuit based on this result.Welding wire 1a through power supply chip 4 inside, implements feeding by the feed rolls 7 of being combined with feed motor WM, and and mother metal 2 between produce Metallic Inert Gas electric arc 3a.The structure of welding torch is identical with Fig. 1, but simplifies to illustrate at this.
Voltage detecting circuit VD detects metal inert gas arc welding voltage Vwm, and voltage sense signal Vd.Average voltage counting circuit VAV calculates the mean value of this voltage detection signal Vd, and output voltage average value signal Vav.
In Fig. 1, as mentioned above, the outside Plasma Welding current setting circuit IWPR that is arranged on metal inert gas arc welding power ps M exports predefined Plasma Welding current settings signal Iwpr.Feed speed initialization circuit FR exports predefined feed speed setting signal Fr.Feeding control circuit FC is using this feed speed setting signal Fr as input, and will output to feed motor WM for the feeding control signal Fc that carrys out feeding welding wire 1a with the feed speed Fw determining according to the value of feed speed setting signal Fr.
Voltage setting circuit VR exports predefined voltage setting signal Vr.Voltage error amplifying circuit EV amplifies the error between this voltage setting signal Vr and above-mentioned average voltage value signal Vav, and output voltage error amplifying signal Ev.Voltage/frequency translation circuit VF output has the pulse-period signal Tf of frequency corresponding to the value of voltage error amplifying signal Ev therewith.This pulse-period signal Tf is that only the short time is the triggering signal of high level (High level) in each pulse period.
Between the peak period, initialization circuit TPR is using the plasma electrode front end mother metal spacing signal Lpc of the Plasma Welding current settings signal Iwpr from above-mentioned and Plasma Welding power ps P as input, computing function between the predefined peak period based on above-mentioned in Fig. 2～Fig. 4, exports setting signal Tpr between the peak period.Signal Tp between the timing circuit TP output peak period between the peak period, between this peak period signal Tp in the time that above-mentioned pulse-period signal Tf is high level, only between according to the above-mentioned peak period value of setting signal Tpr determine during in be high level.When between this peak period, signal Tp is high level, be between the peak period, and be base value when for low level (Low level) during.
Background current initialization circuit IBR exports predefined background current setting signal Ibr.Peak point current initialization circuit IPR is using the plasma electrode front end mother metal spacing signal Lpc of the Plasma Welding current settings signal Iwpr from above-mentioned and Plasma Welding power ps P as input, calculate function based on peak point current above-mentioned in Fig. 2～Fig. 4, export peak point current setting signal Ipr.Current settings control circuit IRC, when between the above-mentioned peak period, signal Tp is low level, the output using above-mentioned background current setting signal Ibr as current settings control signal Irc, and in the time being high level, export above-mentioned peak point current setting signal Ipr as current settings control signal Irc.
Current detection circuit ID detects metal inert gas arc welding electric current I wm, and output electric current measure signal Id.Current error amplifying circuit EI amplifies the error between above-mentioned current settings control signal Irc and above-mentioned current detection signal Id, and output current error amplification signal Ei.By carrying out the output control of the source of welding current according to this current error amplifying signal Ei, in Figure 10 (A), logical above-mentioned metal inert gas arc welding electric current I wm.To above-mentioned metal inert gas arc welding power ps M, change to export control according to the pulse period, so that the mean value of metal inert gas arc welding voltage Vwm equals the value of voltage setting signal Vr, therefore it is the power supply of constant voltage characteristic.
Fig. 7 is the module map that forms the Plasma Welding power ps P of above-mentioned Fig. 1.Represented to calculate Plasma Welding current value I wp and Plasma Welding magnitude of voltage Vwp as the plasma electric arc length computing function of input according to the method for above-mentioned (2) situation of the length L h that is heated with figure.Below, with reference to FIG., describe about each module.
Electric power main circuit PM as inputting, carries out the source power supplies such as 3 phase 200V (diagram omit) the output control of inversion control etc., and exports Plasma Welding electric current I wp according to current error amplifying signal Ei described later.This plasma welding current Iwp switches on by plasma electrode 1b, plasma-arc 3b, mother metal 2.The structure of welding torch is identical with above-mentioned Fig. 1, but simplifies to illustrate at this.
In Fig. 1, as mentioned above, the outside Plasma Welding current setting circuit IWPR that is arranged on Plasma Welding power ps P exports predefined Plasma Welding current settings signal Iwpr.Current detection circuit ID detects above-mentioned Plasma Welding electric current I wp, and output electric current measure signal Id.Current error amplifying circuit EI amplifies the error between above-mentioned Plasma Welding current settings signal Iwpr and above-mentioned current detection signal Id, and output current error amplification signal Ei.By carrying out the output control of the source of welding current according to this current error amplifying signal Ei, in Figure 10 (C), the Plasma Welding electric current I wp of logical above-mentioned direct current.To above-mentioned Plasma Welding power ps P, export control, so that Plasma Welding electric current I wp equals the value of Plasma Welding current settings signal Iwpr, therefore it is the power supply of constant current characteristic.
Voltage detecting circuit VD detects above-mentioned Plasma Welding voltage Vwp, and voltage sense signal Vd.Plasma electrode front end mother metal spacing counting circuit LPC is using above-mentioned Plasma Welding current settings signal Iwpr and above-mentioned voltage detection signal Vd as input, the electric arc that calculates plasma-arc according to predefined plasma electric arc length computing function above-mentioned in Fig. 5 is long, and outputs to metal inert gas arc welding power ps M as plasma electrode front end mother metal spacing signal Lpc.
In the present embodiment, the situation that Plasma Welding electric current I wp is direct current has been described.In the time that Plasma Welding electric current I wp is impulse waveform, as the input that between the above-mentioned peak period, computing function, peak point current calculate function and plasma electric arc length computing function, use the mean value of Plasma Welding electric current I wp and the mean value of Plasma Welding voltage Vwp.
According to above-mentioned embodiment 1, by making between peak period of metal inert gas arc welding electric current according to the length of being heated of welding wire and/or peak point current changes, can compensate the variation of the preheat mode of the welding wire of the variation of following the length of being heated.Therefore, even if thereby the length variations of being heated of the variation welding wires such as torch height also can maintain 1 pulse period, 1 droplet transfer state, therefore welded condition all-the-time stable.
[embodiment 2]
Embodiments of the present invention 2 are the situations of length L h=Lp-La of being heated.At this, as mentioned above, Lp is the distance between plasma electrode front end and mother metal, and La is that the electric arc of Metallic Inert Gas electric arc is long.About the detection method of the distance L p between plasma electrode front end and mother metal, identical with embodiment 1.As the establishing method of the long La of electric arc, there are 3 kinds of methods shown below.
(1) preset the situation of the long La of electric arc
The proper range that is used for the long La of electric arc that carries out good welding is 3～5mm left and right.Therefore, long electric arc La is set as to predefined constant (for example 4mm).Like this, although and can produce the error of 1mm left and right between the long La of actual electric arc, as long as the error of this degree, the impact of the calculated value on the length L h that is heated is just little.If make in this way, there is the simple advantage of computational methods of the length L h that is heated.
(2) set the situation of the long La of electric arc based on voltage setting signal Vr
In Fig. 6, the value of the voltage setting signal Vr in above-mentioned metal inert gas arc welding power ps M is the long desired value of controlling of the electric arc of Metallic Inert Gas electric arc., carry out the long control of electric arc, so that become the long La of the electric arc corresponding with the value of voltage setting signal Vr.Therefore,, according to using this voltage setting signal Vr as input and the long computing function of predefined the first Metallic Inert Gas electric arc, calculate the long La of electric arc.For example, making the long computing function of this first Metallic Inert Gas electric arc is La=aVr+b.At this, a and b are constant, decide by experiment.Constant a and b, according to material and the diameter etc. of the kind of center gas, plasma gas and protective gas, welding wire, are set as appropriate value by experiment.
(3) method of calculating according to metal inert gas arc welding voltage Vwm and metal inert gas arc welding electric current I wm
Because Metallic Inert Gas electric arc is consumable electrode type electric arc, therefore the distance between front end and the mother metal of the welding wire of melting is always the long La of electric arc.If set the feed speed Fw (mean value of metal inert gas arc welding electric current I wm) of welding wire, the mean value of the long La of electric arc and metal inert gas arc welding voltage Vwm is proportional.This proportional relation is known as arc characteristic.Therefore, can in welding, detect the mean value of metal inert gas arc welding voltage Vwm, and calculate the corresponding with it long La of electric arc according to arc characteristic.In this method, according to using the mean value of feed speed Fw and metal inert gas arc welding voltage Vwm as input and the long computing function of predefined the second Metallic Inert Gas electric arc calculates the long La of electric arc.In Fig. 1, this calculating is carried out in metal inert gas arc welding power ps M.
Fig. 8 is the figure that represents the arc characteristic of above-mentioned Metallic Inert Gas electric arc.The mean value (V) that represents metal inert gas arc welding voltage Vwm with the transverse axis of figure, the longitudinal axis represents the long La of the electric arc of Metallic Inert Gas electric arc (mm).In same figure, situation when solid line has represented feed speed Fw=9m/min (mean value=70A of metal inert gas arc welding electric current I wm), situation when dotted line has represented Fw=12m/min (mean value=105A of metal inert gas arc welding electric current I wm), situation when chain-dotted line has represented Fw=14m/min (mean value=135A of metal inert gas arc welding electric current I wm).Wherein, the mean value of the metal inert gas arc welding electric current I wm in () is the situation of Plasma Welding current value I wp=100A.
As shown in the figure, the mean value of metal inert gas arc welding voltage Vwm is larger, and long La is longer for electric arc.In addition, in the time that the mean value of metal inert gas arc welding voltage Vwm is identical value, feed speed Fw is larger, and long La is shorter for electric arc.For example, in the time of feed speed Fw=12m/min, in the case of mean value=17V of metal inert gas arc welding voltage Vwm, the long La of electric arc is 5mm.Like this, can calculate the long La of electric arc of Metallic Inert Gas electric arc.Be the long computing function of the second Metallic Inert Gas electric arc with the arc characteristic shown in figure.The long computing function of this second Metallic Inert Gas electric arc is using the mean value of feed speed Fw and metal inert gas arc welding voltage Vwm as input, and exports the long La of electric arc of Metallic Inert Gas electric arc.The long computing function of this second Metallic Inert Gas electric arc, according to material and the diameter etc. of the kind of above-mentioned center gas 61, plasma gas 62 and protective gas 63, welding wire 1a, is set as appropriate value.This setting is carried out by experiment.
Identical with above-mentioned Fig. 1 for implementing the pie graph of welder of plasma metal inert gas arc welding method of embodiment 2.But the module map (Fig. 6) of the metal inert gas arc welding power ps M that forms this welder is changed over to Fig. 9 described later.In addition, about representing to be heated length L h and the above-mentioned Fig. 2～Fig. 4 as relation between Tp between the peak period of unit pulse condition and peak point current Ip, also identical.About these identical items, the description thereof will be omitted.
Fig. 9 is the module map of the metal inert gas arc welding power ps M of the pie graph 1 of embodiments of the present invention 2.With figure, as mentioned above, be the situation from Plasma Welding power ps P input plasma electrode front end mother metal spacing signal Lpc.Corresponding with above-mentioned Fig. 6 with figure, same module is paid to same mark, the description thereof will be omitted.The same figure is the length computation circuit LHC that is heated that appends the long initialization circuit LAR of the Metallic Inert Gas electric arc dotting and dot in Fig. 6, initialization circuit TPR between the peak period of Fig. 6 is replaced as to initialization circuit TPR2 between the second peak period dotting, and the peak point current initialization circuit IPR of Fig. 6 is replaced as to the second peak point current initialization circuit IPR2 dotting.Below, with reference to FIG., describe about these modules.
The long initialization circuit LAR of Metallic Inert Gas electric arc is using feed speed setting signal Fr and average voltage value signal Vav as input, according to the long computing function of predefined the second Metallic Inert Gas electric arc above-mentioned in Fig. 8, the electric arc that calculates Metallic Inert Gas electric arc is long, and sets it as the long setting signal Lar output of Metallic Inert Gas electric arc.The length computation of being heated circuit LHC in the future since then in the long setting signal Lar of Metallic Inert Gas electric arc and Fig. 7 the plasma electrode front end mother metal spacing signal Lpc of above-mentioned Plasma Welding power ps P as input, the calculating length signals Lhc=Lpc-Lar that is heated, the line output of going forward side by side.
Between the second peak period, initialization circuit TPR2 is using Plasma Welding current settings signal Iwpr and the above-mentioned length signals Lhc that is heated as input, and computing function between the predefined peak period based on above-mentioned in Fig. 2～Fig. 4, exports setting signal Tpr between the peak period.The second peak point current initialization circuit IPR2 is using Plasma Welding current settings signal Iwpr and the above-mentioned length signals Lhc that is heated as input, and the predefined peak point current based on above-mentioned in Fig. 2～Fig. 4 calculates function, exports setting signal Tpr between the peak period.
In same figure, be the situation of carrying out the long setting of Metallic Inert Gas electric arc by the method for above-mentioned (3), and the situation of using the method for (1) and (2) to carry out, for shown below.
(1) preset the situation of the long La of electric arc
The long initialization circuit LAR of Metallic Inert Gas electric arc exports the long setting signal Lar of predefined Metallic Inert Gas electric arc.
(2) set the situation of the long La of electric arc based on voltage setting signal Vr
The long initialization circuit LAR of Metallic Inert Gas electric arc is using voltage setting signal Vr as input, the electric arc that calculates Metallic Inert Gas electric arc according to the above-mentioned long computing function of predefined the first Metallic Inert Gas electric arc is long, and sets it as the long setting signal Lar output of Metallic Inert Gas electric arc.
According to above-mentioned embodiment 2, the value that the length of being heated is obtained as the distance between plasma electrode front end and mother metal deducts the electric arc length of Metallic Inert Gas electric arc is calculated.Therefore, change even if the electric arc of Metallic Inert Gas electric arc is long, also can correctly calculate the length of being heated.Consequently, can compensate more accurately the variation of the preheat mode of the welding wire of the variation of following the length of being heated.
Claims (3)
1. a plasma metal inert gas arc welding method, its by be disposed between plasma electrode in welding torch and mother metal, apply Plasma Welding voltage and logical on plasma welding current, thereby plasma-arc is produced, and, described plasma electrode is arranged to hollow shape, through carrying out the welding wire that feeding is powered via the power supply chip being configured in described plasma electrode in described hollow shape inside, and by between described power supply chip and mother metal, apply metal inert gas arc welding voltage and logical on background current in during peak point current in using between the peak period and base value as the metal inert gas arc welding electric current of 1 pulse period, thereby Metallic Inert Gas electric arc is produced,
This plasma metal inert gas arc welding method is characterised in that, makes between the described peak period and/or described peak point current changes according to the length of being heated of the length of the part of being heated from described plasma-arc as described welding wire,
The described length of being heated is that the distance between front end and the described mother metal of described plasma electrode deducts the value obtaining the electric arc length of described Metallic Inert Gas electric arc, in the situation that simplifying, described in the length of being heated be the distance between front end and the described mother metal of described plasma electrode.
2. plasma metal inert gas arc welding method as claimed in claim 1, is characterized in that,
According to using described Plasma Welding electric current and described Plasma Welding voltage as input and predefined function, calculate the distance between front end and the described mother metal of described plasma electrode.
3. plasma metal inert gas arc welding method as claimed in claim 1, is characterized in that,
According to using the mean value of the feed speed of welding wire and described metal inert gas arc welding voltage as input and predefined function, calculate described electric arc long.
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| US11344964B2 (en) | 2017-06-09 | 2022-05-31 | Illinois Tool Works Inc. | Systems, methods, and apparatus to control welding electrode preheating |
| US11524354B2 (en) | 2017-06-09 | 2022-12-13 | Illinois Tool Works Inc. | Systems, methods, and apparatus to control weld current in a preheating system |
| CN108994465A (en) * | 2018-08-23 | 2018-12-14 | 广东省焊接技术研究所（广东省中乌研究院） | A kind of plasma-arc hybrid welding method of pulse current modulation |
| CN109500481A (en) * | 2018-11-20 | 2019-03-22 | 江苏科技大学 | A kind of thin plate brass does not preheat plasma arc welding method |
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| JP4643161B2 (en) * | 2004-03-25 | 2011-03-02 | 株式会社ダイヘン | Consumable electrode gas shielded arc welding method with constant current characteristics |
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