Arc length control method

Abstract

An arc length control method includes: acquiring a first time length characterizing the arc length; determining an energy deviation value based on a time deviation value between the first time length and a preset time length; and determining a pulse parameter correction amount for the next pulse based on the energy deviation value. By acquiring the first time length characterizing the arc length, using the deviation between the first time length and the preset time length to obtain the energy correction value, and adjusting the pulse parameters of the next pulse based on the energy correction amount, the method aims to control the pulse energy output and ultimately maintain a consistent arc length for the pulses.

Description

Technical Field

[0001] The embodiments of this disclosure relate to the field of welding, and more specifically, to an arc length control method. Background Technology

[0002] In pulse welding, to achieve better weld formation and quality, welding is usually required at a shorter arc length, meaning a slight short circuit needs to occur during the welding process. Conventional welding control methods are based on voltage to control the arc length, using voltage to characterize the arc length. However, when the weld joint type changes (such as corner joints or butt joints) or the shielding gas composition changes, the actual arc length may differ at the same voltage. Summary of the Invention

[0003] To address the aforementioned issues, embodiments of this disclosure provide an arc length control method. By monitoring the moment of short circuit occurrence and comparing it with a time setpoint, the output energy is controlled to ensure a stable and consistent arc length, unaffected by external factors such as joint type and gas ratio.

[0004] At least one embodiment of this disclosure provides an arc length control method, comprising:

[0005] Obtain the first time length representing the arc length;

[0006] The energy deviation value is determined based on the time deviation between the first time length and the set time length; and

[0007] Based on the energy deviation value, the pulse parameter correction amount for the next pulse is determined.

[0008] In one embodiment of this disclosure, the first time length includes the time length from the current pulse start time to the short circuit occurrence time.

[0009] In one embodiment of this disclosure, obtaining the first time length representing the arc length includes:

[0010] Obtain the time length between the pulse start time and the short circuit occurrence time of multiple pulses, including the current pulse;

[0011] Determine the average time length between the pulse start time and the short circuit occurrence time of multiple pulses, including the current pulse; and

[0012] The average time length is taken as the first time length.

[0013] In one embodiment of this disclosure, the first time length includes the sum of the time length from the start time of the current pulse to the time of short circuit occurrence and the time advance of the short circuit occurrence reflected by the short circuit time length of the current pulse.

[0014] In one embodiment of this disclosure, obtaining the first time length representing the arc length includes:

[0015] Obtain the sum of the time length between the pulse start time and the short circuit occurrence time of multiple pulses including the current pulse, and the time advance of the short circuit occurrence time reflected by the short circuit time length of multiple pulses including the current pulse;

[0016] Based on the sum, determine the average time length; and

[0017] The average time length is taken as the first time length.

[0018] In one embodiment of this disclosure, determining the energy deviation value based on the time deviation value between the first time length and the set time length includes:

[0019] The energy deviation value is determined using PID control or fuzzy control based on the deviation between the first time length and the set time length.

[0020] In one embodiment of this disclosure, determining the pulse parameter correction amount for the next pulse based on the energy deviation value includes:

[0021] △Ip=a1*P1+b1;

[0022] △Tp = a2*P1 + b2;

[0023] △Ib = a3*P1 + b3; and

[0024] △T = a4*P1 + b4;

[0025] Where △Ip represents the pulse peak current correction, △Tp represents the pulse peak time correction, △Ib represents the pulse base current correction, △T represents the pulse period correction, P1 represents the energy correction, and a1, b1, a2, b2, a3, b3, a4, and b4 represent coefficients.

[0026] At least one embodiment of this disclosure provides a non-volatile storage medium having a processor-executable computer program stored thereon, the processor being configured to perform operations in any of the above-described arc length control methods in response to the processor executing the computer program.

[0027] At least one embodiment of this disclosure provides a computer program product comprising a processor-executable computer program, wherein when the computer program is executed by a processor, the processor is configured to perform the operations in any of the above-described arc length control methods.

[0028] According to the arc length control method of this disclosure, a first time length characterizing the arc length is obtained. An energy correction value is obtained using the deviation between the first time length and a preset time length. The pulse parameters of the next pulse are adjusted based on the energy correction value, thereby controlling the pulse energy output and ultimately ensuring that the arc length of the pulse remains consistent. Simultaneously, the first time length can be the time between the pulse start time and the short-circuit occurrence time of the current cycle, simplifying calculations. Alternatively, it can be the average time between the pulse start time and the short-circuit occurrence time of multiple pulses including the current pulse, effectively avoiding the impact of abnormal short-circuit occurrence (i.e., early or late short-circuit occurrence) on the determination of the next pulse parameters. Furthermore, a time advance amount of the short-circuit occurrence time reflected by the short-circuit time is introduced, further optimizing the characterization of the arc length, enabling better control of pulse energy, and ensuring that the arc length of the pulse remains consistent. Attached Figure Description

[0029] Figure 1 The pulse welding process is shown;

[0030] Figure 2 A flowchart of an arc length control method according to an embodiment of the present disclosure is shown;

[0031] Figure 3 A flowchart illustrating the acquisition of a first time length in an arc length control method according to an embodiment of the present disclosure is shown; and

[0032] Figure 4 A flowchart illustrating the acquisition of a first time length in an arc length control method according to yet another embodiment of the present disclosure is shown. Detailed Implementation

[0033] The present disclosure will be further described in detail below with reference to the accompanying drawings and embodiments. Through these descriptions, the features and advantages of the present disclosure will become clearer and more apparent.

[0034] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments. Although various aspects of embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless specifically indicated otherwise.

[0035] Furthermore, the technical features involved in the different embodiments of this disclosure described below can be combined with each other as long as they do not conflict with each other.

[0036] In pulse welding, voltage is usually used to characterize arc length. However, when the welding joint type changes (such as corner joint, butt joint, etc.) or the shielding gas ratio changes, the actual arc length may be different under the same voltage.

[0037] In pulse welding, in order to achieve better weld formation and weld quality, welding is usually required to be performed with a shorter arc length, that is, a slight short circuit needs to be generated during the welding process. Figure 1 This illustrates the relationship between droplet formation and the timing of short circuits during the welding process. Typically, the droplet forms at the end of the pulse peak and is then elongated under the influence of the arc force, transitioning towards the workpiece. A short circuit occurs when the droplet contacts the workpiece. A longer arc length results in a later short circuit, while a shorter arc length results in an earlier short circuit. Therefore, the timing of short circuit occurrence can characterize the arc length.

[0038] Based on this, the embodiments of this disclosure provide an arc length control method, which uses real-time monitoring of the moment when a short circuit occurs to control the output energy, thereby achieving a stable and consistent welding arc length that is unaffected by external factors such as joint type and gas ratio.

[0039] At least one embodiment of this disclosure provides an arc length control method, such as Figure 2 As shown, the arc length control method includes:

[0040] S01, obtain the first time length representing the arc length;

[0041] S02, determine the energy deviation value based on the time deviation value between the first time length and the set time length; and

[0042] S03, based on the energy deviation value, obtain the pulse parameter correction amount for the next pulse.

[0043] In one embodiment of this disclosure, the first time length includes the time length from the current pulse start time to the short circuit occurrence time.

[0044] In one embodiment of this disclosure, in order to prevent abnormalities in the timing of short circuit occurrence in the current pulse cycle, i.e., short circuit occurrence is advanced or delayed, the average of the time lengths between the pulse start time and the short circuit occurrence time of multiple consecutive pulses including the current pulse can be used as the first time length, and the energy correction value can be obtained based on the difference between the average value and the set time length.

[0045] In one embodiment of this disclosure, such as Figure 3 As shown, the first time length for obtaining the arc length includes:

[0046] S011, obtain the time length between the pulse start time and the short circuit occurrence time of multiple pulses including the current pulse;

[0047] S012, determine the average time length between the pulse start time and the short circuit occurrence time of multiple pulses, including the current pulse; and

[0048] S013, the average time length is taken as the first time length T1.

[0049] After using the average time length as the first time length T1, the average time length between the pulse start time and the short circuit occurrence time of multiple pulses is determined based on the first time length T1 and used as the first time length between the pulse start time and the short circuit occurrence time of the current pulse. This can effectively avoid the influence of abnormal short circuit occurrence of the current pulse (i.e., early or late short circuit occurrence) on the determination of the parameters of the next pulse. Typically, the time lengths between the pulse start time and the short circuit occurrence time of 10 pulses can be averaged, and the obtained average time length is used as the first time length.

[0050] In some cases, it is also necessary to analyze the duration of the short circuit to analyze and calculate the energy correction. A short circuit duration longer than the standard short circuit duration corresponding to the welding current indicates that the short circuit occurred earlier, while a short circuit duration shorter than the standard short circuit duration corresponding to the welding current indicates that the short circuit occurred later.

[0051] In one embodiment of this disclosure, the first time length includes the sum of the time length from the start time of the current pulse to the time of short circuit occurrence and the time advance of the short circuit occurrence reflected by the short circuit time length of the current pulse.

[0052] If the short-circuit time length T2 of the current pulse is equal to the standard short-circuit time length Ts corresponding to the welding current, it means that the time advance of the short-circuit occurrence reflected by the short-circuit time length is zero, and the first time length is the time length from the start time of the current pulse to the occurrence time of the short circuit; if the short-circuit time length T2 of the current pulse is greater than the standard short-circuit time length Ts corresponding to the welding current, it means that the short-circuit occurrence time is zero. 标准 This means that the time advance of the short circuit occurrence reflected by the short circuit duration is K*(T2-T). 标准 The first time length is the time length from the start of the current pulse to the occurrence of the short circuit, plus the time advance K*(T2-T). 标准 The difference; if the short-circuit time length T2 of the current pulse is less than the standard short-circuit time length T corresponding to the welding current. 标准 Then, the time delay reflected by the short circuit duration is K*(T) 标准 -T2), the first time length is the time length from the start time of the current pulse to the time of short circuit occurrence and the time delay K*(T). 标准 The difference between -T2), where K represents the coefficient.

[0053] In one embodiment of this disclosure, to prevent anomalies in the timing of short circuit occurrence and the duration of short circuit in the current pulse cycle, such as... Figure 4 As shown, the first time length for obtaining the arc length includes:

[0054] S021, obtain the sum of the time length between the pulse start time and the short circuit occurrence time of multiple pulses including the current pulse, and the time advance of the short circuit occurrence time reflected by the short circuit time length of multiple pulses including the current pulse.

[0055] S022, based on the sum, determine the average time length; and

[0056] S023, the average time length is taken as the first time length T1.

[0057] In one embodiment of this disclosure, the energy correction value P1 is determined by PID control or fuzzy control based on the deviation between the first time length T1 and the set time length.

[0058] Based on the deviation between the first time length T1 and the set time length, PID control is used to obtain the energy correction value. This allows for rapid error response, reduction of steady-state error, and complete elimination of system error, bringing the system error to zero, thereby eliminating steady-state error, reducing overshoot, overcoming oscillations, improving system stability, and accelerating the system's dynamic response speed. It also reduces settling time, thus improving the system's dynamics. Furthermore, using fuzzy control to obtain the energy correction value based on the deviation between the first time length and the set time length reduces the complexity of system design and provides good robustness, adaptability, and fault tolerance.

[0059] After obtaining the energy correction value, the pulse parameter correction amount for the next pulse can be adjusted. The pulse parameter correction amounts include the pulse peak current correction amount △Ip, the pulse peak time correction amount △Tp, the pulse base current correction amount △Ib, and the pulse period correction amount △T.

[0060] In one embodiment of this disclosure,

[0061] △Ip=a1*P1+b1;

[0062] △Tp = a2*P1 + b2;

[0063] △Ib = a3*P1 + b3; and

[0064] △T = a4*P1 + b4;

[0065] Where △Ip represents the pulse peak current correction, △Tp represents the pulse peak time correction, △Ib represents the pulse base current correction, △T represents the pulse period correction, and P1 represents the energy correction. a1, b1, a2, b2, a3, b3, a4, and b4 are related to the welding material and their values ​​can be obtained from experimental data.

[0066] The calculated correction amount will be reflected in the next pulse, thereby controlling the pulse energy output and ultimately keeping the pulse arc length consistent.

[0067] According to the arc length control method of this disclosure, a first time length characterizing the arc length is obtained. An energy correction value is obtained using the deviation between the first time length and a preset time length. The pulse parameters of the next pulse are adjusted based on the energy correction value, thereby controlling the pulse energy output and ultimately ensuring that the arc length of the pulse remains consistent. Simultaneously, the first time length can be the time between the pulse start time and the short-circuit occurrence time of the current cycle, simplifying calculations. Alternatively, it can be the average time between the pulse start time and the short-circuit occurrence time of multiple pulses including the current pulse, effectively avoiding the impact of abnormal short-circuit occurrence (i.e., early or late short-circuit occurrence) on the determination of the next pulse parameters. Furthermore, a time advance amount of the short-circuit occurrence time reflected by the short-circuit time is introduced, further optimizing the characterization of the arc length, enabling better control of pulse energy, and ensuring that the arc length of the pulse remains consistent.

[0068] In the description of this disclosure, it should be noted that the terms "upper", "lower", "inner", "outer", "front", "back", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship in the working state of this disclosure, and are only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this disclosure.

[0069] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. Those skilled in the art can understand the specific meaning of these terms in this disclosure based on the specific circumstances.

[0070] The present disclosure has been described above in conjunction with preferred embodiments, but these embodiments are merely exemplary and serve only as an illustration. On this basis, various replacements and improvements can be made to the present disclosure, all of which fall within the scope of protection of the present disclosure.

Claims

1. An arc length control method, comprising: Obtain the time length from the current pulse start time to the short circuit occurrence time, as the first time length characterizing the arc length; The energy deviation value is determined based on the time deviation value between the first time length and the set time length; as well as Based on the energy deviation value, the pulse parameter correction amount for the next pulse is determined.

2. The arc length control method according to claim 1, wherein, Obtain the time length from the current pulse start time to the short circuit occurrence time as the first time length characterizing the arc length, including: Obtain multiple time lengths between the pulse start time and the short circuit occurrence time for each of the multiple pulses, including the current pulse. Determine the average time length of the plurality of time lengths; and The average time length is taken as the first time length.

3. The arc length control method according to claim 1, wherein, The first time length includes the sum of the time length from the start time of the current pulse to the time of short circuit occurrence and the time advance of the short circuit occurrence reflected by the short circuit time length of the current pulse.

4. The arc length control method according to claim 1, wherein, Obtain the time length from the current pulse start time to the short circuit occurrence time as the first time length characterizing the arc length, including: Obtain the time length between the pulse start time and the short circuit occurrence time of each of the multiple pulses including the current pulse, and the time advance of the short circuit occurrence time reflected by the short circuit time length of the multiple pulses including the current pulse. Determine the sum of the plurality of said time lengths and the plurality of said time advances; determine the average time length based on the sum; and The average time length is taken as the first time length.

5. The arc length control method according to any one of claims 1 to 4, wherein, The energy deviation value is determined based on the time deviation between the first time length and the set time length, including: The energy deviation value is determined using PID control or fuzzy control based on the deviation between the first time length and the set time length.

6. The arc length control method according to any one of claims 1 to 4, wherein, Based on the energy deviation value, determining the pulse parameter correction amount for the next pulse includes: △Ip=a1*P1+b1; △Tp = a2*P1 + b2; △Ib = a3*P1 + b3; and △T = a4*P1 + b4; Where △Ip represents the pulse peak current correction, △Tp represents the pulse peak time correction, △Ib represents the pulse base current correction, △T represents the pulse period correction, P1 represents the energy correction, and a1, b1, a2, b2, a3, b3, a4, and b4 represent coefficients.

7. A non-volatile storage medium having a processor-executable computer program stored thereon, the processor being configured to perform operations in the arc length control method of any one of claims 1 to 6 in response to the processor executing the computer program.

8. A computer program product comprising a processor-executable computer program, wherein when the computer program is executed by a processor, the processor is configured to perform operations in the arc length control method of any one of claims 1 to 6.

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