Cold wire filler method and cold wire filler control system for arc welding processes

Abstract

The present application belongs to the field of arc welding process, and discloses a cold wire filling method and a cold wire filling control system for arc welding process, which can adaptively pre-position the cold wire based on the actual groove shape before arc striking, so as to send the outer end of the cold wire to the bottom of the position where the molten pool will be formed in the welding process. In this way, as long as the wire feeding frequency is reasonably adjusted according to the fusion condition of the outer end of the cold wire and the molten pool during welding, the outer end of the cold wire can always be kept in contact with the bottom of the molten pool, so as to ensure the cold wire filling and welding stability, and the melting of the outer end of the cold wire can improve the solidification speed of the bottom of the molten pool, so that the occurrence of welding leakage can be effectively avoided without the need of attaching a ceramic pad, thereby effectively improving the welding forming quality, welding speed and automation degree of the arc welding process.

Description

Technical Field

[0001] This invention relates to the field of arc welding technology, specifically to a cold wire filling method and a cold wire filling control system for arc welding. Background Technology

[0002] In arc welding, the large heat input generated by the arc is the thermal driving force for the continuous melting of the base material at the welding front. However, this can also cause overheating damage to the heat-affected zone and the base material, especially in multi-layer, multi-pass welding of medium and thick plates, where the thermal effect of subsequent welds on preceding welds makes the heat-affected zone more complex and variable. To address this, inserting a cold wire at a suitable position in the molten pool can not only reduce the overheating damage to the base material caused by the large heat input but also increase the deposition of filler metal and the welding speed.

[0003] However, existing wire feeding devices cannot adjust the cold wire insertion direction. The cold wire can only be inserted from the front or rear end of the welding direction, and cannot make adaptive adjustments according to the actual shape of the welding gap. Therefore, it cannot be guaranteed that the outer end of the cold wire can always be inserted into the molten pool. If the outer end of the cold wire does not reach the molten pool, it is easy to cause incomplete fusion and incomplete penetration. If the outer end of the cold wire exceeds the molten pool, it will cause it to fail to melt, and may even cause wire sticking and other consequences that interrupt the welding process.

[0004] On the other hand, to address the issue of intermittent deviations in welding gaps, ceramic gaskets are typically installed at the bottom of the welding gap, and laser or other detection methods are used to extract information such as the welding gap. Based on this, the welding torch position is adaptively adjusted to prevent weld leaks caused by excessive gaps, thereby improving welding quality. However, this method of installing ceramic gaskets is cumbersome, labor-intensive, and unsuitable for automated production. Summary of the Invention

[0005] In view of at least one of the above-mentioned defects or deficiencies in the prior art, the present invention provides a cold wire filling method and a cold wire filling control system for arc welding process, which can keep the outer end of the cold wire in contact with the bottom of the molten pool during the welding process, ensuring welding stability, and preventing weld leakage by eliminating the ceramic backing installation process, thereby achieving the purpose of improving welding quality, welding speed and automation.

[0006] To achieve the above objectives, the first aspect of the present invention provides a cold wire filling method for an arc welding process, comprising:

[0007] Inspect the bevel shape between the two workpieces to be welded before igniting the hot wire;

[0008] The guide bevel surface is determined based on the bevel morphology;

[0009] The cold wire is fed obliquely into the root gap of the bevel along the guide bevel surface of one of the workpieces and into the bevel until the outer end of the cold wire abuts the bottom of the root region of the surface to be welded on the other workpiece.

[0010] Optionally, feeding the cold wire obliquely into the root gap of the bevel along the guide bevel surface of one of the workpieces and feeding it in such a way that the outer end of the cold wire abuts the bottom of the root region of the surface to be welded on the other workpiece includes:

[0011] The cold wire is positioned along the guide bevel surface of one of the workpieces;

[0012] The cold wire is inclined and fed into the gap at the root of the bevel for a preset length;

[0013] Make sure the outer end of the cold wire abuts against the bottom of the root region of the surface to be welded on the other workpiece.

[0014] Optionally, the wire feeding action of the cold wire is driven by a wire feeding motor, and determining that the outer end of the cold wire abuts the bottom of the root region of the surface to be welded of another workpiece includes:

[0015] Determine the change in current of the wire feeding motor during the process of driving the cold wire to feed out the preset wire length;

[0016] The current change is determined to be within a preset ideal range, while keeping the position of the cold wire unchanged.

[0017] Optionally, the wire feeding action of the cold wire is driven by a wire feeding motor, and determining that the outer end of the cold wire abuts the bottom of the root region of the surface to be welded of another workpiece includes:

[0018] Determine the change in current of the wire feeding motor during the process of driving the cold wire to feed out the preset wire length;

[0019] Once the current change is determined to be within a preset fine-tuning range, the angle between the cold wire and the guide bevel surface is finely adjusted so that the outer end of the cold wire moves to the bottom of the root region of the surface to be welded of another workpiece.

[0020] Optionally, the guide bevel surface is a flat surface, so that when the cold wire is placed along the guide bevel surface of one of the workpieces, the cold wire is parallel to the guide bevel surface.

[0021] Optionally, the cold wire feeding action is driven by a wire feeding motor, and the cold wire filling method further includes:

[0022] The current of the wire feed motor is continuously monitored during the welding process;

[0023] The fusion status of the cold wire and the molten pool is determined based on the current of the wire feeding motor.

[0024] The wire feeding frequency of the wire feeding motor is adjusted according to the fusion condition between the cold wire and the molten pool.

[0025] Optionally, the cold wire filling method further includes:

[0026] During the welding process, the cross-sectional shape of each bevel is tracked and detected along the welding direction.

[0027] The cold wire is driven to produce a corresponding displacement based on the currently tracked and detected bevel cross-sectional shape, so that the outer end of the cold wire always remains in contact with the bottom of the molten pool.

[0028] Optionally, determining the guide bevel surface based on the bevel morphology includes:

[0029] The bevel formed between the two workpieces is determined to be a double-sided bevel.

[0030] Select one of the bevel surfaces on the workpiece as the guide bevel surface;

[0031] The cold wire is fed obliquely into the root gap of the bevel along the guide bevel surface of one of the workpieces and into the gap until the outer end of the cold wire abuts the bottom of the root region of the surface to be welded on the other workpiece, including:

[0032] This causes the outer end of the cold wire to abut the bottom of the beveled blunt edge region of another workpiece.

[0033] A second aspect of the present invention provides a cold wire filling control system for an arc welding process, comprising:

[0034] The cold wire control assembly includes a cold wire, a wire feeding drive mechanism capable of driving the cold wire to perform a wire feeding action, and a position adjustment mechanism capable of adjusting the position of the cold wire.

[0035] Scanning and inspection equipment can detect the bevel morphology between two workpieces to be welded before the hot wire is ignited; and

[0036] The processing device communicates with the wire feeding drive mechanism, the positioning adjustment mechanism, and the scanning detection device, respectively, and is configured as follows:

[0037] The guide bevel surface is determined based on the bevel morphology obtained from the scanning and detection equipment;

[0038] The wire feeding drive mechanism and the positioning adjustment mechanism are controlled to feed the cold wire at an angle along the guide bevel surface on one of the workpieces into the bevel root gap and into the gap until the outer end of the cold wire abuts the bottom of the root region of the surface to be welded on the other workpiece.

[0039] Optionally, the wire feeding drive mechanism includes a wire feeding length detection device for detecting the wire feeding length of the cold wire, and the processing device communicates with the wire feeding length detection device and is further configured to:

[0040] Control the movement of the positioning adjustment mechanism to position the cold wire along the guide bevel surface of one of the workpieces;

[0041] Control the operation of the wire feeding drive mechanism to tilt and feed the cold wire into the bevel root gap for a preset wire feeding length;

[0042] Make sure the outer end of the cold wire abuts against the bottom of the root region of the surface to be welded on the other workpiece.

[0043] Optionally, the wire feeding drive mechanism includes a wire feeding motor and a current detection device for detecting the current of the wire feeding motor, and the processing device communicates with the current detection device and is further configured to:

[0044] Determine the change in current of the wire feeding motor during the process of driving the cold wire to feed out the preset wire length;

[0045] The current change is determined to be within a preset ideal range, and the position of the cold wire is controlled to remain unchanged.

[0046] Optionally, the wire feeding drive mechanism includes a wire feeding motor and a current detection device for detecting the current of the wire feeding motor, and the processing device communicates with the current detection device and is further configured to:

[0047] Determine the change in current of the wire feeding motor during the process of driving the cold wire to feed out the preset wire length;

[0048] Once the current change is determined to be within a preset fine-tuning range, the positioning adjustment mechanism is controlled to fine-tune the angle between the cold wire and the guide bevel surface, so that the outer end of the cold wire moves to the bottom of the root region of the surface to be welded of another workpiece.

[0049] Optionally, the processing device is further configured to:

[0050] The guide bevel surface is determined to be a flat surface;

[0051] The positioning adjustment mechanism is controlled to position the cold wire parallel to the guide bevel surface of one of the workpieces.

[0052] Optionally, the wire feeding drive mechanism includes a wire feeding motor and a current detection device, the current detection device being configured to continuously detect the current of the wire feeding motor during welding, and the processing device communicating with the current detection device and being further configured to:

[0053] The fusion status of the cold wire and the molten pool is determined based on the current of the wire feeding motor.

[0054] The wire feeding frequency of the wire feeding motor is adjusted according to the fusion condition between the cold wire and the molten pool.

[0055] Optionally, the scanning detection device is further configured as follows:

[0056] During the welding process, the cross-sectional shape of each bevel is tracked and detected along the welding direction.

[0057] The processing device is further configured as follows:

[0058] The wire feeding drive mechanism and the positioning adjustment mechanism are controlled according to the currently detected bevel cross-sectional shape to drive the cold wire to produce a corresponding displacement, so that the outer end of the cold wire always remains in contact with the bottom of the molten pool.

[0059] Optionally, the processing device is further configured to:

[0060] The bevel formed between the two workpieces is determined to be a double-sided bevel.

[0061] Select one of the bevel surfaces on the workpiece as the guide bevel surface;

[0062] The wire feeding drive mechanism and the positioning adjustment mechanism are controlled to move the cold wire at an angle along the guide bevel surface on one of the workpieces and into the bevel root gap until the outer end of the cold wire abuts the bottom of the bevel blunt edge region of the other workpiece.

[0063] By employing the cold wire filling technology of this invention, the cold wire can be adaptively pre-positioned based on the actual bevel shape before arc initiation. During pre-positioning, the cold wire is inclinedly fed into the root gap of the bevel along the guide bevel surface on one of the workpieces. After pre-positioning, the outer end of the cold wire abuts against the bottom of the root area of ​​the surface to be welded on the other workpiece, thereby pre-feeding the outer end of the cold wire to the bottom of the position where the molten pool will be formed during welding. In this way, by reasonably adjusting the wire feeding frequency according to the fusion condition between the outer end of the cold wire and the molten pool during welding, the outer end of the cold wire can always maintain contact with the bottom of the molten pool, ensuring stable cold wire filling and welding. The melting of the outer end of the cold wire can increase the solidification rate of the bottom of the molten pool, effectively preventing weld leaks without the need for ceramic backing, thereby effectively improving the welding quality, welding speed, and automation level of the arc welding process.

[0064] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0065] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the following detailed description to explain the invention, but do not constitute a limitation thereof. In the drawings:

[0066] Figure 1 This is a schematic flowchart of a cold wire filling method for arc welding in a specific embodiment of the present invention.

[0067] Figure 2 Based on Figure 1 A flowchart illustrating an optional method for step S3 in the process;

[0068] Figure 3 A schematic diagram of the cross-section when a double-sided V-shaped groove is formed between two workpieces to be welded;

[0069] Figure 4 In order to be in Figure 3 A schematic diagram showing how a cold wire is filled using a cold wire filling method for arc welding process according to a specific embodiment of the present invention before welding two workpieces;

[0070] Figure 5 In order to be in Figure 3 A schematic diagram showing how a cold wire is filled using a cold wire filling method for arc welding process according to a specific embodiment of the present invention when welding two workpieces;

[0071] Figure 6 for Figure 5 A diagram from another perspective;

[0072] Figure 7 A schematic diagram of the cross-section when a single-sided V-shaped bevel is formed between two workpieces to be welded;

[0073] Figure 8 A schematic diagram of the cross-section when a double V-shaped bevel is formed between two workpieces to be welded;

[0074] Figure 9 This is a schematic diagram of a cold wire filling control system for an arc welding process according to a specific embodiment of the present invention;

[0075] Figure 10 This is a schematic diagram of a cold wire control assembly according to a specific embodiment of the present invention.

[0076] Explanation of reference numerals in the attached figures:

[0077] 1. Hot wire 2. Cold wire

[0078] 3. Workpiece 4. Bevel

[0079] 5. Molten pool 6. Processing equipment

[0080] 7. Wire feeding drive mechanism 8. Position adjustment mechanism

[0081] 9. Scanning and Inspection Equipment

[0082] 3a Bevel face; 3b Bevel blunt edge region

[0083] 3c Root area of ​​the surface to be welded; 4a Bevel root gap.

[0084] 7a Wire feeding motor 7b Wire feeding drive mechanism

[0085] 7c Wire feed length detection equipment; 7d Current detection equipment

[0086] 8a Cold wire welding torch 9a Laser beam Detailed Implementation

[0087] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0088] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0089] In the embodiments of the present invention, unless otherwise stated, directional terms such as "upper," "lower," "top," and "bottom" are generally used to describe the relative positional relationships of the components in relation to the directions shown in the accompanying drawings or in relation to the vertical, perpendicular, or gravitational directions.

[0090] The present invention will now be described in detail with reference to the accompanying drawings and exemplary embodiments.

[0091] like Figure 1 , Figures 3 to 8 As shown, a first exemplary embodiment of the present invention provides a cold wire filling method for an arc welding process, the method comprising:

[0092] Step S1: Inspect the bevel shape between the two workpieces 3 to be welded before igniting the hot wire 1;

[0093] Step S2: Determine the guide bevel surface based on the bevel shape;

[0094] Step S3: The cold wire 2 is inclined along the guide bevel surface on one of the workpieces 3 and fed into the bevel root gap 4a until the outer end of the cold wire 2 abuts the bottom of the root area 3c of the surface to be welded on the other workpiece 3.

[0095] The specific execution of the above steps varies slightly depending on the bevel shape, and examples will be provided below for further explanation.

[0096] exist Figure 3 In this embodiment, the bevel 4 formed between the two workpieces 3 to be welded is a double-sided V-shaped bevel. At this time, the surface to be welded of each workpiece 3 is composed of a bevel surface 3a and a bevel blunt edge region 3b. A bevel root gap 4a is formed between the two bevel blunt edge regions 3b of the two workpieces 3. At this time, the bevel blunt edge region 3b is equivalent to the root region 3c of the surface to be welded.

[0097] After performing step S1, the current bevel shape can be detected as a double-sided V-shaped bevel. When performing step S2, one of the two bevel surfaces 3a can be selected as the guide bevel surface, for example, referring to... Figure 4 Select the bevel surface 3a on the workpiece 3 located on the left as the guide bevel surface. During step S3, the cold wire 2 is inclinedly fed into the bevel root gap 4a along the guide bevel surface of one of the workpieces 3 until the outer end of the cold wire 2 abuts the bottom of the bevel blunt edge region 3b of the other workpiece 3. For example, refer to... Figure 4 The cold wire 2 is fed obliquely into the bevel root gap 4a along the guide bevel surface on the workpiece 3 located on the left, and is fed until the outer end of the cold wire 2 abuts the bottom of the bevel blunt edge region 3b of the workpiece 3 located on the right. Note that this step is also applicable to other double bevels (such as double U-shaped bevels).

[0098] exist Figure 7 In this embodiment, the bevel 4 formed between the two workpieces 3 to be welded is a single-sided V-shaped bevel. At this time, the surface to be welded on the right side of the workpiece 3 has not been machined with a bevel surface, and the surface to be welded on the left side of the workpiece 3 consists of a bevel surface 3a and a bevel blunt edge region 3b. A bevel root gap 4a is formed between the bevel blunt edge region 3b and the root region 3c of the surface to be welded on the right side of the workpiece 3.

[0099] After performing step S1, the current bevel shape is detected as a single-sided V-shaped bevel. In step S2, the bevel surface 3a on the workpiece 3 on the left is used as the guide bevel surface. In step S3, the cold wire 2 is inclined and fed into the bevel root gap 4a along the guide bevel surface on the workpiece 3 on the left, until the outer end of the cold wire 2 abuts against the bottom of the root region 3c of the surface to be welded on the workpiece 3 on the right. Note that this step also applies to other single-sided bevels (such as J-shaped bevels).

[0100] exist Figure 8 In this embodiment, the bevel 4 formed between the two workpieces 3 to be welded is a double V-shaped bevel, which can be understood as two bevels 4. At this time, the welding surface of each workpiece 3 is composed of two bevel surfaces 3a and a bevel blunt edge region 3b located between the two bevel surfaces 3a, and a bevel root gap 4a is formed between the two bevel blunt edge regions 3b of the two workpieces 3.

[0101] Figure 8 The two bevels 4 are usually welded sequentially. After welding the first bevel 4, the deposited metal in the bevel root gap 4a needs to be removed before welding the second bevel 4. Therefore, before welding both bevels 4, the cold wire 2 can be pre-positioned in the bevel root gap 4a. However, due to the different bevel shapes of individual bevels 4... Figure 3 The bevel shape is the same in the embodiments, therefore it can be referred to Figure 3 The steps S1 to S3 are performed in the manner described in the embodiments, and will not be repeated here.

[0102] As can be seen from the above examples, the method of this exemplary embodiment is suitable for application under a variety of different bevel shapes, and has a certain degree of flexibility and versatility. Of course, in addition to the three bevel shapes listed above, the applicability of the method of this exemplary embodiment to other bevel shapes is not limited. For example, when the bevel surface 3a is a curved surface or other non-flat surface, the method of this exemplary embodiment may also be applicable.

[0103] Regardless of whether the bevel surface 3a is flat, when performing step S3, it is not necessary to make the cold wire 2 completely conform to the contour of the bevel surface 3a for wire feeding. It is sufficient to make the cold wire 2 feed along the inclined direction roughly defined by the bevel surface 3a to meet the requirements of the step.

[0104] On the other hand, despite Figure 3 , Figure 7 and Figure 8In this embodiment, both workpieces 3 are positioned by butt welding, but this does not preclude the applicability of the method of this exemplary embodiment to other workpiece positioning methods (e.g., positioning by fillet welding). In fact, as long as the bevel shape meets the applicability requirements of the method, it is acceptable.

[0105] By employing the method of this exemplary embodiment, the cold wire 2 can be adaptively pre-positioned based on the actual bevel shape before arc initiation. During pre-positioning, the cold wire 2 is inclinedly fed into the root gap 4a of the bevel along the guide bevel surface on one of the workpieces 3. After pre-positioning, the outer end of the cold wire 2 abuts against the bottom of the root region 3c of the surface to be welded on the other workpiece 3, thereby pre-feeding the outer end of the cold wire 2 to the bottom of the position where the molten pool 5 will be formed during welding. In this way, by reasonably adjusting the wire feeding frequency according to the fusion condition between the outer end of the cold wire 2 and the molten pool 5 during welding, the outer end of the cold wire 2 can always be kept in contact with the bottom of the molten pool 5, ensuring cold wire filling and welding stability. The melting of the outer end of the cold wire 2 can increase the solidification speed of the bottom of the molten pool 5, effectively avoiding weld leakage without the need for ceramic backing, thereby effectively improving the welding formation quality, welding speed, and automation level of the arc welding process.

[0106] In an optional or preferred embodiment, refer to Figure 2 Step S3 includes:

[0107] Step S31: Place the cold wire 2 along the guide bevel surface of one of the workpieces 3;

[0108] Step S32: Incline the cold wire 2 into the bevel root gap 4a and feed it into the preset wire feeding length;

[0109] Step S33: Determine that the outer end of the cold wire 2 abuts against the bottom of the root region 3c of the surface to be welded of another workpiece 3.

[0110] The purpose of step S31 is to initially position the cold wire 2, ensuring that it can be fed into the bevel root gap 4a during the subsequent step S32, and that even if the outer end of the cold wire 2 deviates from the bottom of the root region 3c of the surface to be welded of another workpiece 3, the deviation will not be too great. The purpose of step S33 is to precisely position the cold wire 2. This step should include determining the position of the outer end of the cold wire 2, and determining whether to fine-tune the position of the cold wire 2 based on the result of this position determination, so that after step S33, the outer end of the cold wire 2 abuts against the bottom of the root region 3c of the surface to be welded of the other workpiece 3.

[0111] In an optional or preferred embodiment, refer to Figure 10The wire feeding action of the cold wire 2 is driven by the wire feeding motor 7a. It is known that when the load on the wire feeding motor 7a changes, its current also changes. After step S32 is completed, there are three possible positions for the outer end of the cold wire 2: Ideally, the outer end of the cold wire 2 should be exactly touching the bottom of the root region 3c of the surface to be welded on another workpiece 3; in another scenario, the outer end of the cold wire 2 touches the root region 3c of the surface to be welded on another workpiece 3 before the preset wire feeding length is reached, causing the outer end to deviate from the accurate position after the preset wire feeding length is reached; and in the third scenario, the cold wire 2 is suspended in the air, and its outer end fails to touch the root region 3c of the surface to be welded on another workpiece 3. In these three positions, the force acting on the outer end of the cold wire 2 is different, resulting in different loads on the wire feeding motor 7a. Therefore, the change in current of the wire feeding motor 7a is also different throughout the entire wire feeding process.

[0112] Based on the above, as long as the current change of the wire feeding motor 7a in the above three cases is determined in advance, it is possible to determine whether the outer end of the cold wire 2 just touches the bottom of the root region 3c of the surface to be welded of another workpiece 3 by detecting the current change of the wire feeding motor 7a when executing step S33.

[0113] Therefore, step S33 may include:

[0114] Step S331: Determine the change in current of the wire feeding motor 7a during the process of driving the cold wire 2 to feed out the preset wire length;

[0115] Step S332: Determine that the change in current is within the preset ideal range, and keep the position of the cold wire 2 unchanged.

[0116] In other words, when the current change of the wire feeding motor 7a during the process of driving the cold wire 2 to feed out the preset wire length is detected to be within the preset ideal range, it can be determined that the outer end of the cold wire 2 just touches the bottom of the root area 3c of the surface to be welded of another workpiece 3. At this time, there is no need to fine-tune the position of the cold wire 2.

[0117] Alternatively, step S33 may also include:

[0118] Step S332': Determine that the current change is within the preset fine-tuning range, and fine-tune the angle between the cold wire 2 and the guide bevel surface so that the outer end of the cold wire 2 moves to the bottom of the root region 3c of the surface to be welded of another workpiece 3.

[0119] In other words, when the current change of the wire feeding motor 7a during the process of driving the cold wire 2 to feed out the preset wire length is detected to be within the preset fine adjustment range, it can be determined that the outer end of the cold wire 2 has not reached the bottom of the root area 3c of the surface to be welded of another workpiece 3. At this time, the position of the cold wire 2 needs to be finely adjusted until the outer end of the cold wire 2 is in the correct position.

[0120] In an optional or preferred embodiment, when the guide bevel surface is flat, the cold wire 2 can be placed parallel to the guide bevel surface when it is placed along the guide bevel surface of one of the workpieces 3, so as to achieve the initial positioning of the cold wire 2.

[0121] In an optional or preferred embodiment, the wire feeding action of the cold wire 2 is driven by the wire feeding motor 7a. As mentioned above, the current of the wire feeding motor 7a changes when the load changes. During the welding process, refer to... Figure 5 and Figure 6 The cold wire 2 will fuse with the molten pool 5. When the fusion of the cold wire 2 and the molten pool 5 is different, the force on the cold wire 2 will also be different, which will also cause the load of the wire feeding motor 7a to be different. Accordingly, the current of the wire feeding motor 7a will also be different.

[0122] Therefore, by conducting relevant experiments, the correspondence between the current of the wire feeding motor 7a and the fusion status of the cold wire 2 and the molten pool 5 can be obtained. By detecting the current of the wire feeding motor 7a during the welding process, the current fusion status of the cold wire 2 and the molten pool 5 can be determined based on this correspondence.

[0123] Specifically, cold wire filling methods may also include:

[0124] The current of the wire feed motor 7a is continuously monitored during the welding process;

[0125] The fusion status of the cold wire 2 and the molten pool 5 is determined based on the current of the wire feeding motor 7a.

[0126] Adjust the wire feeding frequency of the wire feeding motor 7a according to the fusion condition of the cold wire 2 and the molten pool 5.

[0127] Through the above steps, the wire feeding frequency of the wire feeding motor 7a can be adjusted in real time during the welding process, so that the outer end of the cold wire 2 can always keep in contact with the bottom of the molten pool 5, thereby ensuring the stability of cold wire filling and welding stability, and effectively improving the welding quality.

[0128] In an optional or preferred embodiment, refer to Figure 5 and Figure 6 Cold wire filling methods also include:

[0129] During the welding process, the cross-sectional shape of each bevel is tracked and detected along the welding direction.

[0130] Based on the current tracked and detected bevel cross-sectional shape, the cold wire 2 is driven to produce a corresponding displacement, so that the outer end of the cold wire 2 always remains in contact with the bottom of the molten pool 5.

[0131] The reason for setting up the above steps is that when arranging the two workpieces 3 to be welded, it is difficult to ensure that the cross-sectional shape of the bevel 4 remains consistent along the welding direction due to factors such as machining accuracy and positioning accuracy. This often results in excessive assembly gaps. If the cross-sectional shape of the bevel is not monitored in real time during welding, it becomes difficult to adjust the position of the cold wire 2 when the gap between the two workpieces 3 is too large, which can easily lead to weld leaks and other issues affecting welding quality. By performing the above steps, this weld leak problem can be solved, effectively improving the quality of the weld formation.

[0132] A second exemplary embodiment of the present invention provides a cold wire filling control system for an arc welding process, capable of executing the cold wire filling method described above. Therefore, the various embodiments of the cold wire filling control system described below can obviously also obtain the technical effects brought about by the corresponding embodiments of the above method. Thus, for the various embodiments described below, only their structural features or the additional technical effects brought about by these structural features are described, without repeating the foregoing content.

[0133] Reference Figure 9 The cold wire filling control system of this exemplary embodiment includes:

[0134] The cold wire control assembly includes a cold wire 2, a wire feeding drive mechanism 7 capable of driving the cold wire 2 to perform wire feeding actions, and a position adjustment mechanism 8 capable of adjusting the position of the cold wire 2.

[0135] The scanning and inspection equipment 9 is capable of detecting the bevel morphology between the two workpieces 3 to be welded before the arc-ignition hot wire 1 is lit; and

[0136] Processing device 6 communicates with the wire feeding drive mechanism 7, the positioning adjustment mechanism 8, and the scanning detection device 9, respectively, and is configured as follows:

[0137] The guide bevel surface is determined based on the bevel morphology obtained from the scanning and detection device 9;

[0138] The wire feeding drive mechanism 7 and the positioning adjustment mechanism 8 are controlled to feed the cold wire 2 at an angle along the guide bevel surface on one of the workpieces 3 into the bevel root gap 4a and feed it in until the outer end of the cold wire 2 abuts the bottom of the root region 3c of the surface to be welded on the other workpiece 3.

[0139] It should be noted that, referring to Figure 10The wire feeding drive mechanism 7 may include a wire feeding motor 7a and a wire feeding transmission mechanism 7b. Driven by the wire feeding motor 7a, the wire feeding transmission mechanism 7b drives the cold wire 2 to stably perform the wire feeding action. The positioning adjustment mechanism 8 includes a cold wire welding gun 8a, in which the cold wire 2 passes. During the wire feeding action, the outer end of the cold wire 2 is ejected from the port of the cold wire welding gun 8a. The positioning adjustment mechanism 8 adjusts the cold wire welding gun 8a to synchronously adjust the positioning of the cold wire 2. According to the figure, the cold wire welding gun 8a can be displaced at least in the vertical direction, the horizontal direction, and the rotational direction to execute the instructions of the processing equipment 6 and position the cold wire 2 along the guide bevel surface on one of the workpieces 3.

[0140] The scanning and inspection device 9 can be a device with scanning and inspection functions, such as a laser sensor, a vision sensor, or an ultrasonic sensor. For example, when using a laser sensor, the laser sensor can scan the bevel shape through the laser beam 9a, and the processing device 6 establishes a coordinate system based on the bevel shape to calculate the bevel face angle, and then precisely adjusts the rotation angle of the cold wire welding gun 8a.

[0141] By employing the cold wire filling control system of this exemplary embodiment, the cold wire filling action can be performed manually during arc welding, which can greatly improve the automation level of the arc welding process, thereby improving welding speed and welding quality.

[0142] In an optional or preferred embodiment, the wire feeding drive mechanism 7 includes a wire feeding length detection device 7c for detecting the wire feeding length of the cold wire 2. For example, the wire feeding length detection device 7c can be a rotary encoder, etc. The processing device 6 communicates with the wire feeding length detection device 7c, and the wire feeding length information is fed back in real time through the wire feeding length detection device 7c, which helps the processing device 6 to accurately control the wire feeding length of the cold wire 2. In this setting, the processing device 6 is further configured as follows:

[0143] Control the movement of the positioning adjustment mechanism 8 to position the cold wire 2 along the guide bevel surface of one of the workpieces 3;

[0144] Control the operation of the wire feeding drive mechanism 7 to tilt and feed the cold wire 2 into the bevel root gap 4a to a preset wire feeding length;

[0145] Make sure the outer end of the cold wire 2 abuts against the bottom of the root region 3c of the surface to be welded of another workpiece 3.

[0146] In an optional or preferred embodiment, the wire feeding drive mechanism 7 includes a wire feeding motor 7a and a current detection device 7d for detecting the current of the wire feeding motor 7a. For example, the current detection device 7d may be a Hall sensor or the like. The processing device 6 communicates with the current detection device 7d to obtain current information of the wire feeding motor 7a from the current detection device 7d. In this configuration, the processing device 6 is further configured to:

[0147] Determine the change in current of the wire feeding motor 7a during the process of driving the cold wire 2 to feed out a preset wire length;

[0148] Ensure that the change in current is within the preset ideal range, and control the position of the cold wire 2 to remain unchanged.

[0149] Alternatively, processing device 6 may be further configured as follows:

[0150] Determine the change in current of the wire feeding motor 7a during the process of driving the cold wire 2 to feed out a preset wire length;

[0151] Once the current change is determined to be within the preset fine-tuning range, the position adjustment mechanism 8 is controlled to fine-tune the angle between the cold wire 2 and the guide bevel surface, so that the outer end of the cold wire 2 moves to the bottom of the root region 3c of the surface to be welded of another workpiece 3.

[0152] Of course, to determine whether the outer end of the cold wire 2 is in contact with the bottom of the root area 3c of the surface to be welded of another workpiece 3, other types of sensors such as force sensors can also be used for detection and judgment.

[0153] In an optional or preferred embodiment, the processing device 6 is further configured as follows:

[0154] Ensure the guide bevel surface is flat;

[0155] The positioning adjustment mechanism 8 is controlled to position the cold wire 2 parallel to the guide bevel surface of one of the workpieces 3.

[0156] In an optional or preferred embodiment, the wire feeding drive mechanism 7 includes a wire feeding motor 7a and a current detection device 7d, the current detection device 7d being configured to continuously detect the current of the wire feeding motor 7a during welding. The processing device 6 communicates with the current detection device 7d to acquire current information of the wire feeding motor 7a from the current detection device 7d during welding. In this configuration, the processing device 6 is further configured to:

[0157] The fusion status of the cold wire 2 and the molten pool 5 is determined based on the current of the wire feeding motor 7a.

[0158] Adjust the wire feeding frequency of the wire feeding motor 7a according to the fusion condition of the cold wire 2 and the molten pool 5.

[0159] In an optional or preferred embodiment, the scanning detection device 9 is further configured as follows:

[0160] During the welding process, the cross-sectional shape of each bevel is tracked and detected along the welding direction.

[0161] Processing device 6 is further configured as follows:

[0162] The wire feeding drive mechanism 7 and the positioning adjustment mechanism 8 are controlled according to the current tracked and detected bevel cross-sectional shape to drive the cold wire 2 to produce a corresponding displacement, so that the outer end of the cold wire 2 always remains in contact with the bottom of the molten pool 5.

[0163] For example, when the scanning and detection device 9 is a laser sensor, the laser sensor can scan the cross-sectional shape of the bevel at the position to be welded through the laser beam 9a during the welding process, so that the processing device 6 can adjust the position of the cold wire 2 accordingly.

[0164] In an optional or preferred embodiment, the processing device 6 is further configured as follows:

[0165] The bevel 4 formed between the two workpieces 3 is determined to be a double-sided bevel;

[0166] Select one of the bevel surfaces 3a on workpiece 3 as the guide bevel surface;

[0167] The wire feeding drive mechanism 7 and the positioning adjustment mechanism 8 are controlled to feed the cold wire 2 at an angle along the guide bevel surface on one of the workpieces 3 into the bevel root gap 4a and into the bevel until the outer end of the cold wire 2 abuts the bottom of the bevel blunt edge region 3b of the other workpiece 3.

[0168] When the bevel 4 is in other bevel shapes (such as the aforementioned single-sided V-shaped bevel, J-shaped bevel, double V-shaped bevel, etc.), the configuration of the processing device 6 in this embodiment can be adapted.

[0169] The optional embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the embodiments of the present invention are not limited to the specific details in the above embodiments. Within the scope of the technical concept of the embodiments of the present invention, various simple modifications can be made to the technical solutions of the embodiments of the present invention, and these simple modifications all fall within the protection scope of the embodiments of the present invention.

[0170] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the embodiments of the present invention will not describe the various possible combinations separately.

[0171] Furthermore, various different implementations of the present invention can be combined arbitrarily, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed in the present invention.

Claims

1. A cold wire filling method for arc welding process, comprising: detecting a bevel profile between two workpieces (3) to be welded before igniting a hot wire (1) ; determining a guide bevel surface according to the bevel profile; driving a cold wire (2) to perform a wire feeding action by a driving mechanism (7), and adjusting the position of the cold wire (2) by a position adjusting mechanism (8), so that the cold wire (2) is inclined along the guide bevel surface on one of the workpieces (3) and fed into a root gap (4a), and fed to a position where the outer end of the cold wire (2) abuts against the bottom of a root area (3c) of a welding surface of the other workpiece (3).

2. The cold wire filler method for an electric arc welding process according to claim 1, wherein, inclining the cold wire (2) along the guide bevel surface on one of the workpieces (3) and feeding it into the root gap (4a), and feeding it to a position where the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the welding surface of the other workpiece (3) comprises: positioning the cold wire (2) along the guide bevel surface on one of the workpieces (3) ; inclining the cold wire (2) into the root gap (4a) by a preset wire feeding length; determining that the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the welding surface of the other workpiece (3).

3. The cold wire filler method for an electric arc welding process of claim 2 wherein, The wire feeding action of the cold wire (2) is driven by a wire feeding motor (7a), and determining that the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the welding surface of the other workpiece (3) comprises: determining the current change amount of the wire feeding motor (7a) during driving the cold wire (2) to feed out the preset wire feeding length; determining that the current change amount is within a preset ideal range, and keeping the position of the cold wire (2) unchanged.

4. The cold wire filler method for an electric arc welding process of claim 2 wherein, The wire feeding action of the cold wire (2) is driven by a wire feeding motor (7a), and determining that the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the welding surface of the other workpiece (3) comprises: determining the current change amount of the wire feeding motor (7a) during driving the cold wire (2) to feed out the preset wire feeding length; determining that the current change amount is within a preset fine adjustment range, and fine adjusting the included angle of the cold wire (2) relative to the guide bevel surface, so that the outer end of the cold wire (2) moves to abut against the bottom of the root area (3c) of the welding surface of the other workpiece (3).

5. The cold wire filler method for an electric arc welding process of claim 2 wherein, The guide bevel surface is a flat surface, and when the cold wire (2) is positioned along the guide bevel surface on one of the workpieces (3), the cold wire (2) is parallel to the guide bevel surface.

6. The cold wire filler method for an electric arc welding process of claim 1 wherein, The wire feeding action of the cold wire (2) is driven by a wire feeding motor (7a), and the cold wire filling method further comprises: continuously detecting the current of the wire feeding motor (7a) during welding; determining the fusion condition of the cold wire (2) with a molten pool (5) according to the current of the wire feeding motor (7a) ; adjusting the wire feeding frequency of the wire feeding motor (7a) according to the fusion condition of the cold wire (2) with the molten pool (5).

7. The cold wire filler method for an electric arc welding process of claim 1 wherein, The cold wire filling method further comprises: tracking and detecting each bevel cross-sectional profile in the welding direction during welding; According to the detected cross-sectional shape of the groove, the cold wire (2) is driven to generate a corresponding displacement, so that the outer end of the cold wire (2) always remains in contact with the bottom of the molten pool (5).

8. The cold wire filler method for an electric arc welding process of claim 1, wherein, The guide groove face is determined according to the groove shape, which comprises: The groove (4) formed between the two workpieces (3) is determined as a double-sided groove; The groove face (3a) on one of the workpieces (3) is selected as the guide groove face; The cold wire (2) is inclined along the guide groove face on one of the workpieces (3) and is sent into the groove root gap (4a) until the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the to-be-welded surface of the other workpiece (3), which comprises: The outer end of the cold wire (2) abuts against the bottom of the groove fillet area (3b) of the other workpiece (3).

9. A cold wire filling control system for an electric arc welding process, comprising: a cold wire control assembly, including a cold wire (2), a wire feeding driving mechanism (7) capable of driving the cold wire (2) to perform a wire feeding action, and a position adjusting mechanism (8) capable of adjusting the position of the cold wire (2); a scanning detection device (9) capable of detecting the groove shape between the two workpieces (3) to be welded before an arc ignition hot wire (1) is ignited; and a processing device (6) in communication with the wire feeding driving mechanism (7), the position adjusting mechanism (8), and the scanning detection device (9), respectively, and configured to: determine a guide groove face according to the groove shape obtained from the scanning detection device (9); control the wire feeding driving mechanism (7) and the position adjusting mechanism (8) to act, respectively, so that the cold wire (2) is inclined along the guide groove face on one of the workpieces (3) and is sent into the groove root gap (4a) until the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the to-be-welded surface of the other workpiece (3). The wire feeding driving mechanism (7) includes a wire feeding length detection device (7c) for detecting the wire feeding length of the cold wire (2), and the processing device (6) is in communication with the wire feeding length detection device (7c) and is further configured to:

10. The cold wire fill control system for an electric arc welding process of claim 9, wherein, control the position adjusting mechanism (8) to act so that the cold wire (2) is positioned along the guide groove face of one of the workpieces (3); control the wire feeding driving mechanism (7) to act so that the cold wire (2) is inclined into the groove root gap (4a) by a preset wire feeding length; determine that the outer end of the cold wire (2) abuts against the bottom of the root area (3c) of the to-be-welded surface of the other workpiece (3). The wire feeding driving mechanism (7) includes a wire feeding motor (7a) and a current detection device (7d) for detecting the current of the wire feeding motor (7a), and the processing device (6) is in communication with the current detection device (7d) and is further configured to:

11. The cold wire fill control system for an electric arc welding process of claim 10, wherein, determine the current variation of the wire feeding motor (7a) during the process of driving the cold wire (2) to feed out the preset wire feeding length; determine that the current variation is within a preset ideal range, and control the position of the cold wire (2) to remain unchanged. ​ 12. The cold wire fill control system for an electric arc welding process of claim 10, wherein, The wire feeding driving mechanism (7) comprises a wire feeding motor (7a) and a current detection device (7d) for detecting the current of the wire feeding motor (7a), the processing device (6) is in communication with the current detection device (7d) and is further configured to: determine the current variation of the wire feeding motor (7a) in the process of driving the cold wire (2) to feed out the preset wire feeding length; determine that the current variation is within a preset fine adjustment range, control the positioning adjustment mechanism (8) to act, so as to fine adjust the included angle of the cold wire (2) relative to the guide groove surface, and move the outer end of the cold wire (2) to the bottom of the root area (3c) of the welding surface of the other workpiece (3).

13. The cold wire fill control system for an electric arc welding process of claim 10, wherein, The processing device (6) is further configured to: determine that the guide groove surface is a flat surface; control the positioning adjustment mechanism (8) to act, so as to position the cold wire (2) parallel to the guide groove surface of one of the workpieces (3).

14. The cold wire fill control system for an electric arc welding process of claim 9, wherein, The wire feeding driving mechanism (7) comprises a wire feeding motor (7a) and a current detection device (7d), the current detection device (7d) is configured to continuously detect the current of the wire feeding motor (7a) during welding, the processing device (6) is in communication with the current detection device (7d) and is further configured to: determine the fusion of the cold wire (2) and the molten pool (5) according to the current of the wire feeding motor (7a); adjust the wire feeding frequency of the wire feeding motor (7a) according to the fusion of the cold wire (2) and the molten pool (5).

15. The cold wire fill control system for an electric arc welding process of claim 9, wherein, The scanning detection device (9) is further configured to: track and detect each groove cross section shape in the welding direction during welding; The processing device (6) is further configured to: control the wire feeding driving mechanism (7) and the positioning adjustment mechanism (8) to act according to the groove cross section shape currently tracked and detected, so as to drive the cold wire (2) to generate corresponding displacement, so that the outer end of the cold wire (2) always remains in contact with the bottom of the molten pool (5).

16. The cold wire fill control system for an electric arc welding process of claim 9, wherein, The processing device (6) is further configured to: determine that the groove (4) formed between the two workpieces (3) is a double-sided groove; select the groove surface (3a) on one of the workpieces (3) as the guide groove surface; respectively control the wire feeding driving mechanism (7) and the positioning adjustment mechanism (8) to act, so as to tilt the cold wire (2) along the guide groove surface on one of the workpieces (3) into the groove root gap (4a) and to the bottom of the groove fillet region (3b) of the other workpiece (3).

Images