A pulse control and waveform adjustment method and apparatus for welding rust-proof painted plates.

Abstract

This invention discloses a pulse control and waveform adjustment method and apparatus for welding rust-proof painted plates, belonging to the field of rust-proof painted plate welding technology. The method includes acquiring initial values ​​of pulse waveform parameters before welding begins and the actual output pulse peak voltage Us at the start of welding, wherein the initial values ​​of pulse waveform parameters include a voltage anomaly determination voltage Ua; determining whether an abnormal voltage has occurred by comparing the actual output pulse peak voltage Us and the voltage anomaly determination voltage Ua; changing the pulse control mode from variable period to fixed period control mode when an abnormal voltage occurs; calculating new pulse waveform parameter values ​​using Us and Ua, and adjusting the pulse waveform using the new pulse waveform parameter values. This invention effectively reduces the impact of rust-proof paint on welding through pulse control and pulse waveform adjustment, achieving the effect of normal welding without prior grinding.

Description

Technical Field

[0001] This invention relates to a pulse control and waveform adjustment method and device for welding rust-proof painted plates, belonging to the field of rust-proof painted plate welding technology. Background Technology

[0002] With the rapid development of welding technology, the application of gas metal arc welding (GMAW) has become increasingly common and widespread, and welding technologies based on GMAW are emerging one after another.

[0003] Gas metal arc welding (GMAW), as one of the most widely used welding processes, has the following advantages: ① high efficiency and fast welding speed; ② deep penetration and small welding deformation; ③ ability to weld in various positions, offering high flexibility; ④ open arc operation, facilitating observation of the molten pool and arc. With the widespread application of GMAW, higher demands have been placed on welding speed and quality, leading to the development of pulsed GMAW. Pulsed GMAW possesses advantages not found in traditional GMAW, including a more stable welding process, less spatter, and less material loss. During production, welders can perform workpiece welding manually or using robots. However, in welding production, instability can sometimes occur during pulsed welding due to the influence of on-site conditions and base material.

[0004] To prevent steel from rusting, manufacturers often spray a layer of anti-rust paint onto the steel surface. However, the presence of this paint can cause instability in the pulse welding process during welding, leading to abnormal arcs and a decline in weld quality, which can even result in product scrap in severe cases.

[0005] Enhancing the adaptability of pulse welding to anti-rust paint and minimizing its impact on the welding process is a major challenge in gas metal arc welding (GMAW). Generally, when welding anti-rust painted plates, the welding area needs to be ground before welding, followed by surface spraying after welding. This method is time-consuming and labor-intensive, hindering welding efficiency. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a pulse control and waveform adjustment method and device for welding anti-rust paint plates. By adjusting the pulse control method and pulse waveform, the influence of anti-rust paint on welding can be effectively reduced, achieving the effect of normal welding without prior grinding.

[0007] To achieve the above objectives, the present invention is implemented using the following technical solution:

[0008] In a first aspect, the present invention provides a pulse control and waveform adjustment method for welding rust-proof painted plates, comprising:

[0009] Obtain the initial values ​​of the pulse waveform parameters before welding begins and the actual output pulse peak voltage Us at the start of welding. The initial values ​​of the pulse waveform parameters include the voltage anomaly detection voltage Ua.

[0010] By comparing the actual output pulse peak voltage Us with the voltage anomaly detection voltage Ua, it is determined whether an abnormal voltage has occurred.

[0011] When an abnormal voltage occurs, the pulse control mode is changed from variable period to fixed period control mode;

[0012] Calculate new pulse waveform parameter values ​​using Us and Ua, and then adjust the pulse waveform using these new parameter values.

[0013] Furthermore, the step of determining whether an abnormal voltage has occurred by comparing the actual output pulse peak voltage Us with the voltage anomaly detection voltage Ua includes:

[0014] If the actual output pulse peak voltage Us is greater than or equal to the voltage anomaly detection voltage Ua, it is determined that no abnormal voltage has occurred;

[0015] If the actual output pulse peak voltage Us is less than the voltage anomaly detection voltage Ua, it is determined that an abnormal voltage has occurred.

[0016] Furthermore, if no abnormal voltage is detected, the pulse waveform is not adjusted. If an abnormal voltage is detected, the pulse waveform is adjusted in the next pulse cycle and the abnormality is detected again until no abnormal voltage is detected, at which point the pulse waveform adjustment process ends.

[0017] Furthermore, the initial values ​​of the pulse waveform parameters also include the first pulse fall time L1, the second pulse fall time L2, the pulse peak current I1, the pulse base current I2, and the pulse second base current I3, wherein the pulse second base current I3 is equal to the pulse base current I2 in the initial state.

[0018] Furthermore, the calculation of new pulse waveform parameter values ​​using Us and Ua includes:

[0019] The specific formulas for calculating the new pulse second fall time L2, pulse second base current I3, and pulse peak current I1 are as follows:

[0020] L2' = L2 + K1*(Us - Ua)

[0021] I3' = I3 + K2*(Us - Ua)

[0022] I1' = I1 + K3*(Us - Ua)

[0023] K1 and K2 are both negative values, while K3 is a positive value.

[0024] Furthermore, when adjusting the pulse waveform using the new pulse waveform parameter values, the first pulse fall time L1 is not adjusted, but the pulse waveform is adjusted using L2', I3', and I1'.

[0025] Secondly, the present invention provides a pulse control and waveform adjustment device for welding rust-proof painted plates, comprising:

[0026] The acquisition module is used to acquire the initial values ​​of the pulse waveform parameters before welding starts and the actual output pulse peak voltage Us at the start of welding. The initial values ​​of the pulse waveform parameters include the voltage anomaly judgment voltage Ua.

[0027] The judgment module is used to determine whether an abnormal voltage has occurred by comparing the actual output pulse peak voltage Us with the voltage abnormality judgment voltage Ua.

[0028] The pulse control adjustment module is used to change the pulse control mode from variable period to fixed period control mode when an abnormal voltage occurs.

[0029] The waveform adjustment module is used to calculate new pulse waveform parameter values ​​using Us and Ua, and then adjust the pulse waveform using these new parameter values.

[0030] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of any of the preceding methods.

[0031] Fourthly, the present invention provides a computer device / equipment / system, characterized in that it comprises:

[0032] Memory, used to store computer programs / instructions;

[0033] A processor for executing the computer program / instructions to implement the steps of any of the preceding methods.

[0034] Fifthly, the present invention provides a computer program product, including a computer program / instructions, characterized in that, when the computer program / instructions are executed by a processor, they implement the steps of any of the methods described above.

[0035] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0036] This invention provides a pulse control and waveform adjustment method and device for welding rust-proof paint plates. By adjusting the pulse control method and pulse waveform, the influence of rust-proof paint on welding is effectively reduced, achieving the effect of normal welding without prior grinding. Attached Figure Description

[0037] Figure 1 This is a pulse waveform diagram when Us≥Ua provided in an embodiment of the present invention;

[0038] Figure 2 This is a pulse waveform diagram when Us < Ua provided in an embodiment of the present invention;

[0039] Figure 3 This is an adjustment diagram of the pulse waveform provided in an embodiment of the present invention;

[0040] Figure 4 This is a flowchart of the entire welding process provided in an embodiment of the present invention. Detailed Implementation

[0041] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0042] Example 1

[0043] This embodiment describes a pulse control and waveform adjustment method for welding rust-proof painted plates, including:

[0044] Obtain the initial values ​​of the pulse waveform parameters before welding begins and the actual output pulse peak voltage Us at the start of welding. The initial values ​​of the pulse waveform parameters include the voltage anomaly detection voltage Ua.

[0045] By comparing the actual output pulse peak voltage Us with the voltage anomaly detection voltage Ua, it is determined whether an abnormal voltage has occurred.

[0046] When an abnormal voltage occurs, the pulse control mode is changed from variable period to fixed period control mode;

[0047] Calculate new pulse waveform parameter values ​​using Us and Ua, and then adjust the pulse waveform using these new parameter values.

[0048] The pulse control and waveform adjustment method for welding rust-proof paint plates provided in this embodiment involves the following steps in its application:

[0049] The first step is to record the data used in the calculation.

[0050] Before welding begins, record the first pulse fall time L1, the second pulse fall time L2, the pulse peak current I1, the pulse base current I2, the pulse second base current I3, and the voltage anomaly detection voltage Ua as the initial values ​​for the initial stage of welding. In the initial state, the pulse second base current I3 is equal to the pulse base current I2.

[0051] When welding begins, the actual output pulse peak voltage Us is recorded in real time.

[0052] The second step is to determine if there is any abnormal voltage.

[0053] The specific judgment method is as follows:

[0054] By comparing the actual output pulse peak voltage Us with the voltage anomaly detection voltage Ua, it is determined whether an abnormal voltage has occurred.

[0055] 1> Mode 1: If the actual output pulse peak voltage Us is greater than or equal to the voltage anomaly detection voltage Ua, i.e., Us≥Ua, then it is in a normal state, as shown in the attached diagram. Figure 1 As shown;

[0056] 2> Mode 2: If the actual output pulse peak voltage Us is less than the voltage anomaly detection voltage Ua, i.e., Us < Ua, then it is determined to be an abnormal voltage. This is an abnormal state, as shown in the attached diagram. Figure 2 As shown;

[0057] The third step is to adjust the waveform based on the judgment results:

[0058] 1> If Us≥Ua, no abnormality occurs, and the pulse control and waveform are not adjusted.

[0059] 2> If Us < Ua, an anomaly occurs. In this case, the output waveform is an abnormal pulse waveform, which needs to be adjusted. The adjustment steps are as follows:

[0060] The first step is to change the pulse control mode from variable period to fixed period control mode, that is, the time of each pulse cycle is consistent and does not change during welding;

[0061] The second step is pulse waveform adjustment. The first pulse fall time L1 is not adjusted. The second pulse fall time L2, the second pulse base current I3, and the pulse peak current I1 are adjusted as follows:

[0062] L2' = L2 + K1*(Us - Ua)

[0063] I3' = I3 + K2*(Us - Ua)

[0064] I1' = I1 + K3*(Us - Ua)

[0065] K1 and K2 are both negative values, and K3 is a positive value. The new value obtained is used as the new parameter of the current pulse waveform.

[0066] Through the above solutions and actual welding verification, adjusting the pulse control and waveform can achieve the purpose of adjusting the arc state, so that the improved pulse arc can be adapted to the welding of anti-rust paint plates.

[0067] Appendix Figure 1The pulse waveform diagram is shown when the actual output pulse peak voltage Us is greater than or equal to the voltage anomaly judgment voltage Ua, that is, when Us≥Ua. At this time, no anomaly has occurred, and the pulse waveform is not adjusted.

[0068] Appendix Figure 2 The pulse waveform diagram is shown when the actual output pulse peak voltage Us is less than the voltage anomaly judgment voltage Ua, i.e., Us < Ua. At this time, it is judged that an anomaly has occurred and the pulse waveform needs to be adjusted.

[0069] Appendix Figure 3 This is an adjustment diagram of the pulse waveform. After an abnormality is detected, the pulse waveform is adjusted. For specific adjustment methods, please refer to the above text. The adjustment trend of the pulse waveform is: the pulse peak current I1 decreases, the pulse second base current I3 increases, the pulse first fall time L1 remains unchanged, and the pulse second fall time L2 increases.

[0070] By adjusting the pulse waveform, the following electric arc state can be presented:

[0071] 1. By adjusting the pulse waveform, the welding capability of the pulse arc for rust-proof paint plates can be improved.

[0072] 2. Regardless of how the pulse waveform is adjusted, a stable one-pulse-one-droplet transition state can be guaranteed, and the arc maintains good stability throughout the entire welding process.

[0073] It should be noted that this patent does not explicitly specify the corresponding relationship between the adjustment amounts of the pulse peak current, the pulse second base current, the pulse first fall time, and the pulse second fall time when adjusting the pulse waveform. The adjustment amounts of the four can change with the welding material, shielding gas, or welding conditions, but as long as they conform to the overall trend of current waveform adjustment, they are within the protection scope of this patent.

[0074] Appendix Figure 4 This is a flowchart of the entire welding process. When the welding machine is turned on, before welding begins, the initial values ​​for the following pulse parameters are set: first pulse fall time L1, second pulse fall time L2, peak pulse current I1, base pulse current I2, second base pulse current I3, and voltage anomaly detection voltage Ua.

[0075] When welding begins, the actual output pulse peak voltage Us is recorded in real time, and the relationship between the actual output pulse peak voltage Us and the voltage anomaly judgment voltage Ua is compared to determine whether an anomaly has occurred. If no anomaly is found, the pulse waveform is not adjusted. If an anomaly is found, the pulse waveform is adjusted in the next pulse cycle and the anomaly is judged again until no anomaly is found, at which point the pulse waveform adjustment process ends.

[0076] Example 2

[0077] This embodiment provides a pulse control and waveform adjustment device for welding rust-proof painted plates, including:

[0078] The acquisition module is used to acquire the initial values ​​of the pulse waveform parameters before welding starts and the actual output pulse peak voltage Us at the start of welding. The initial values ​​of the pulse waveform parameters include the voltage anomaly judgment voltage Ua.

[0079] The judgment module is used to determine whether an abnormal voltage has occurred by comparing the actual output pulse peak voltage Us with the voltage abnormality judgment voltage Ua.

[0080] The pulse control adjustment module is used to change the pulse control mode from variable period to fixed period control mode when an abnormal voltage occurs.

[0081] The waveform adjustment module is used to calculate new pulse waveform parameter values ​​using Us and Ua, and then adjust the pulse waveform using these new parameter values.

[0082] Example 3

[0083] This embodiment provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of any of the methods described in Embodiment 1.

[0084] Example 4

[0085] This embodiment provides a computer device / equipment / system, characterized in that it includes:

[0086] Memory, used to store computer programs / instructions;

[0087] A processor for executing the computer program / instructions to implement the steps of any of the methods described in Embodiment 1.

[0088] Example 5

[0089] This embodiment provides a computer program product, including a computer program / instructions, characterized in that, when the computer program / instructions are executed by a processor, they implement the steps of any of the methods described in Embodiment 1.

[0090] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

[0091] Those skilled in the art will understand that embodiments of this disclosure can be provided as methods, systems, or computer program products. Therefore, this disclosure can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this disclosure can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0092] This disclosure is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create a machine for implementing the flowchart illustrations. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0093] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0094] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0095] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this disclosure and not to limit its protection scope. Although this disclosure has been described in detail with reference to the above embodiments, those skilled in the art should understand that after reading this disclosure, they can still make various changes, modifications or equivalent substitutions to the specific implementation of the invention, but these changes, modifications or equivalent substitutions are all within the protection scope of the pending claims.

Claims

1. A pulse control and waveform adjustment method for welding rust-proof painted plates, characterized in that, include: Obtain the initial values ​​of the pulse waveform parameters before welding begins and the actual output pulse peak voltage Us at the start of welding. The initial values ​​of the pulse waveform parameters include the voltage anomaly detection voltage Ua. By comparing the actual output pulse peak voltage Us with the voltage anomaly detection voltage Ua, it is determined whether an abnormal voltage has occurred. When an abnormal voltage occurs, the pulse control mode is changed from variable period to fixed period control mode; Calculate new pulse waveform parameter values ​​using Us and Ua, and then adjust the pulse waveform using these new pulse waveform parameter values. The step of determining whether an abnormal voltage has occurred by comparing the actual output pulse peak voltage Us with the voltage anomaly detection voltage Ua includes: If the actual output pulse peak voltage Us is greater than or equal to the voltage anomaly detection voltage Ua, it is determined that no abnormal voltage has occurred; If the actual output pulse peak voltage Us is less than the voltage anomaly detection voltage Ua, it is determined that an abnormal voltage has occurred. If no abnormal voltage is detected, the pulse waveform is not adjusted. If an abnormal voltage is detected, the pulse waveform is adjusted in the next pulse cycle and the abnormality is detected again until no abnormal voltage is detected, at which point the pulse waveform adjustment process ends. The calculation of new pulse waveform parameter values ​​using Us and Ua includes: The specific formulas for calculating the new pulse second fall time L2', pulse second base current I3', and pulse peak current I1' are as follows: L2' = L2 + K1 * (Us - Ua) I3' = I3 + K2 * (Us - Ua) I1' = I1 + K3 * (Us - Ua) Where L2 is the initial second pulse fall time, I3 is the initial second pulse base current, I1 is the initial pulse peak current, K1 and K2 are both negative, and K3 is positive.

2. The pulse control and waveform adjustment method for welding rust-proof paint plates according to claim 1, characterized in that, The initial values ​​of the pulse waveform parameters also include the first pulse fall time L1, the second pulse fall time L2, the pulse peak current I1, the pulse base current I2, and the pulse second base current I3, wherein the pulse second base current I3 is equal to the pulse base current I2 in the initial state.

3. The pulse control and waveform adjustment method for welding rust-proof painted plates according to claim 2, characterized in that, When adjusting the pulse waveform using the new pulse waveform parameter values, the first pulse fall time L1 is not adjusted, and the pulse waveform is adjusted using L2', I3', and I1'.

4. A pulse control and waveform adjustment device for welding rust-proof painted steel sheets, used to implement the pulse control and waveform adjustment method for welding rust-proof painted steel sheets according to any one of claims 1-3, characterized in that, include: The acquisition module is used to acquire the initial values ​​of the pulse waveform parameters before welding starts and the actual output pulse peak voltage Us at the start of welding. The initial values ​​of the pulse waveform parameters include the voltage anomaly judgment voltage Ua. The judgment module is used to determine whether an abnormal voltage has occurred by comparing the actual output pulse peak voltage Us with the voltage abnormality judgment voltage Ua. The pulse control adjustment module is used to change the pulse control mode from variable period to fixed period control mode when an abnormal voltage occurs. The waveform adjustment module is used to calculate new pulse waveform parameter values ​​using Us and Ua, and then adjust the pulse waveform using these new parameter values.

5. A computer-readable storage medium having a computer program stored thereon, characterized in that: When executed by a processor, the program implements the steps of the method described in any one of claims 1-3.

6. A computer device / equipment / system, characterized in that, include: Memory, used to store computer programs / instructions; A processor for executing the computer program / instructions to implement the steps of the method according to any one of claims 1-3.

7. A computer program product comprising a computer program / instructions, characterized in that, When the computer program / instructions are executed by the processor, they implement the steps of the method described in any one of claims 1-3.

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