Quickly-replaceable full-digital wire feeder for underwater complex working conditions

Abstract

The application provides a quick-replacement full-digital wire feeder for underwater complex working conditions, which comprises a wire feeder shell, a quick-release fixed connection base, a wire feeder welding wire rack, a wire feeder mechanism assembly, a quick-replacement wire feeding control motor module, a gas feeding electromagnetic valve module, an arc voltage feedback function component, and a data relay control box; the wire feeder welding wire rack, the wire feeder mechanism assembly, the quick-replacement wire feeding control motor module, the gas feeding electromagnetic valve module, the arc voltage feedback function component, the data relay control box, and a manual jogging control module are respectively installed on the wire feeder shell; and the wire feeder shell and the quick-release fixed connection base are detachably connected. The wire feeder can be quickly replaced between manual welding equipment and robot welding equipment, has good underwater welding capability, good portability, and can well cooperate with other welding equipment to realize high-quality welding operation, and comprehensively meets the needs of manual welding, robot automatic welding, and underwater welding working conditions.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of underwater welding, more particularly to a quick-replaceable full-digital wire feeder for underwater complex working conditions. BACKGROUND

[0002] With the increasing exploration and development of marine space and resources, the demand for marine engineering technology is becoming increasingly urgent. Underwater welding technology is a key research topic in marine engineering construction and operation, which has extremely complex working condition challenges and high professional technical content, and advanced underwater welding equipment is an important basis for the application of underwater welding technology. The underwater welding wire feeder is one of the main components of underwater welding equipment. The existing manual diving welding operation is limited by water depth and has low welding efficiency, but due to its strong engineering adaptability, this operation mode will exist for a long time in engineering applications. The existing underwater welding robot automatic welding operation has developed rapidly and can complete high-efficiency underwater welding operation under certain working conditions; therefore, underwater welding operation often coexists with manual and automatic methods. If a machine can be used for multiple purposes, it can be suitable for both manual welding and automatic welding, which can greatly improve the convenience, but the current wire feeder can only meet one of the use requirements.

[0003] In addition, when facing complex working conditions, the existing underwater welding robot automatic welding operation has poor adaptability, and its welding precision, stability and automation degree still need to be improved. Therefore, it is necessary to improve the underwater welding wire feeder with digital technology and improve its automatic welding operation capability.

[0004] During underwater welding, it is necessary to ensure the stable combustion of the welding arc under the influence of factors such as water pressure, which must rely on the stable wire feeding of the underwater wire feeder, which requires an advanced wire feeder to have an arc-wire feeding speed feedback control system and multiple wire feeding modes such as uniform speed, variable speed and pulse wire feeding.

[0005] In the application scenario of manual diving welding, the requirements for underwater welding wire feeder are accurate point movement, stable wire feeding speed and good portability, and in the application scenario of underwater robot automatic welding, the requirements for underwater welding wire feeder are full-digital automatic wire feeding, complex variable speed wire feeding and simple and efficient control. In summary, a digital wire feeder that can quickly switch between manual welding operation and robot automatic welding operation, and has high-precision wire feeding control and arc pressure feedback function, will greatly improve the efficiency of various engineering construction. SUMMARY

[0006] The present application aims to overcome the shortcomings and deficiencies in the prior art, and provides a quick replacement type full-digital wire feeder for underwater complex working conditions; the wire feeder can be quickly replaced between manual welding equipment and robot welding equipment, has good underwater welding capability, good portability, can well cooperate with other welding equipment to realize high-quality welding operation, comprehensively meets the needs of manual welding, robot automatic welding and underwater welding working conditions, and realizes one machine with multiple uses.

[0007] In order to achieve the above-mentioned purpose, the present application is implemented by the following technical scheme: a quick replacement type full-digital wire feeder for underwater complex working conditions, comprising:

[0008] A wire feeder shell;

[0009] A quick-release fixed connection base for installation with a welding robot device;

[0010] A wire feeder wire reel rack for placing a welding wire reel;

[0011] A wire feeder mechanism assembly for pressing and conveying welding wire in the welding wire reel outward;

[0012] A quick-change wire feeding control motor module for providing power to the wire feeder mechanism assembly so that the wire feeder mechanism assembly drives the welding wire to be conveyed outward;

[0013] A gas electromagnetic valve module for controlling the delivery of welding protection gas and drainage gas used in underwater local dry welding;

[0014] An arc voltage feedback function component for sampling arc voltage data;

[0015] An artificial jogging control module for realizing artificial control;

[0016] And a data relay control box for receiving signals of the arc voltage feedback function component and outputting signals to the quick-change wire feeding control motor module and the gas electromagnetic valve module;

[0017] The wire feeder wire reel rack, the wire feeder mechanism assembly, the quick-change wire feeding control motor module, the gas electromagnetic valve module, the arc voltage feedback function component, the data relay control box and the artificial jogging control module are respectively installed in the wire feeder shell; the wire feeder shell and the quick-release fixed connection base are detachably connected.

[0018] Preferably, the data relay control box comprises a wire feeding main control driving board, a wire feeding working state and parameter display screen, a wire feeding mode switching knob and a wire feeding power supply switch; the wire feeding main control driving board receives welding wire feeding task instructions from an external welding power supply device, or receives variable-speed wire feeding task instructions from an external welding robot, and displays the current wire feeding mode, wire feeding task type and wire feeding speed on the wire feeding working state and parameter display screen.

[0019] Preferably, the wire feeding master control drive board comprises a master control chip, a display screen SPI interaction module, a key knob GPIO input module, a gas feeding electromagnetic valve control GPIO output module, an RS485 communication module, a CAN communication module, a motor drive PWM output module, an ADC current sampling module, an ADC overvoltage and overtemperature active protection sampling module, a motor rotor encoder ENCODER input module, a jog digital speed regulation TIMER input module, and an arc voltage feedback ADC input module.

[0020] Preferably, the wire feeding mechanism assembly comprises a wire feeding pressure mechanism, a wire feeding pressure wheel gear transmission mechanism, and a wire feeding assembly rack; the wire feeding pressure mechanism is installed in the middle of the wire feeding assembly rack and is used for pressing the welding wire and adjusting the pressure; the wire feeding pressure wheel gear transmission mechanism is engaged with the wire feeding pressure mechanism gear and is connected with the quick-change wire feeding control motor module through a shaft coupling to conduct torque and rotational speed; the wire feeding pressure mechanism and the wire feeding pressure wheel gear transmission mechanism make the welding wire be fed in a straight line; the wire outlet of the wire feeding assembly rack is directly connected with the welding gun docking interface on the wire feeder shell.

[0021] Preferably, the quick-change wire feeding control motor module comprises a quick-change motor support and an underwater servo wire feeding motor; the underwater servo wire feeding motor adopts a self-waterproof permanent magnet synchronous motor or a stepping motor; the underwater servo wire feeding motor can be quickly replaced according to different working conditions, welding modes, and cost requirements; the quick-change motor support is connected with the underwater servo wire feeding motor in advance, the output shaft of the underwater servo wire feeding motor passes through the motor mounting hole on the wire feeder shell and is connected with the wire feeding mechanism assembly through a shaft coupling; when the underwater servo wire feeding motor is replaced, the quick-change motor support is fastened to the wire feeder shell through a screwing piece, and the motor shaft of the underwater servo wire feeding motor is fixed by using a jack on the shaft coupling.

[0022] Preferably, when the underwater servo wire feeding motor adopts a permanent magnet synchronous motor, a rotor position encoder is integrated at the rear of the permanent magnet synchronous motor for sensing the change of the conduction rotor position of the permanent magnet synchronous motor; the underwater servo wire feeding motor and the rotor position encoder are respectively connected with the data relay control box signal.

[0023] Preferably, the drive algorithm of the permanent magnet synchronous motor adopts a model predictive control algorithm.

[0024] The model predictive control algorithm refers to: setting the target rotational speed ω ref of the permanent magnet synchronous motor, obtaining the target torque current and the target excitation current The rotor position encoder obtains actual rotating speed ω by data differential operation; the current sampling data obtained by sampling in the data relay control box is obtained by Clarke transformation and Park transformation to obtain actual torque current i q and actual excitation current i d ; the actual rotating speed ω, actual torque current i q and actual excitation current i d are input into a discretized motor system model to predict current prediction value at next switching time and combined with eight kinds of vector voltage states of the voltage type three-phase inverter in the data relay control box and target torque current and target excitation current to calculate value function J:

[0025]

[0026] Wherein, k is the current time value, k+1 represents the next time value;

[0027] The optimal vector voltage state is obtained by solving the finite set optimization problem.

[0028] Preferably, the quick release fixing connection base is connected with the quick release structure of the wire feeder shell bottom, and is fastened by the second screwing part; the wire feeding mechanism assembly is connected to the wire feeder shell through the second screwing part, so that the relative position of the wire feeding mechanism assembly and the wire feeder shell is fixed during the wire feeding process.

[0029] Preferably, the gas feeding electromagnetic valve module is installed at the front part of the wire feeder shell and includes two electromagnetic valves; one of the electromagnetic valves controls the welding protective gas delivery, and the other electromagnetic valve controls the water drainage gas delivery for underwater local dry welding; each electromagnetic valve is connected with the data relay control box; the gas outlet end of the gas feeding electromagnetic valve module is directly connected with the double-way gas feeding output interface, and the gas inlet end is connected with the external gas cylinder through a gas pipe.

[0030] Preferably, the manual jogging control module is installed at the top of the wire feeder shell and is provided with a wire feeding speed adjusting knob, a wire feeding direction knob and a jogging wire feeding button; the wire feeding speed adjusting knob on the manual jogging control module is connected with the data relay control box and outputs pulse code signals to the data relay control box; the wire feeding direction knob and the jogging wire feeding button are respectively connected with the data relay control box to send the jogging wire feeding control signals.

[0031] Preferably, the arc pressure feedback functional part includes a positive end metal sampling connector and a negative end sampling fixed terminal; the positive end metal sampling connector is used as a welding gun docking interface and is installed at the wire outlet of the wire feeding mechanism assembly; the negative end sampling fixed terminal is used as a negative cable transfer terminal and is installed at the bottom surface of the wire feeder shell.

[0032] The working principle of the quick-replaceable full-digital wire feeder for underwater complex working conditions of the application is that an external power supply is used to power the quick-replaceable full-digital wire feeder for underwater complex working conditions of the application, and the power input is controlled by a wire feeding power supply switch on a data transfer control box. A wire feeding main control drive board in the data transfer control box detects the state of a wire feeding mode switching knob to determine the working mode of the wire feeder. The wire feeding main control drive board outputs an initial motor drive pulse to an underwater servo wire feeding motor through a wire feeding motor power port and detects the signal of a wire feeding motor rotor position encoder data port to judge the type of the underwater servo wire feeding motor. The wire feeding main control drive board controls the display of the current wire feeding mode, wire feeding task type and wire feeding speed on the wire feeding working state and parameter display screen. The type of the underwater servo wire feeding motor is self-identified through whether there is an encoder signal; if there is no encoder signal, it is determined that the motor is a stepper motor.

[0033] In the robot welding working condition, the quick-release fixed connection base is installed on the robot, and the quick-release structure at the bottom of the wire feeder shell is embedded into the quick-release fixed connection base. The data transfer control box receives welding wire feeding task instructions from the external welding robot through the CAN communication cable, including wire feeding step, wire feeding speed, wire feeding direction and wire feeding motor torque instructions. When a permanent magnet synchronous motor is selected as the underwater servo wire feeding motor, the rotor position encoder in the quick-replaceable wire feeding control motor module outputs encoding data to the wire feeding main control drive board, and the wire feeding main control drive board outputs motor drive signals to the quick-replaceable wire feeding control motor module after combining and processing the current data sampled from the motor, the welding wire feeding task instructions and the encoding data. The quick-replaceable wire feeding control motor module transmits torque and speed to the wire feeding pressure wheel gear transmission mechanism in the wire feeding mechanism assembly through a shaft coupling, and cooperates with the friction force provided by the wire feeding pressure mechanism to feed the welding wire to the welding torch connected to the welding gun interface. The data transfer control box receives gas feeding control instructions from the external welding power supply device through the RS485 communication cable, and outputs electromagnetic valve control signals to the gas feeding electromagnetic valve module according to the instructions. The wire feeding main control drive board feeds back and adjusts the wire feeding speed by collecting the welding arc voltage at the positive metal sampling joint and the negative sampling fixed terminal in the arc voltage feedback function part. When the underwater servo wire feeding motor is selected as a permanent magnet synchronous motor, the robot welding wire feeding application model predictive control algorithm is used.

[0034] In the manual welding working condition, the quick release structure of the wire feeder shell is separated from the quick release fixed connection base. The data relay control box receives the jog wire feeding control signal and the pulse encoding signal of the wire feeding speed knob through the jog control signal port. The data relay control box receives the gun switch signal from the external welding gun through the welding gun press switch signal port. At this time, the data relay control box outputs the motor drive signal to the quick change wire feeding control motor module. Only when the gun switch instruction is received, the data relay control box receives the welding wire feeding task instruction from the external welding power source through the RS485 communication cable, and the data relay control box outputs the electromagnetic air valve control signal to the air feeding electromagnetic air valve module and collects the welding arc voltage through the arc voltage feedback function component to realize the arc voltage feedback function.

[0035] Compared with the prior art, the present application has the following advantages and beneficial effects:

[0036] 1. The present application adopts quick release and quick change design: the connection between the wire feeder shell and the quick release fixed connection base can be quickly disassembled, and only needs to be pre-installed on the welding robot equipment, so that the quick switching from manual welding scene to robot welding scene can be realized.

[0037] 2. The present application, the quick change wire feeding control motor module can select permanent magnet synchronous motor or stepping motor as underwater servo wire feeding motor according to different working conditions, welding modes and cost requirements; the wire feeding main control drive board can self-identify the type of underwater servo wire feeding motor; when the permanent magnet synchronous motor is selected as the underwater servo wire feeding motor, the model predictive control algorithm can be applied to realize precise jog wire feeding and complex variable speed wire feeding with high dynamic response performance; when the stepping motor is selected as the underwater servo wire feeding motor, compared with the traditional PWM modulated wire feeding motor, the wire feeding speed control stability is also better, and the wire feeding precision is higher, so that the underwater servo wire feeding motor can be selected as the stepping motor in simple welding demand and low cost scene, so as to simplify the control system and reduce the cost. BRIEF DESCRIPTION OF DRAWINGS

[0038] Figure 1 is one of the structure schematic diagrams of the quick change underwater complex working condition full digital wire feeder of the present application;

[0039] Figure 2 is the second structure schematic diagram of the quick change underwater complex working condition full digital wire feeder of the present application;

[0040] Figure 3 is the third structure schematic diagram of the quick change underwater complex working condition full digital wire feeder of the present application;

[0041] Figure 4 is the motor quick change structure schematic diagram of the quick change underwater complex working condition full digital wire feeder of the present application;

[0042] Figure 5 This is a schematic diagram of the quick-release structure of the fully digital wire feeder for complex underwater working conditions of the present invention.

[0043] Figure 6 This is the control principle diagram of the fully digital wire feeder for quick-change underwater complex working conditions of the present invention;

[0044] Figure 7 This is a schematic diagram of the model predictive control algorithm for the fully digital wire feeder for rapid-change underwater complex working conditions of this invention. Detailed Implementation

[0045] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0046] Example

[0047] The present invention relates to a quick-change fully digital wire feeder for complex underwater working conditions, such as... Figures 1 to 5 As shown, the device includes a wire feeder housing 110, a data transfer control box 120, a wire feeding mechanism assembly 130, a quick-change wire feeding control motor module 140, a quick-release fixed connection base 150, an air supply solenoid valve module 160, a manual jog control module 170, an arc voltage feedback function component 180, and a wire feeder wire spool holder 190. The outer surface of the wire feeder housing 110 has a welding torch docking interface 111, a dual-channel air supply output interface 112, and a wire feeder control cable connector 113. The data transfer control box 120 is placed above the water surface during operation. It includes a main wire feeding control drive board installed inside the box, and a wire feeding working status and parameter display screen, a wire feeding mode switching knob, and a wire feeding power supply switch installed on the box surface. An external power supply is used, controlled by the wire feeding power supply switch on the data transfer control box 120, to power the quick-change fully digital underwater wire feeder of this invention for complex working conditions.

[0048] The data relay control box 120 is connected with the external welding power supply device through RS485 communication cable, the data relay control box 120 is connected with the external welding robot device through CAN communication cable, the data relay control box 120 is connected with the wire feeder control cable total joint 113 on the wire feeder shell 110 through the wire feeder control bus cable. The wire feeder assembly 130 is installed in the wire feeder shell 110 through bolt connection, which includes wire feeder pressing mechanism 131, wire feeder pressing wheel gear transmission mechanism 132 and wire feeder assembly rack 133. The wire feeder pressing mechanism 131 is used to press the welding wire and can adjust the pressing force. The wire feeder pressing wheel gear transmission mechanism 132 is engaged with the wire feeder pressing mechanism 131 gear. The layout of the wire feeder pressing mechanism 131 and the wire feeder pressing wheel gear transmission mechanism 132 in the wire feeder assembly rack 133 will ensure that the welding wire is sent out in a straight line. The wire outlet of the wire feeder assembly rack 133 is directly connected with the welding gun docking interface 111 on the wire feeder shell 110. The gas feeding electromagnetic valve module 160 is bolted to the front of the wire feeder shell 110, which includes two-way gas feeding electromagnetic valve 161. The gas outlet of the two-way gas feeding electromagnetic valve is connected with the double-way gas feeding output interface 112, one way controls the welding protective gas delivery, the other way controls the drainage gas delivery used for underwater local dry welding. The manual jogging control module 170 is connected to the top of the wire feeder shell 110 through sealing glue, which includes wire feeder speed adjusting knob 171, wire feeder direction knob 172 and jogging wire feeder button 173 installed on the surface of the module. The arc pressure feedback function component 180 includes positive end metal sampling joint 181 and negative end sampling fixed terminal 182. The positive end metal sampling joint 181 is also used for the connection of the welding gun and the wire feeder assembly 130 and is connected with the welding gun docking interface 111, and the negative end sampling fixed terminal 182 is also used for the welding negative cable connection to the welding power supply through the wire feeder and is installed on the bottom surface of the wire feeder shell 110. The wire feeder welding wire rack 190 is bolted to the rear of the wire feeder shell 110, which includes damping shaft 191 and welding wire rack 192. The welding wire rack 192 is sleeved on the damping shaft 191, and the damping shaft 191 is used to prevent the welding wire rack 192 from rotating randomly to make the welding wire scattered and cause the wire feeder to be stuck.

[0049] The quick-change wire feeding control motor module 140 comprises a quick-release motor bracket 141 and an underwater servo wire feeding motor 142. The quick-release motor bracket 141 is connected with the underwater servo wire feeding motor 142 in advance, and the output shaft of the underwater servo wire feeding motor 142 passes through the motor mounting hole on the wire feeder shell 110 and is connected with the wire feeding mechanism assembly 130 through a coupling. When the underwater servo wire feeding motor 142 is quickly replaced, the quick-release motor bracket 141 is fixed to the wire feeder shell 110 through bolts, and the motor shaft of the replaced underwater servo wire feeding motor 142 is fixed by using the jack screw on the coupling. The quick-release fixed connection base 150 is pre-installed at a suitable position of the welding robot, and the wire feeder shell 110 is designed with a quick-release structure that can be embedded with the quick-release fixed connection base 150. When the wire feeder is switched from the manual welding mode to the robot welding mode, the wire feeder shell 110 is embedded into the quick-release fixed connection base 150 and fixed through bolts, so that the relative position of the wire feeding mechanism assembly and the wire feeder shell is fixed during the wire feeding process.

[0050] As Figure 6As shown, the control system of the quick-replaceable full-digital wire feeder for underwater complex working conditions of the application takes a wire feeding main control driving board as a control core, the wire feeding main control driving board includes a main control chip, a display screen SPI interaction module, a key knob GPIO input module, a gas feeding electromagnetic valve control GPIO output module, an RS485 communication module, a CAN communication module, a motor driving PWM output module, an ADC current sampling module, an ADC overvoltage and overtemperature active protection sampling module, a motor rotor encoder ENCODER input module, a jog digital speed regulation TIMER input module and an arc voltage feedback ADC input module. The main control chip adopts an STM32F407RGT6. The display screen SPI interaction module is connected to a wire feeding working state and parameter display screen through an SPI communication bus to control the display content. The key knob GPIO input module is connected to a wire feeding direction knob 172 and a jog wire feeding button 173 on a manual jog control module 170, a press gun button connected to an external welding gun and a wire feeding mode switching knob connected to a data relay control box 120 through GPIO pins of the main control chip, receives and detects their level state signals and is respectively used for controlling the jog wire feeding direction, the jog wire feeding start-stop, the manual welding start-stop and the wire feeding mode switching. The gas feeding electromagnetic valve control GPIO output module is connected with a gas feeding electromagnetic valve module 160 and controls the opening and closing of a gas feeding electromagnetic valve 161 through GPIO level output. The RS485 communication module includes USART function pins of the main control chip and a 485 chip connected thereto and communicates with an external welding power source through an RS485 communication protocol. The CAN communication module includes CAN function pins of the main control chip and a CAN chip connected thereto and communicates with an external welding robot through a CAN communication protocol. The motor driving PWM output module includes GPIO function pins of the main control chip and a brushless motor driving chip DRV8301 and a stepper motor driver connected thereto, and a voltage type three-phase inverter connected with the brushless motor driving chip DRV8301, the output of the voltage type three-phase inverter and the output of the stepper motor driver are used for driving underwater servo wire feeding motors 142 of permanent magnet synchronous motor and stepper motor types. The ADC current sampling module includes two sampling resistors connected with the voltage type three-phase inverter and two current sampling operational amplifiers, the output of the current sampling operational amplifier is connected to the ADC pin of the main control chip, and the current sampling data is used for the operation of the model prediction control of the underwater servo wire feeding motor 142 by the main control chip. The ADC overvoltage and overtemperature active protection sampling module includes two voltage sampling operational amplifiers connected to both ends of a bus voltage dividing resistor and both ends of a thermistor respectively, and a one-way active brake half-bridge connected to the GPIO pin of the main control chip, the output of the voltage sampling operational amplifier is connected to the ADC pin of the main control chip, and the active brake half-bridge is used for actively releasing the bus energy when overvoltage.The motor rotor encoder ENCODER input module includes the ENCODER pin of the main control chip and a magnetic encoder chip connected thereto, and is used for receiving and processing rotor position encoder data from the underwater servo wire feeding motor 142. The motor drive PWM output module outputs an initial motor drive pulse to the underwater servo wire feeding motor 142, and the signal received by the motor rotor encoder ENCODER input module can be used to determine the type of the underwater servo wire feeding motor 142. The jog digital speed TIMER input module is connected to the wire feeding speed knob 171 of the manual jog control module 170 from the TIMER pin of the main control chip, and receives the pulse coded signal thereof. The arc voltage feedback ADC input module is connected to the output end of the arc voltage sampling amplifier from the ADC pin of the main control chip, and the input end of the arc voltage sampling amplifier is connected to the arc voltage feedback function part 180.

[0051] As shown in Figure 7 When the permanent magnet synchronous motor is selected as the underwater servo wire feeding motor 140, the model predictive control algorithm is applied to the quick-replaceable underwater full-digital wire feeder for complex working conditions of the present application. Compared with the traditional PI-FOC control algorithm, the model predictive control algorithm has the advantages of simple system, simplified parameter adjustment process and better variable speed and variable torque dynamic response performance, and can be used to realize the complex variable speed wire feeding function. The principle is as follows: the target speed ω ref The target torque current i and the target excitation current i The actual speed ω is obtained by differentiating the rotor position encoder data received by the motor rotor encoder ENCODER input module, the actual torque current i q and the actual excitation current i d are obtained by current sampling data of the ADC current sampling module through Clarke transformation and Park transformation. The actual speed ω, the actual torque current i q and the actual excitation current i d are input into the discretized motor system model to predict the current prediction value at the next switching time and Further combined with the eight kinds of vector voltage states of the voltage type three-phase inverter in the motor drive PWM output module and the target torque current i and the target excitation current i The value function J is calculated:

[0052]

[0053] Wherein, k is the current time value, k+1 represents the next time value;

[0054] Solving the finite set optimization problem, the optimal vector voltage state is obtained, and the underwater servo wire feeding motor 140 is driven by the motor driving PWM output module to operate.

[0055] The waterproof design of the application includes using a self-waterproof permanent magnet synchronous motor or a stepping motor as the underwater servo wire feeding motor 140, all cables and joints use IP68 waterproof cables and waterproof aviation joints, and waterproof glue filling glue static sealing treatment is used at the air feeding electromagnetic air valve module 160 and the manual jogging control module 170.

[0056] The above embodiment is the preferred embodiment of the application, but the embodiment of the application is not limited by the above embodiment, and any change, modification, substitution, combination, simplification made without departing from the spirit and principle of the application should be an equivalent replacement method, which is included in the protection scope of the application.

Claims

1. A quick-change type full-digital wire feeder for underwater complex working conditions, characterized in that: The application relates to a welding wire feeder, which comprises the following parts: a welding wire feeder shell; a quick-release fixed connection base for installation with a welding robot device; a welding wire feeder wire reel rack for placing a welding wire reel; a welding wire feeder mechanism assembly for pressing and conveying welding wire in a welding wire reel outward; a quick-change welding wire feeder control motor module for providing power to the welding wire feeder mechanism assembly so that the welding wire feeder mechanism assembly drives the welding wire to be conveyed outward; a gas valve module for controlling the conveying of shielding gas and drainage gas used in underwater local dry welding; an arc voltage feedback function component for sampling arc voltage data; a manual jog control module for manual control; and a data relay control box for receiving signals of the arc voltage feedback function component and outputting signals to the quick-change welding wire feeder control motor module and the gas valve module; the welding wire feeder wire reel rack, the welding wire feeder mechanism assembly, the quick-change welding wire feeder control motor module, the gas valve module, the arc voltage feedback function component, the data relay control box and the manual jog control module are respectively installed in the welding wire feeder shell; the welding wire feeder shell is detachably connected with the quick-release fixed connection base; the welding wire feeder mechanism assembly comprises a welding wire feeder pressing mechanism, a welding wire feeder pressing wheel gear transmission mechanism and a welding wire feeder assembly rack; the welding wire feeder pressing mechanism is installed in the middle part of the welding wire feeder assembly rack and is used for pressing and adjusting the pressing force of the welding wire; the welding wire feeder pressing wheel gear transmission mechanism is in gear engagement with the welding wire feeder pressing mechanism and is connected with the quick-change welding wire feeder control motor module through a shaft coupling to conduct torque and rotating speed; the welding wire feeder pressing mechanism and the welding wire feeder pressing wheel gear transmission mechanism enable the welding wire to be linearly fed out; a wire outlet of the welding wire feeder assembly rack is directly connected with a welding gun docking interface on the welding wire feeder shell; the quick-change welding wire feeder control motor module comprises a quick-change motor support and an underwater servo welding wire feeder motor; the underwater servo welding wire feeder motor is a self-waterproof permanent magnet synchronous motor or a stepping motor; the quick-change motor support is connected with the underwater servo welding wire feeder motor in advance; an output shaft of the underwater servo welding wire feeder motor penetrates through a motor mounting hole on the welding wire feeder shell and is connected with the welding wire feeder mechanism assembly through a shaft coupling; when the underwater servo welding wire feeder motor is replaced, the quick-change motor support is fastened to the welding wire feeder shell through a screwing piece and the motor shaft of the underwater servo welding wire feeder motor is fixed by a jack screw on the shaft coupling.

2. The quick-change underwater complex working condition full-digital wire feeder according to claim 1, characterized in that: the data relay control box comprises a welding wire feeder main control driving board, a welding wire feeder working state and parameter display screen, a welding wire feeder mode switching knob and a welding wire feeder power supply switch; the welding wire feeder main control driving board receives welding wire feeding task instructions from an external welding power supply device or receives variable-speed welding wire feeding task instructions from an external welding robot and displays the current welding wire feeding mode, welding wire feeding task type and welding wire feeding speed on the welding wire feeder working state and parameter display screen.

3. The quick-change underwater complex working condition full-digital wire feeder according to claim 2, characterized in that: The wire feeding master control driving board comprises a master control chip, a display screen SPI interaction module, a key knob GPIO input module, a gas feeding electromagnetic valve control GPIO output module, an RS485 communication module, a CAN communication module, a motor driving PWM output module, an ADC current sampling module, an ADC overvoltage and overtemperature active protection sampling module, a motor rotor encoder ENCODER input module, a jog digital speed regulation TIMER input module and an arc voltage feedback ADC input module.

4. The quick-change underwater complex working condition full-digital wire feeder according to claim 1, characterized in that: When the underwater servo wire feeding motor adopts a permanent magnet synchronous motor, a rotor position encoder is integrated at the rear of the permanent magnet synchronous motor to sense the change of the permanent magnet synchronous motor conduction rotor position; the underwater servo wire feeding motor and the rotor position encoder are respectively connected with the data relay control box signal.

5. The quick-change underwater complex working condition full-digital wire feeder according to claim 4, characterized in that: The driving algorithm of the permanent magnet synchronous motor adopts a model predictive control algorithm. The model predictive control algorithm is: setting a target rotating speed ω of the permanent magnet synchronous motor ref , obtaining a target torque current and a target excitation current through PI algorithm and MPTA algorithm operation; and a rotor position encoder obtains actual rotating speed ω through differential operation of data acquisition. The current sampling data obtained by sampling the data relay control box is subjected to Clarke transformation and Park transformation to obtain actual torque current i q and actual field current i d ; The actual rotational speed ω, the actual torque current i q and the actual field current i d are jointly input into the discretized motor system model to predict the current prediction value at the next switching time and combine the eight vector voltage states of the voltage type three-phase inverter in the data center control box and the target torque current and the target field current to calculate the value function J: Wherein, k is the current time value, and k+1 represents the next time value. The optimal vector voltage state is obtained by solving the finite set optimization problem.

6. The quick-change underwater complex working condition full-digital wire feeder according to claim 1, characterized in that: The quick release is connected with the quick release structure of the fixing connection base and the bottom of the wire feeder shell, and is fastened by the second screwing element.

7. The quick-change underwater complex working condition full-digital wire feeder according to claim 1, characterized in that: The gas feeding electromagnetic valve module comprises two-way electromagnetic valves; one-way electromagnetic valve controls the welding protection gas delivery, and the other way electromagnetic valve controls the drainage gas delivery for underwater local dry welding; each way electromagnetic valve is connected with the data relay control box signal.

8. The quick-change underwater complex working condition full-digital wire feeder according to claim 1, characterized in that: The manual jog control module is provided with a wire feeding speed regulation knob, a wire feeding direction knob and a jog wire feeding button; the wire feeding speed regulation knob on the manual jog control module is connected with the data relay control box signal and outputs pulse code signals to the data relay control box; the wire feeding direction knob and the jog wire feeding button are respectively connected with the data relay control box signal to send the jog wire feeding control signal. The arc voltage feedback function component comprises a positive end metal sampling joint and a negative end sampling fixed terminal; the positive end metal sampling joint is installed at the wire outlet of the wire feeding mechanism assembly; and the negative end sampling fixed terminal is installed at the bottom surface of the wire feeder shell.

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