Synchronous wire feeding power assisting device, system and method without buffer
Through the synchronous wire feeding power assist device without buffer, a wire pulling motor with fixed torque and fixed speed is used, combined with a wire press handle and wire feeding conduit, the problem of high difficulty in synchronous control of dual motors is solved, and efficient and stable wire conveying is achieved , reducing costs and complexity.
Patent Information
- Application Number
- CN202411462212.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-18
- Publication Date
- 2024-12-24
AI Technical Summary
In push-pull wire welding systems, the synchronization control of the dual motor is difficult, which increases cost and complexity, and the method of adding buffers to achieve synchronization results in wire deformation and threading difficulties.
Using a synchronous wire feeding power assist device without buffers, the fixed torque of the power-supported wire pusher and the fixed speed of the wire drawing motor are adjusted through resistance changes, so as to achieve synchronous operation of the dual motors, and through the wire pressing handle and feeding Wire conduit ensures stable delivery of the welding wire.
It reduces system complexity and cost, reduces welding wire breakpoints, improves the stability of wire feeding and simplicity of wire threading, and realizes efficient synchronous control of dual motors.
Smart Images
Figure CN119175430A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of welding technology, and in particular to a buffer-free synchronous wire feeding assist device, system and method. Background Art
[0002] During consumable electrode welding, a wire feeder is required to feed the welding wire to the welding gun conductive tip. The stability of wire feeding is an important factor in determining the quality of the welding process. Unstable wire feeding will directly lead to unstable welding arc, resulting in uneven weld formation, incomplete welding and other welding defects.
[0003] In some special cases, due to the large resistance of wire feeding or the low power of the power-assisted wire pusher, the stability of wire feeding cannot be guaranteed by controlling a single motor. At this time, two motors are generally needed for wire feeding. The one that performs power-assisted wire feeding at the back is called a wire pusher, and the one that performs wire feeding at the front is called a wire drawing machine. The wire pusher overcomes most of the rear-end resistance and pushes the welding wire into the wire feeding tube. The wire drawing machine steadily delivers the welding wire to the conductive nozzle to complete a stable welding process. The dual-motor wire feeding welding control system is also called a push-wire welding system.
[0004] In the push-pull wire welding system, the synchronization problem of dual motors has always been a difficult control point. Some researchers have proposed dual motor master-slave control strategy, parallel control strategy, etc., but in actual applications, due to different application conditions, different motor types, different actual welding materials, etc., it is difficult to ensure the absolute synchronization of the two motors. Even if synchronization can be achieved, it also places high requirements on hardware such as motors, controllers, and speed sensors, which not only increases costs and increases the difficulty of control, but also fails to achieve ideal control effects.
[0005] In order to reduce the difficulty of synchronous control of dual motors and achieve the effect of stable wire feeding, some researchers have added a first-level welding wire buffer device between the two motors. After the wire pusher pushes the welding wire into the buffer device, it will cause the welding wire to deform and bend. The buffer device has a sensor that can detect the curvature of the welding wire. The subsequent wire pusher changes the wire feeding speed according to the feedback value of the sensor to ensure that the bending degree of the welding wire is consistent. For example, the push-pull synchronous wire feeding device and control method disclosed in CN 101786195A can achieve a better synchronous wire feeding effect, but it adds a first-level buffer in the middle, resulting in many intermediate wire feeding nodes, difficulty in wire threading, and complex control and high cost. Summary of the invention
[0006] In view of one or more deficiencies in the above-mentioned prior art, the present invention provides a buffer-free synchronous wire feeding assist device, system and method, which can realize synchronous wire feeding of a push-pull motor under the condition of removing the buffer, reduce wire feeding breakpoints, reduce the difficulty of wire threading, save costs, and better solve the above-mentioned problems in the prior art.
[0007] In order to achieve the above object, the present invention adopts the following technical solution:
[0008] A buffer-free synchronous wire feeding assist device comprises a power-assisted wire pushing machine, the power-assisted wire pushing machine adopts a torque motor, a wire feeding wheel is fixedly mounted on the power-assisted wire pushing machine; the wire feeding wheel is mounted on a wire feeding machine bracket, a wire pressing handle is also mounted on the wire feeding machine bracket, the wire pressing handle presses the welding wire onto the wire feeding wheel for wire feeding operation; a wire feeding guide tube is also mounted on the wire feeding machine bracket, the welding wire enters the interior of the welding gun through the wire feeding guide tube, and the welding wire is guided.
[0009] As a further implementation, a wire pressing wheel is connected to the end of the wire pressing handle, and there is a gap between the outer edges of the wire pressing wheel and the wire feeding wheel for the welding wire to pass through, and the wire pressing handle is used to adjust the pressure between the wire pressing wheel and the wire feeding wheel.
[0010] As a further implementation method, the wire pressing handle has an internal hollow structure and is provided with a spring connected to the wire pressing wheel. The pressure between the wire feeding wheel and the wire pressing wheel can be adjusted by the expansion and contraction of the spring to clamp the welding wire.
[0011] As a further implementation method, the wire feeding duct is provided with two coaxial sections, and the two sections of the wire feeding duct are arranged on both sides of the wire feeding wheel, so as to guide the welding wire being transported and improve the stability of the wire feeding.
[0012] As a further implementation method, a wire feeder protective shell is provided on the outside of the power-assisted wire pushing machine to protect the power-assisted wire pushing machine. The wire feeder protective shell is fixedly connected to a barreled wire holder, and the barreled wire holder is used to install the synchronous wire feeding assist device on the barreled welding wire, which can release the welding wire to connect with the power-assisted wire pushing machine.
[0013] As a further implementation method, a control interface is provided on the wire feeder protective shell, and the control interface is connected to the controller of the welding machine through a cable. The torque of the power-assisted wire pusher is controlled by the controller of the welding machine to ensure the stability of the output wire feeding torque.
[0014] As a further implementation, the controller includes a current sensor for collecting the real-time current value of the power-assisted wire pushing machine, and controlling the torque of the power-assisted wire pushing machine by adjusting the current value.
[0015] A buffer-free synchronous wire feeding system comprises the synchronous wire feeding assist device described in any one of the above items, and also comprises a wire drawing motor and a wire drawing roller. The wire drawing roller is driven by the wire drawing motor. The welding wire after being pushed by the wire feeding wheel contacts the wire drawing roller through the wire feeding guide tube. The wire drawing speed is controlled by the wire drawing motor and then reaches the welding gun.
[0016] A bufferless synchronous wire feeding control method, based on the above bufferless synchronous wire feeding system, comprises:
[0017] The wire drawing motor runs at a fixed speed, and the power-assisted wire pushing machine runs at a fixed torque;
[0018] When the speed of the power-assisted wire pusher is 0 or small, the resistance is small, the output torque is large, and the welding wire at one end of the power-assisted wire pusher accelerates;
[0019] When the speed of the power-assisted wire-pushing machine is equal to the speed of the wire-drawing motor, the welding wire cannot be deformed and is synchronized with the welding wire speed at the wire-drawing machine end.
[0020] As a further implementation method, when the wire drawing motor runs at a reduced speed, the speed of the power-assisted wire pushing machine is greater than the speed of the wire drawing motor, the resistance encountered by the power-assisted wire pushing machine increases, the output torque decreases, and the power-assisted wire pushing machine slows down until it is synchronized with the speed of the wire drawing motor.
[0021] As a further implementation method, when the wire drawing motor accelerates, the speed of the power-assisted wire pushing machine is lower than that of the wire drawing motor, the resistance encountered by the power-assisted wire pushing machine is reduced, the output torque is increased, and the power-assisted wire pushing machine is accelerated until it is synchronized with the speed of the wire drawing motor.
[0022] By adopting one or more of the above technical solutions, the beneficial effects of the present invention are as follows:
[0023] 1. The present invention can adjust the wire feeding torque by changing the resistance through the fixed torque of the power-assisted wire pushing machine, and then adjust the rotation speed of the power-assisted wire pushing machine, so that the welding wire has the same output speed at one end of the power-assisted wire pushing machine and one end of the wire drawing motor, thereby realizing synchronous wire pushing and drawing speeds. In this way, the system complexity is reduced and the control is simple, and dual-motor synchronous wire feeding can be efficiently realized; the welding wire is pressed between the wire feeding wheel and the wire pressing wheel through the wire pressing handle to realize friction wire feeding, thereby ensuring the stability of the wire feeding process, and the friction force between the welding wire and the wire feeding wheel can be adjusted through the wire pressing handle.
[0024] 2. The present invention realizes speed adjustment of the wire-pushing machine by operating the wire-drawing motor at a fixed speed and the power-assisted wire-pushing machine at a fixed torque, and combines the combination changes at different speeds to ultimately achieve synchronous operation of wire pushing and drawing, and has rapid response and high operating efficiency. Compared with the traditional method of achieving dual-motor speed synchronization by setting a buffer, the present invention reduces wire breakage, simplifies wire threading, is convenient to control, and saves costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.
[0026] Figure 1This is a schematic diagram of the overall structure of Embodiment 1 of the present invention;
[0027] Figure 2 It is a schematic diagram of a partial structure of the first embodiment of the present invention;
[0028] Figure 3 It is a schematic diagram of the synchronous wire feeding process with a conventional buffer unit;
[0029] Figure 4 This is a schematic diagram of the synchronous wire feeding process of embodiment 3 of the present invention.
[0030] In the figure: 1. Wire feeder bracket; 2. Power-assisted wire pusher; 3. Wire feed guide tube; 4. Wire feed wheel; 5. Wire pressing wheel; 6. Wire pressing handle; 7. Wire feeder protective case; 8. Control interface; 9. Bucket wire holder. DETAILED DESCRIPTION
[0031] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.
[0032] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.
[0033] Embodiment 1
[0034] In a typical embodiment of the present invention, a synchronous wire feeding assist device without a buffer is provided, such as Figure 1-4 The figure shows that it includes a power-assisted wire pushing machine 2, which adopts a torque motor, and a wire feeding wheel 4 is fixedly installed on the power-assisted wire pushing machine 2; the wire feeding wheel 4 is installed on a wire feeding machine bracket 1, and a wire pressing handle 6 is also installed on the wire feeding machine bracket 1, and the wire pressing handle 6 presses the welding wire on the wire feeding wheel 4 to perform wire feeding operation; a wire feeding guide tube 3 is also installed on the wire feeding machine bracket 1, and the welding wire is transmitted to the front end wire drawing motor through the wire feeding guide tube 3, and the wire feeding guide tube guides the welding wire.
[0035] This embodiment takes barreled welding wire as an example, and the synchronous wire feeding assist device is installed on the barreled welding wire for use. Of course, in other embodiments, it can also be installed on the coiled welding wire for use after simple modification.
[0036] Specifically, Figure 1 As shown, the wire feeder bracket 1 is installed on one side of the power-assisted wire pusher 2, and the power-assisted wire pusher 2 is connected to the wire feeder 4 wheel through the wire feed shaft, and the welding wire is pressed on the wire feeder 4 by the wire pressing handle 6 to perform the wire feeding operation. After the welding wire is released from the barreled welding wire, it is fed into the wire feed guide tube through the wire feeder wheel, and then transported to the wire drawing motor at the front end, and then enters the inside of the welding gun. There are no other connection points and breakpoints, and the wire threading is simple and convenient to use.
[0037] In this embodiment, Figure 2 As shown, the end of the wire pressing handle 6 is connected with a wire pressing wheel 5, the wire pressing wheel 5 is close to the wire feeding wheel 4, and there is a gap between the wire pressing wheel 5 and the outer edge of the wire feeding wheel 4 for the welding wire to pass through, the welding wire is pressed between the wire feeding wheel 4 and the wire pressing wheel 5, and the wire pressing handle 6 adjusts the pressure between the wire pressing wheel 4 and the wire feeding wheel 5 by controlling the wire pressing wheel 5, thereby pressing the welding wire between the wire pressing wheel and the wire feeding wheel to achieve friction wire feeding, with a simple structure and convenient wire feeding. In this embodiment, the welding wire passes through the gap between the wire pressing wheel and the wire feeding wheel, and the tightening is controlled by the wire pressing handle, and the wire pressing handle can be opened and clamped. Specifically, the wire pressing handle is an internal hollow structure, and a spring is provided inside to connect with the wire pressing wheel, and the pressure between the wire pressing wheel and the wire feeding wheel can be adjusted by the expansion and contraction amount of the spring. Rotating the wire pressing handle can compress the spring, thereby increasing the pressure between the wire pressing wheel and the wire feeding wheel; the tighter the wire pressing handle is pressed, the greater the pressure between the wire pressing wheel and the wire feeding wheel, and the tighter the welding wire is clamped, which is conducive to stable wire feeding.
[0038] In this embodiment, Figure 1 , 2 As shown, the wire feeding duct 3 is provided with two coaxial sections, and the two sections of the wire feeding duct 3 are respectively located on both sides of the wire feeding wheel 4 and are coaxially arranged. The welding wire released from the barreled welding wire reaches the wire feeding wheel through the front section of the wire feeding duct, and after being compressed by the wire pressing wheel and the wire feeding wheel, it reaches the wire drawing motor through the rear section of the wire feeding duct, thereby improving the stability of wire feeding.
[0039] In addition, if Figure 1 As shown, the synchronous wire feeding assist device of this embodiment also includes a barreled wire support 9 and a wire feeder protective shell 7, and the wire feeding assist device can be conveniently installed on the barreled welding wire through the barreled wire support 9. Specifically, the wire feeder protective shell 7 is arranged outside the power-assisted wire pushing machine 2, and the wire feeder protective shell 7 is fixedly installed on the barreled wire support 9 by bolt connection, and then connected to the barreled welding wire. Among them, the wire feeder housing 7 is connected and fixed to the internal power-assisted wire pushing machine 2 by screws, which plays a protective role for the power-assisted wire pushing machine.
[0040] In this embodiment, Figure 1As shown, a control interface 8 is provided on the wire feeder protective shell 7, and the control interface 8 is connected to the welding machine through a cable, and the torque of the power-assisted wire pusher can be controlled by the controller on the welding machine to ensure the stability of the output wire feeding torque and achieve the power-assisted wire feeding effect. Among them, the controller on the welding machine includes a current sensor for collecting the real-time current value of the power-assisted wire pusher, so as to control the output torque of the power-assisted wire pusher by adjusting the current value.
[0041] In addition, in this embodiment, the power-assisted wire pushing machine is a key component and adopts a torque motor, which is not limited to a DC torque motor or an AC torque motor. Its characteristic is that it can output a wire feeding force with a fixed torque. The wire feeding torque can be automatically or manually adjusted according to the wire feeding resistance. Therefore, the output torque is fixed, but the speed of the wire feeding wheel is not fixed.
[0042] Embodiment 2
[0043] In another typical embodiment of the present invention, a buffer-free synchronous wire feeding system is provided, including a buffer-free synchronous wire feeding assist device of embodiment one, and also including a wire drawing motor and a wire drawing roller. The wire drawing roller is driven by the wire drawing motor. The welding wire after being pushed by the wire feeding wheel contacts the wire drawing roller through the wire feeding guide tube, and the wire drawing speed is controlled by the wire drawing motor to reach the welding gun.
[0044] Among them, the wire feeding duct in the rear section is arranged between the wire feeding wheel and the wire drawing roller to transport the welding wire to the wire drawing motor for wire drawing. The welding wire enters the welding gun after being compressed by the wire drawing roller. There are no other breakpoints, which greatly reduces the difficulty of wire threading. At the same time, it is convenient to control and effectively improves the wire feeding efficiency.
[0045] In this embodiment, when the wire drawing motor is working, the power-assisted wire pushing machine can respond quickly and follow the wire feeding; when the wire drawing motor stops running, the power-assisted wire pushing machine can stop working quickly and respond quickly.
[0046] Embodiment 3
[0047] In another typical embodiment of the present invention, a buffer-free synchronous wire feeding method is provided, based on a buffer-free synchronous wire feeding system of the second embodiment, such as Figure 3 , 4 As shown, including:
[0048] The wire drawing motor runs at a fixed speed, and the power-assisted wire pushing machine runs at a fixed torque;
[0049] When the speed of the power-assisted wire pusher is 0 or small, the resistance is small, the output torque is large, and the welding wire at one end of the power-assisted wire pusher accelerates;
[0050] When the speed of the power-assisted wire-pushing machine is equal to the speed of the wire-drawing motor, the welding wire cannot be deformed and is synchronized with the welding wire speed at the wire-drawing machine end.
[0051] Specifically, compared to Figure 3 The traditional method of achieving synchronous wire pushing and drawing speed through a buffer unit is shown. In this embodiment, the buffer unit is cancelled, and a synchronous wire feeding assist device is coordinated with the wire drawing motor to achieve simple structure, convenient control and efficient dual-motor synchronous control.
[0052] Among them, the output torque of the power-assisted wire-pushing machine is fixed when working, but the value of this output torque can be adjusted in advance according to the usage situation. For example, when the wire guide tube is too long and the resistance of the wire in the barrel at the rear end is large, the output torque needs to be increased, otherwise it needs to be reduced. The torque output of the motor is proportional to the current value, so the output torque is controlled by the current. In order to achieve synchronous wire feeding, the current value of the power-assisted wire-pushing machine is directly adjusted.
[0053] When working, first set an initial torque value for the power-assisted wire-pushing machine. Since the controller closed-loop controls the output torque of the power-assisted wire-pushing machine, that is, the output torque remains constant, when the speed of the wire drawing machine changes, the output torque of the power-assisted wire-pushing machine will not change macroscopically. Specifically, the relationship between the output torque and the current is as follows:
[0054] F=K*I
[0055] Where F is the torque, K is the coefficient, and I is the current.
[0056] Again, torque is the reason for changing the rotational speed of an object, and the formula is as follows:
[0057] M=J*w
[0058] Where M represents torque, J represents moment of inertia, and ω represents angular velocity.
[0059] The final output torque of the wire pusher can be expressed as:
[0060] M 输出 =M 电机 -M 阻力
[0061] Since the torque of the motor is a fixed value, when the resistance increases, the wire feeding torque acting on the wire feeding wheel decreases, thereby assisting the speed of the wire pushing machine to decrease.
[0062] In this embodiment, the process of achieving speed synchronization between the power-assisted wire pushing machine and the wire feeding motor is as follows:
[0063] When the wire drawing motor runs at a fixed speed, the power-assisted wire pushing machine runs at a fixed torque. At the beginning, the speed of the power-assisted wire pushing machine is 0, and the running resistance M 阻力 is also very small, so when the power-assisted wire-pushing machine is running at a fixed torque, the wire-feeding torque M 输出The power-assisted wire-pushing machine accelerates its movement; when the speed of the power-assisted wire-pushing machine reaches the speed of the wire-drawing motor, the welding wire cannot be further accelerated because it is rigid and cannot be deformed. At this time, the power-assisted wire-pushing machine maintains the same speed as the wire-drawing motor to achieve acceleration synchronization.
[0064] When the wire drawing motor runs at a reduced speed, the running resistance M of the power-assisted wire drawing machine is 阻力 Increase, output torque M 电机 is a constant value, then the wire feeding torque M 输出 Decrease, causing the speed of the power-assisted wire pushing machine to decrease, until it is synchronized with the speed of the wire drawing motor, thus achieving deceleration synchronization.
[0065] Similarly, when the wire drawing motor accelerates, the speed of the power-assisted wire pushing machine is lower than that of the wire drawing motor, the resistance encountered by the power-assisted wire pushing machine is reduced, and thus the output torque increases, and the power-assisted wire pushing machine accelerates until it is synchronized with the speed of the wire drawing motor.
[0066] Therefore, in this embodiment, the speed synchronization of pushing and pulling the wire can be achieved without a buffer. Not only is there no extra breakpoints in wire feeding, making wire threading simple and efficient, but it is also easy to control and saves costs.
[0067] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Those skilled in the art should understand that the present invention may have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the present invention.
Claims
1. A synchronous wire feeding assist device without a buffer, characterized in that: It includes a power-assisted wire pushing machine, which adopts a torque motor and is fixedly provided with a wire feeding wheel; the wire feeding wheel is installed on a wire feeding machine bracket, and a wire pressing handle is also installed on the wire feeding machine bracket, and the wire pressing handle presses the welding wire on the wire feeding wheel for wire feeding operation; a wire feeding guide tube is also installed on the wire feeding machine bracket, and the welding wire enters the interior of the welding gun through the wire feeding guide tube.
2. A buffer-free synchronous wire feeding assist device as claimed in claim 1, characterized in that: The end of the wire pressing handle is connected with a wire pressing wheel, and there is a gap between the wire pressing wheel and the outer edge of the wire feeding wheel for the welding wire to pass through.
3. A buffer-free synchronous wire feeding assist device as claimed in claim 2, characterized in that: The wire pressing handle is an internal hollow structure and is provided with a spring to connect with the wire pressing wheel.
4. A buffer-free synchronous wire feeding assist device as claimed in claim 1, characterized in that: The wire feeding duct is provided with two coaxial sections, and the two sections of the wire feeding duct are provided on both sides of the wire feeding wheel.
5. A buffer-free synchronous wire feeding assist device as claimed in claim 1, characterized in that: A wire feeder protective shell is arranged outside the power-assisted wire pushing machine to protect the power-assisted wire pushing machine, and the wire feeder protective shell is fixedly connected to a barreled wire holder.
6. A buffer-free synchronous wire feeding assist device as claimed in claim 5, characterized in that: The wire feeder protective shell is provided with a control interface, and the control interface is connected to a controller of the welding machine through a cable.
7. A buffer-free synchronous wire feeding assist device as claimed in claim 6, characterized in that: The controller includes a current sensor for collecting the real-time current value of the power-assisted wire pushing machine.
8. A bufferless synchronous wire feeding system, comprising a bufferless synchronous wire feeding assisting device according to any one of claims 1 to 7, characterized in that: It also includes a wire drawing motor and a wire drawing roller, wherein the wire drawing roller is driven by the wire drawing motor, and the welding wire after being pushed by the wire feeding wheel contacts the wire drawing roller through the wire feeding guide tube, and the wire drawing speed is controlled by the wire drawing motor.
9. A bufferless synchronous wire feeding method, based on a bufferless synchronous wire feeding system as claimed in claim 8, characterized in that: include: The wire drawing motor runs at a fixed speed, and the power-assisted wire pushing machine runs at a fixed torque; When the speed of the power-assisted wire pusher is 0 or small, the resistance is small, the output torque is large, and the welding wire at one end of the power-assisted wire pusher accelerates; When the speed of the power-assisted wire-pushing machine is equal to the speed of the wire-drawing motor, the welding wire cannot be deformed and is synchronized with the welding wire speed at the wire-drawing machine end.
10. A buffer-free synchronous wire feeding method as claimed in claim 9, characterized in that: When the wire drawing motor is running at a reduced speed, the speed of the power-assisted wire pushing machine is greater than that of the wire drawing motor, the resistance of the power-assisted wire pushing machine increases, the output torque decreases, and the power-assisted wire pushing machine decelerates until it is synchronized with the speed of the wire drawing motor; When the wire drawing motor accelerates, the speed of the power-assisted wire pushing machine is lower than that of the wire drawing motor, the resistance encountered by the power-assisted wire pushing machine is reduced, the output torque is increased, and the power-assisted wire pushing machine is accelerated until it is synchronized with the speed of the wire drawing motor.