Wire feeding mechanism control method of collaborative welding machine and welding system

Abstract

The invention belongs to the technical field of welding, and discloses a wire feeding mechanism control method of a collaborative welding machine, which comprises the following steps: configuring parameters of a welding process, determining laser power, and obtaining wire breaking power based on the laser power; energy needed for melting the welding wire is determined, and the wire breaking delay time m2 is obtained based on the energy needed for melting the welding wire and the wire breaking power; the welding machine sends out a shutdown instruction, the welding machine takes the moment when the shutdown instruction is obtained as the first reference moment, the wire breaking power is kept for the time m2, and the laser power of the welding machine is in a falling edge trend at the moment m2. The invention further discloses a welding system.

Description

Technical Field

[0001] The present invention belongs to the technical field of welding, and in particular relates to a wire feeding mechanism control method and a welding system of a collaborative welding machine. Background Art

[0002] The existing control method between the laser welding machine and the wire feeding mechanism is relatively crude. The welding machine can only control the wire feeding mechanism to start and stop the wire feeding. Usually, for the welding process, in addition to operating the welding machine, the staff also needs to independently operate the wire feeding mechanism. The relevant settings of the wire feeding mechanism require the staff to have certain professional capabilities and have a certain understanding and operation expectations of each related setting, which is not friendly to staff who are not familiar with the welding process.

[0003] In particular, in order to achieve the most suitable wire breaking effect to meet welding requirements, the entire debugging process is also time-consuming. Summary of the invention

[0004] In order to solve the above technical problems, the present invention discloses a control method for a wire feeding mechanism of a coordinated welding machine, which can control the wire feeding mechanism to cooperate with the welding machine to act reasonably while stopping wire feeding, thereby ensuring the welding effect. The present invention also discloses a welding system.

[0005] The specific technical solutions of the present invention are as follows:

[0006] A wire feeding mechanism control method for a collaborative welding machine, comprising:

[0007] Configure welding process parameters, determine laser power w, and obtain broken wire power w1 based on laser power w;

[0008] Configure the parameters of the welding process, determine the energy p1 required to melt the welding wire, and obtain the wire breaking delay time m2 based on the energy p1 required to melt the welding wire and the wire breaking power w1;

[0009] The welding machine issues a shutdown command. The welding machine takes the moment of issuing the shutdown command as the first reference moment, and maintains the time m2 at the broken wire power w1. The laser power w of the welding machine shows a downward trend at the moment m2.

[0010] Preferably, it also includes:

[0011] Configure the parameters of the welding process to obtain the wire drawing speed s1 and the wire drawing length d1;

[0012] At the first reference time, the wire feeding mechanism draws the wire at a drawing speed s1 to a drawing length d1.

[0013] Preferably, it also includes:

[0014] Configure the parameters of the welding process, determine the heat dissipation time tm of the welding material and the heat dissipation time ts of the welding wire, compare tm and ts, and determine the larger one as the wire filling delay time m3;

[0015] The wire feeding mechanism stops feeding the wire at the first reference moment and starts drawing the wire, with the wire drawing being in place as the second reference moment, and maintains the time m3. The wire feeding mechanism starts to supplement the wire at moment m3 until the supplemented wire is in place.

[0016] Preferably, it also includes:

[0017] According to the configuration parameters of the welding process, the wire filling speed s2 and the wire filling length d2 are obtained.

[0018] Preferably, the material type and / or workpiece thickness of the welding workpiece is obtained, and data compensation is performed on the wire break delay time m2, wire drawing speed s1, wire drawing length d1, wire supplement delay time m3, wire supplement speed s2 and wire supplement length d2.

[0019] Preferably, the material type of the welding workpiece is obtained, and at the beginning of welding, the welding workpiece is preheated and the wire feeding delay time m1 is maintained.

[0020] Preferably, the configuration parameters of the welding process include laser power, oscillation frequency, oscillation width, weld width, weld type, welding wire material, welding wire specification, material type of welding workpiece, and workpiece thickness of the welding workpiece.

[0021] A welding system, applying the above method to control the action of a wire feeding mechanism, the welding system comprising a welding machine, a wire feeding mechanism, and a controller;

[0022] The controller is in communication connection with the welding machine, and the welding machine is in communication connection with the wire feeding mechanism.

[0023] Preferably, the welding machine is connected to the wire feeding mechanism through a communication wire, and the communication wire includes a power line, a data line and a control line that electrically connect the welding machine and the wire feeding mechanism respectively; the power line includes a 24V line and a GND line; the data line includes an RS485A line, an RS485B line and an RS485GND line; the control line includes a CTRL+ line and a CTRL- line.

[0024] Preferably, the wire feeding mechanism comprises:

[0025] A welding wire driving unit, wherein the welding wire driving unit is used to drive the welding wire to move or brake the welding wire;

[0026] A data detection unit, wherein the data detection unit detects the welding wire length, welding wire movement speed, related time, etc. in the corresponding process stage in real time, and feeds back the result to enable the welding wire driving unit to brake the welding wire;

[0027] An information interaction unit is used to obtain process parameters sent by the welding machine and transmit the process parameters to the data detection unit and the welding wire driving unit.

[0028] Compared with the prior art, the present invention significantly improves the wire breaking effect through timing control and energy control required for wire breaking; the present invention can effectively reduce the operating difficulty of the staff and can well meet the welding requirements for different welding scenes; in addition, the present invention can well reduce the debugging time of the staff and greatly save time cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A timing diagram of the welding process in an embodiment of the present invention;

[0030] Figure 2 Schematic diagram of a welding system in an embodiment of the present invention. DETAILED DESCRIPTION

[0031] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention is further described in detail below in conjunction with specific implementation methods.

[0032] Laser filling welding is a common welding method, which is usually achieved by using a laser welding machine and a wire feeding mechanism to cooperate with each other. After welding is completed, if the welding wire cannot be accurately controlled to leave the molten pool, the molten pool will solidify and cause the welding wire to stick to the welding workpiece, affecting the next welding. Therefore, in order to ensure the continuity and integrity of the welding, the wire drawing of the wire feeding mechanism should be accurately controlled to avoid the welding wire and the welding workpiece sticking after the welding is completed. At the same time, the actual effect of the welding process should also be avoided. Generally speaking, the welding process usually includes the following steps:

[0033] S100, the user controls the welding machine to issue a start command, starts the welding operation, and the wire feeding mechanism starts feeding the wire;

[0034] S200, the user controls the welding machine to issue a shutdown command, the wire feeding mechanism stops feeding the wire, and starts drawing the wire. At this time, the laser power of the welding machine decreases along the falling edge until the output power is 0, so as to complete the welding operation;

[0035] S300: The wire feeding mechanism stops drawing wire and starts to fill wire to prepare for the next welding.

[0036] In the above process, the process of the wire feeding mechanism requires the staff to continuously adjust and debug it before it can be used with the welding machine. The whole process takes too long, affecting the efficiency of the whole process. The wire drawing process and wire filling process after welding are relatively fast and short processes, which need to be coordinated with the opening and closing timing of the welding machine to achieve the best wire breaking effect. However, since the welding machine and the wire feeding mechanism are relatively independent, it is difficult to coordinate with each other. Among them, it should be noted that the wire feeding speed indicates the speed of the wire feeding mechanism in the forward direction of the welding process; when welding stops, in order to prevent the welding wire from sticking to the welding workpiece, the wire feeding mechanism will perform a reverse wire feeding operation, which is called wire drawing, the wire drawing speed indicates the speed of the wire drawing operation, and the wire drawing length indicates the length of the wire drawing operation; after the wire drawing operation is completed, in order to facilitate the next welding operation, the wire feeding mechanism will perform forward wire feeding, which is called wire filling, the wire filling speed indicates the speed of the wire filling operation, and the wire filling length indicates the length of the wire filling operation.

[0037] In this embodiment, the configuration parameters of the welding process include laser power, swing frequency, swing width, weld width, weld type, welding wire material, welding wire specification, material type of welding workpiece, and workpiece thickness of welding workpiece. The parameters of the welding process can be seen in the following table 1:

[0038] Table 1: Welding process configuration contents

[0039] Configuration Content Configuration options Laser power 500～3000W Oscillation frequency 0~200Hz Swing width 0~8mm Welding materials Carbon steel, stainless steel, aluminum, galvanized sheet, copper Material thickness 1~10mm Weld width 1~8mm Weld Type Flat welding, lap welding, T-welding, fillet welding Welding wire material Carbon steel, stainless steel, aluminum, copper Welding wire specifications 0.8mm, 1.0mm, 1.2mm, 1.6mm, 2.0mm

[0040] According to the welding process, the required basic parameters can be obtained.

[0041] According to the welding process, the energy c1 required per unit area of ​​the welding workpiece is obtained by looking up the table;

[0042] Based on the material thickness h of the welding workpiece and the weld width l, the energy p0 required for theoretical welding can be calculated:

[0043] p0=c1×h×l (Formula 1)

[0044] According to the welding process, the energy c2 required per unit area of ​​the welding wire material is obtained by looking up the table;

[0045] Based on the wire specifications, the wire radius r is known and the wire cross-sectional area m is calculated:

[0046] m=π×r 2 (Formula 2)

[0047] Based on the energy c2 per unit area of ​​the welding wire material and the cross-sectional area of ​​the welding wire, the energy p1 required to melt the welding wire can be calculated:

[0048] p1=c2×m (Formula 3)

[0049] According to the welding process, the weld type is determined, and the welding loss coefficient β is obtained by looking up the table. The energy p2 required for welding can be obtained based on the energy p0 required for welding and the energy p1 required to melt the welding wire:

[0050] p2=(p0+p1)×β (Formula 4)

[0051] According to the welding process, the oscillation frequency is determined, and the laser loss coefficient γ is obtained by looking up the table. Based on the determined laser power w, the time t required for welding can be calculated:

[0052]

[0053] Therefore, based on Formula 1 to Formula 5, it can be known that after determining the welding process, the laser power w and the time t required for welding can be obtained, so that the actual output power and time of the welding machine in the conventional process stage can be obtained to meet the welding requirements. It can also be known that after obtaining the laser power w and the time t required for welding, after issuing the power-on command, the welding machine outputs the laser power w, and after a duration of t, it automatically shuts down, and the laser power w shows a falling edge to 0. It should be known that in the above process, the wire feeding mechanism has processes such as wire feeding, wire drawing, and wire filling, in which wire breaking needs to be achieved while drawing. In order to ensure a good wire breaking effect, this embodiment uses wire breaking delay and switching wire breaking power to ensure that the welding wire and the welding workpiece can be disconnected normally.

[0054] That is, this embodiment discloses a wire feeding mechanism control method for a collaborative welding machine, comprising:

[0055] S1, obtaining the broken wire power w1 based on the laser power w;

[0056] S2. Obtain the wire breaking delay time m2 based on the energy p1 required to melt the welding wire and the wire breaking power w1.

[0057] S201, the welding machine issues a shutdown command. The welding machine takes the time of issuing the shutdown command as the first reference time, maintains the wire breaking delay time m2 at the wire breaking power w1, and the laser power w of the welding machine shows a downward trend at time m2.

[0058] The broken wire power is obtained according to the following formula:

[0059] w1=w×1.1 (Formula 6)

[0060] The wire breaking power w1 is slightly larger than the actual laser power w (the power of the laser used in the welding process). The reason is that when the welding machine receives the shutdown command, the laser power w generally shows a falling edge until it is reduced to 0. In this process, the connection between the welding wire and the welding workpiece may not be melted due to insufficient power. Therefore, after the welding is completed, the output power of the welding machine is increased to ensure the wire breaking effect. It should be noted that in this embodiment, the shutdown command is automatically issued after the actual welding time t. Of course, during the welding process, the shutdown command can also be manually issued according to the time situation.

[0061] Based on the energy p1 required to melt the welding wire and the wire breaking power w1, the wire breaking delay time m2 is obtained:

[0062]

[0063] Therefore, according to the energy p1 required for melting the welding wire and the wire breaking delay time m2, it is ensured that the welding wire and the welding workpiece are separated after the welding is completed, thereby ensuring a good welding effect.

[0064] Of course, it is known that during the welding process, the wire feeding mechanism needs to continuously feed the wire so that the welding process has enough welding wire to achieve welding with the welding workpiece. Therefore, according to the swing width d, the wire feeding speed s0 can be obtained:

[0065]

[0066] Therefore, during the welding process, feeding the wire at a wire feeding speed of s0 can well meet the welding requirements.

[0067] In order to achieve better welding effect on some welding workpieces (such as aluminum), it is generally necessary to preheat them, that is, to output laser for a period of time before feeding the wire.

[0068] At this time, in this embodiment, the material type of the welding workpiece is obtained, and when welding starts, the welding workpiece is preheated and the wire feeding delay time m1 is maintained.

[0069] According to the welding process, the specific heat capacity y of the material can be known. Based on the energy p0 and laser power w required for welding, the wire feeding delay time m1 can be obtained:

[0070]

[0071] That is to say, after the laser output time m1 is turned on, the wire is fed again to ensure the welding effect. In other words, it can ensure that the welding wire can continue to melt, making it easier to separate from the welding workpiece, thereby improving the wire breaking effect. It can be seen that at this time, the laser power increases along the rising edge from 0, and after maintaining the output time m1, it is already in a stable output state.

[0072] Furthermore, in order to better meet the wire breaking effect, the following steps are also included:

[0073] S3. Configure welding process parameters to obtain wire drawing speed s1 and wire drawing length d1.

[0074] S202. At a first reference moment, the wire feeding mechanism draws the wire at a drawing speed s1 to a drawing length d1.

[0075] According to the material type and specification of the welding wire, the wire drawing speed coefficient α1 and the wire drawing length coefficient x1 can also be obtained by looking up the table. Based on the wire feeding speed s0, the wire drawing speed s1 can be obtained:

[0076] s1=s0×α1 (Formula 10)

[0077] And, based on the radius r of the welding wire, the wire drawing length d1 can be obtained:

[0078] d1=r×x1(Formula 11)

[0079] Therefore, after welding is completed and a shutdown command is issued, the wire feeding mechanism draws wire at a drawing speed s1, and when the length reaches the drawing length d1, the drawing operation is completed, thereby ensuring good welding results during the welding process through precise numerical values.

[0080] In this embodiment, after the wire drawing is completed, in order to facilitate the next welding operation, it is necessary to perform wire supplementation, thereby improving the efficiency of the welding process. Specifically, the following steps are also included:

[0081] S4. Configure the parameters of the welding process, determine the heat dissipation time tm of the welding material and the heat dissipation time ts of the welding wire, compare tm and ts, and determine the larger one as the wire filling delay time m3.

[0082] S301, the wire feeding mechanism stops feeding the wire at the first reference time and starts drawing the wire, and takes the wire drawing into place as the second reference time, and maintains the time m3. The wire feeding mechanism starts to supplement the wire at time m3 until the supplemented wire is in place.

[0083] According to the welding process, the heat dissipation coefficient g1 of the welding workpiece can be known from the table, so it can be known that after the laser power is 0, the heat dissipation time tm of the welding workpiece is:

[0084]

[0085] According to the welding process, the heat dissipation coefficient g2 of the welding wire can be known from the table, and thus the heat dissipation time ts of the welding wire after the laser power is 0 can be known:

[0086]

[0087] In this way, a numerical comparison can be made between the heat dissipation time tm of the welding material and the heat dissipation time ts of the welding wire, and the larger one is taken as the wire filling delay time m3, that is, the timing starts when the output power of the welding machine is 0, and the wire filling starts after time m3. At this time, both the welding material and the welding wire have completely dissipated heat, so there will be no adhesion problem between the two.

[0088] Furthermore, the method further comprises the following steps:

[0089] S5. According to the configuration parameters of the welding process, the wire filling speed s2 and the wire filling length d2 are obtained.

[0090] According to the material type and specification of the welding wire, the wire feeding speed coefficient α2 and the wire feeding length coefficient x2 can also be obtained by looking up the table. Based on the wire feeding speed s0, the wire feeding speed s2 can be obtained:

[0091] s2=s0×α2 (Formula 14)

[0092] And, based on the radius r of the welding wire, the length of the filler wire d2 can be obtained:

[0093] d2=r×x2(Formula 15)

[0094] Therefore, during the wire supplementing process, the wire feeding mechanism supplements the wire at a wire supplementing speed s2, and stops supplementing the wire when the wire supplementing length reaches d2.

[0095] like Figure 1 As shown, during the welding process, precise control of wire feeding parameters, wire drawing parameters and wire filling parameters can further improve welding efficiency and welding effect compared with the existing technology. The details in the figure can be seen in Table 2 below.

[0096] Welding process timing table 2

[0097]

[0098] It can also be seen from the table that the actual output time t of the welding machine in the conventional process stage is:

[0099] t=t1+t2 (Formula 16)

[0100] It can be seen that the control method of this embodiment, based on the actual process conditions required for welding, can greatly facilitate welding operations, avoid excessive debugging time, thereby improving welding efficiency, and also enable staff with lower professional capabilities to perform operations.

[0101] In this embodiment, for some materials that are difficult to weld (such as copper), or the workpiece has a large thickness (greater than 8mm as shown in the figure), data compensation can also be performed to improve the welding effect. Usually, the data for compensation include but are not limited to the wire breaking delay time m2, the wire drawing speed s1, the wire drawing length d1, the wire supplement delay time m3, the wire supplement speed s2 and the wire supplement length d2. Generally speaking, the compensation method is to increase the wire feeding delay m1, increase the wire breaking delay m2, reduce the wire drawing speed s1, reduce the wire drawing length d1, increase the wire supplement delay m3, reduce the wire supplement speed s2, and reduce the wire supplement length d2.

[0102] It should be noted that, for the above-mentioned steps S1 to S5, they belong to the calculation part and their order can be swapped, which is equivalent to determining the prerequisite of the process means according to the configuration parameters; and steps S201 and S202 are two of the multiple sub-steps based on step S200, and S301 is one of the multiple sub-steps based on step S300.

[0103] In another aspect, Figure 2 As shown, this embodiment also discloses a welding system, which applies the method as described above to control the action of the wire feeding mechanism. The welding system includes a welding machine, a wire feeding mechanism, and a controller; the controller is communicatively connected to the welding machine, and the welding machine is communicatively connected to the wire feeding mechanism.

[0104] The welding machine is connected to the wire feeding mechanism through a communication wire, and the communication wire includes a power line, a data line and a control line that electrically connect the welding machine and the wire feeding mechanism respectively; the power line includes a 24V line and a GND line; the data line includes an RS485A line, an RS485B line and an RS485GND line; the control line includes a CTRL+ line and a CTRL- line. In addition, other wired or wireless communication methods such as 232 communication and CAN communication (WiFi, 4G, 5G, ZigBee, Bluetooth, etc.) can also be used to realize the communication between the welding machine and the wire feeding mechanism.

[0105] Wherein, the wire feeding mechanism includes a wire driving unit, a data detection unit, and an information interaction unit; the information interaction unit is used to obtain the process parameters issued by the welding machine, and transmit the process parameters to the data detection unit and the wire driving unit; the data detection unit detects the wire length, wire movement speed, related time, etc. of the corresponding process stage in real time, and feeds back the results to enable the wire driving unit to brake the wire; the wire driving unit is used to drive the wire to move or brake the wire. The data detection unit is usually composed of sensors, which is convenient and fast. The wire length includes the wire drawing length d1 and the wire filling length d2; the wire movement speed includes the wire feeding speed s0, the wire drawing speed s1, and the wire filling speed s2; the related time includes the wire feeding delay time m1, the wire filling delay time m3, and the wire breaking delay time m2.

[0106] Therefore, through the welding system provided in this embodiment, the control of the wire drawing mechanism can be realized in a simpler and more efficient manner during the welding process, which effectively reduces the requirements for the staff's professional welding ability and reduces the staff's on-site debugging time; in particular, this embodiment realizes the linkage timing between the welding machine and the wire feeding mechanism, and through precise data control, the wire breaking effect is greatly improved, further improving the welding effect.

[0107] In addition, it should be noted that the welding machine and the wire feeding mechanism are respectively provided with a processor for processing information data to complete specific control.

[0108] The above are only preferred embodiments of the present invention. It should be noted that the above preferred embodiments should not be regarded as limiting the present invention, and the protection scope of the present invention should be based on the scope defined by the claims. For ordinary technicians in this technical field, several improvements and modifications can be made without departing from the spirit and scope of the present invention, and these improvements and modifications should also be regarded as the protection scope of the present invention.

Claims

1. A wire feeding mechanism control method for a cooperative welding machine, characterized in that: include: Configure welding process parameters, determine laser power w, and obtain broken wire power w1 based on laser power w; Configure the parameters of the welding process, determine the energy p1 required to melt the welding wire, and obtain the wire breaking delay time m2 based on the energy p1 required to melt the welding wire and the wire breaking power w1; The welding machine issues a shutdown command. The welding machine takes the moment of issuing the shutdown command as the first reference moment, and maintains the time m2 at the broken wire power w1. The laser power w of the welding machine shows a downward trend at the moment m2.

2. A wire feeding mechanism control method for a cooperative welding machine as claimed in claim 1, characterized in that: Also includes: Configure the parameters of the welding process to obtain the wire drawing speed s1 and the wire drawing length d1; At the first reference time, the wire feeding mechanism draws the wire at a drawing speed s1 to a drawing length d1.

3. A wire feeding mechanism control method for a cooperative welding machine as claimed in claim 2, characterized in that: Also includes: Configure the parameters of the welding process, determine the heat dissipation time tm of the welding material and the heat dissipation time ts of the welding wire, compare tm and ts, and determine the larger one as the wire filling delay time m3; The wire feeding mechanism stops feeding the wire at the first reference moment and starts drawing the wire, with the wire drawing being in place as the second reference moment, and maintains the time m3. The wire feeding mechanism starts to supplement the wire at moment m3 until the supplemented wire is in place.

4. A wire feeding mechanism control method for a cooperative welding machine as claimed in claim 3, characterized in that: Also includes: According to the configuration parameters of the welding process, the wire filling speed s2 and the wire filling length d2 are obtained.

5. A wire feeding mechanism control method for a cooperative welding machine as claimed in claim 4, characterized in that: The material type and / or workpiece thickness of the welding workpiece are obtained, and data compensation is performed on the wire breaking delay time m2, the wire drawing speed s1, the wire drawing length d1, the wire supplement delay time m3, the wire supplement speed s2 and the wire supplement length d2.

6. A wire feeding mechanism control method for a cooperative welding machine as claimed in claim 1, characterized in that: The material type of the welding workpiece is obtained. At the beginning of welding, the welding workpiece is preheated and the wire feeding delay time m1 is maintained.

7. A wire feeding mechanism control method for a cooperative welding machine as claimed in claim 1, characterized in that: The configuration parameters of the welding process include laser power, oscillation frequency, oscillation width, weld width, weld type, welding wire material, welding wire specification, material type of welding workpiece, and workpiece thickness of the welding workpiece.

8. A welding system, characterized in that: Applying the method according to any one of claims 1 to 7 to control the action of a wire feeding mechanism, the welding system comprising a welding machine, a wire feeding mechanism, and a controller; The controller is in communication connection with the welding machine, and the welding machine is in communication connection with the wire feeding mechanism.

9. A welding system according to claim 8, characterized in that: The welding machine is connected to the wire feeding mechanism through a communication wire, and the communication wire includes a power line, a data line and a control line that are electrically connected to the welding machine and the wire feeding mechanism respectively; the power line includes a 24V line and a GND line; the data line includes an RS485A line, an RS485B line and an RS485GND line; the control line includes a CTRL+ line and a CTRL- line.

10. A welding system according to claim 8, characterized in that: The wire feeding mechanism comprises: A welding wire driving unit, wherein the welding wire driving unit is used to drive the welding wire to move or brake the welding wire; A data detection unit, wherein the data detection unit detects the welding wire length, welding wire movement speed, related time, etc. in the corresponding process stage in real time, and feeds back the result to enable the welding wire driving unit to brake the welding wire; An information interaction unit is used to obtain process parameters sent by the welding machine and transmit the process parameters to the data detection unit and the welding wire driving unit.

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