Single-wire laser-arc hybrid welding device and method

Abstract

The present invention provides a single-wire laser-arc hybrid welding device and method, comprising: three circuits, respectively connected to the left wall, the right wall and the lower part of the weld of the weldment; an electronic controller, respectively connected to the welding power supply and the three circuits, and used to control the switching of the three circuits; a laser head, located above the weld of the weldment, and used to direct the laser toward the weld; a laser, transmitting the laser to the laser head through an optical fiber; an arc welding gun, located above the weld of the weldment, and connected to the welding power supply; starting the laser and the welding power supply so that the laser head directs the laser toward the weld, and the arc welding gun simultaneously strikes an arc, and under the control of a motion mechanism, the arc welding gun and the laser head perform cyclic welding along the weld; and during the welding process, periodically controlling the switching of the three circuits through the electronic controller to achieve control of the arc shape to the left, right and center of the weld during the welding process, thereby achieving precise control of the arc shape and improving the welding quality.

Description

Technical Field

[0001] The present invention relates to the field of welding technology, and in particular to a single-wire laser-arc hybrid welding device and method. Background Art

[0002] As an important means of material processing, welding technology plays a key role in modern industrial production. From early manual arc welding to later gas shielded welding, laser welding, etc., various welding methods have emerged to meet the welding needs in different scenarios. For example, arc welding has been widely used in the field of medium and thick plate welding due to its simple equipment and flexible operation; laser welding has shown its unique charm in precision manufacturing and thick plate welding due to its advantages such as high energy density, fast welding speed and small heat-affected zone. However, with the continuous improvement of industrial manufacturing level, the requirements for welding quality are also getting higher and higher, especially in the field of medium and thick plate welding, such as the manufacture of key structures such as rail transit bodies, sleeper beams and large ship hulls. Traditional single welding methods are often difficult to meet the needs of high-quality and high-efficiency welding.

[0003] To address the shortcomings of traditional single welding methods, laser-arc hybrid welding technology has emerged. This technology combines laser welding with arc welding, leveraging the high energy density of the laser and the stability of the arc to achieve efficient, high-quality welding of thick plates. In practical applications, laser-arc hybrid welding technology has indeed achieved certain results, improving welding efficiency and quality to a certain extent. However, existing laser-arc hybrid welding technology still has significant limitations in controlling arc morphology and optimizing weld seam profile. Specifically, arc morphology control plays a crucial role in weld seam quality during laser-arc hybrid welding. However, existing hybrid welding technologies lack effective control methods for this critical aspect. Firstly, arc stability is difficult to ensure and is easily affected by factors such as welding parameter fluctuations and workpiece surface conditions, resulting in unstable arc morphology, which in turn affects weld fusion and quality. Secondly, there is a lack of targeted arc morphology control strategies for different welding positions and passes, which prevents the full utilization of the advantages of laser-arc hybrid welding.

[0004] Therefore, how to achieve precise control of arc morphology and improve welding quality has become a key issue that needs to be urgently solved in current laser-arc hybrid welding technology. Summary of the Invention

[0005] The present invention provides a single-wire laser-arc hybrid welding device and method, which are used to solve the technical defect of the prior art in lacking effective control means in controlling the arc shape.

[0006] The present invention provides a single-wire laser-arc hybrid welding device, comprising:

[0007] Three circuits are connected to the left wall, right wall and lower part of the weld respectively;

[0008] An electronic controller, connected to the welding power source and the three circuits respectively, for controlling switching of the three circuits;

[0009] a laser head, the laser head being located above the weld of the weldment and being used to direct laser light toward the weld;

[0010] A laser that transmits laser light to the laser head via an optical fiber;

[0011] An arc welding gun, the arc welding gun is located above the weld seam of the weldment and is connected to a welding power source;

[0012] The laser and the welding power supply are started, so that the laser head directs the laser toward the weld, and the arc welding gun simultaneously strikes an arc. Under the control of the motion mechanism, the arc welding gun and the laser head perform cyclic welding along the weld. During the welding process, the electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right, and center of the weld during the welding process.

[0013] According to the single-wire laser-arc hybrid welding device provided by the present invention, the electronic controller includes a microcontroller, a solid-state relay and a single-pole three-way switch, the microcontroller is connected to the solid-state relay and the single-pole three-way switch in sequence, and the single-pole three-way switch is connected to the three circuits respectively;

[0014] The microcontroller generates a control signal and outputs the control signal to the single-pole three-way switch via the solid-state relay to control the single-pole three-way switch to be connected to one of the circuits.

[0015] According to the single-wire laser-arc hybrid welding device provided by the present invention, within each time period, the motion mechanism controls the arc welding gun and the laser head to perform cyclic motion along the weld using an N-layer N-pass welding method, and the electronic controller generates multiple control signals to periodically control the switching of the three circuits; wherein, N is an integer greater than 1.

[0016] According to the single-wire laser-arc hybrid welding device provided by the present invention, when a three-layer three-pass welding method is adopted:

[0017] During the welding of the first weld bead, in each first cycle, the electronic controller switches the circuit to connect to the lower portion of the weld seam and maintains the connection for a first time period through the control signal, then switches the circuit to connect to the left wall of the weldment and maintains the connection for a second time period through the control signal, and then switches the circuit to connect to the right wall of the weldment and maintains the connection for a third time period through the control signal;

[0018] During the second weld bead welding, in each second cycle, the electronic controller switches the circuit to connect to the left wall of the weldment through the control signal and maintains the connection for a fourth time period, then switches the circuit to connect to the lower portion of the weld through the control signal and maintains the connection for a fifth time period, and then switches the circuit to connect to the right wall of the weldment through the control signal and maintains the connection for a sixth time period;

[0019] When welding the third weld, in each third cycle, the electronic controller switches the circuit to connect with the lower part of the weld through the control signal and maintains it for the seventh time period, then switches the circuit to connect with the left wall of the weldment through the control signal and maintains it for the eighth time period, and then switches the circuit to connect with the right wall of the weldment through the control signal and maintains it for the ninth time period.

[0020] According to the single-wire laser-arc hybrid welding device provided by the present invention, one end of the three-way circuit is respectively connected to the geometric center of the left wall of the weldment, the geometric center of the right wall of the weldment, and the geometric center of the part below the weld, and the other end of the three-way circuit is connected in parallel with the electronic controller.

[0021] According to the single-wire laser-arc hybrid welding device provided by the present invention, the current of the welding power supply is 150 to 250A, and welding is performed in a dual-pulse mode; the angle between the arc welding gun and the vertical direction is set to 30°; the laser head is welded perpendicular to the welding surface, the laser power of the laser head is set to 2000 to 5000 W, and the welding speed is set to 1 to 2 m / min.

[0022] The present invention provides a single-wire laser-arc hybrid welding method, which is used for the single-wire laser-arc hybrid welding device described above, and the method comprises:

[0023] Starting the laser and the welding power supply so that the laser head emits the laser toward the weld and the arc welding gun simultaneously strikes the arc;

[0024] The arc welding gun and the laser head are controlled by a motion mechanism to move cyclically along the welding direction of the weld, and during the welding process, the electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right and center of the weld during the welding process.

[0025] According to the single-wire laser-arc hybrid welding method provided by the present invention, the arc welding gun and the laser head are controlled to cyclically move along the welding direction of the weld by a motion mechanism, and during the welding process, the electronic controller periodically controls the switching of the three circuits, including:

[0026] In each time period, the motion mechanism controls the arc welding gun and the laser head to perform cyclic motion along the weld using an N-layer, N-pass welding method, and during the welding process, the electronic controller generates multiple control signals to periodically control the switching of the three circuits; wherein N is an integer greater than 1.

[0027] According to the single-wire laser-arc hybrid welding method provided by the present invention, when a three-layer three-pass welding method is adopted, the electronic controller generates multiple control signals to periodically control the switching of the three circuits, specifically including:

[0028] During the welding of the first weld bead, in each first cycle, the electronic controller switches the circuit to connect to the lower portion of the weld seam and maintains the connection for a first time period through the control signal, then switches the circuit to connect to the left wall of the weldment and maintains the connection for a second time period through the control signal, and then switches the circuit to connect to the right wall of the weldment and maintains the connection for a third time period through the control signal;

[0029] During the second weld bead welding, in each second cycle, the electronic controller switches the circuit to connect to the left wall of the weldment through the control signal and maintains the connection for a fourth time period, then switches the circuit to connect to the lower portion of the weld through the control signal and maintains the connection for a fifth time period, and then switches the circuit to connect to the right wall of the weldment through the control signal and maintains the connection for a sixth time period;

[0030] When welding the third weld, in each third cycle, the electronic controller switches the circuit to connect with the lower part of the weld through the control signal and maintains it for the seventh time period, then switches the circuit to connect with the left wall of the weldment through the control signal and maintains it for the eighth time period, and then switches the circuit to connect with the right wall of the weldment through the control signal and maintains it for the ninth time period.

[0031] The present invention also provides an electronic device comprising a memory, a processor and a computer program stored in the memory and executable on the processor, wherein when the processor executes the program, any of the above-described single-wire laser-arc hybrid welding methods is implemented.

[0032] The single-wire laser-arc hybrid welding device and method provided by the present invention, under the control of a motion mechanism, an arc welding gun and a laser head perform cyclic welding along the weld seam; and during the welding process, an electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right, and directly toward the center of the weld seam during the welding process, thereby achieving precise control of the arc shape, effectively improving the welding quality, reducing the post-weld processing cost, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the technical solutions in the present invention or the prior art, a brief introduction is given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0034] Figure 1 It is a structural schematic diagram of the single-wire laser-arc hybrid welding device provided by the present invention.

[0035] Figure 2 Schematic diagram of the electronic controller provided by the present invention.

[0036] Figure 3 It is a schematic flow chart of the single-wire laser-arc hybrid welding method provided by the present invention.

[0037] Figure 4 It is a structural schematic diagram of the electronic device provided by the present invention.

[0038] 101—electronic controller; 102—arc welding gun;

[0039] 103 - laser head; 104 - laser; 105 - welding power supply;

[0040] 106, 107, 108—three-way circuit; 109—protection circuit;

[0041] 201—microcontroller; 202—solid-state relay; 203—single-pole three-position switch;

[0042] 204—voltage regulator; 205—independent power supply. DETAILED DESCRIPTION

[0043] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0044] First, the terms involved in the embodiments of the present invention are schematically explained.

[0045] Three-layer, three-pass welding: A welding process that utilizes three welds, each consisting of three weld paths (passes). This method is commonly used for welding medium-thick plates. Through multiple passes, this method ensures complete weld fusion, reduces lack of fusion defects, and improves the strength and reliability of the welded joint. Meticulous control of each pass ensures weld quality, resulting in a smoother weld surface and appropriate reinforcement, reducing stress concentration.

[0046] Laser-arc hybrid welding: A welding technology that combines laser welding with arc welding. Leveraging the high energy density of the laser and the stability of the arc, it achieves efficient, high-quality welding of thick plates. Laser welding offers advantages such as high welding speed, a small heat-affected zone, and aesthetically pleasing welds, while arc welding boasts simple equipment and flexible operation. Combining the two methods leverages their respective strengths, improving welding efficiency and quality. Suitable for welding medium and thick plates, this method is particularly effective in the manufacture of critical structures such as rail transit bodies, bolsters, and large ship hulls, effectively resolving issues such as difficult sidewall fusion and unsightly welds in medium and thick plate welds.

[0047] Solid-state relays: Solid-state relays are composed of solid-state devices (such as transistors and triacs) whose conduction and cutoff are controlled by electrical signals. Compared with traditional mechanical relays, solid-state relays offer advantages such as fast response, long life, and the absence of mechanical contacts. In this invention, solid-state relays are used to receive control signals from an electronic controller and transmit them to the load circuit, thereby controlling the arc morphology.

[0048] A single-pole, three-position switch (SP3P): A switch with three output positions. It can switch an input signal to three different output positions and is typically used when switching between multiple circuits. In this invention, the SP3P switch is used to switch current between different circuits, thereby controlling the arc's shape.

[0049] Welding power supply: A device that provides electrical energy for the welding process. Welding power supplies typically come in two types: DC and AC. In this invention, the welding power supply uses a reverse DC connection method, with the positive terminal connected to the welding gun and the negative terminal connected to the workpiece via an electronic controller and wiring. The welding power supply current is set to 150 to 250 A, and welding is performed in dual-pulse mode.

[0050] Arc welding gun: A welding tool used to generate and maintain an arc. An arc welding gun typically consists of an electrode, a nozzle, and an insulating housing. In this invention, the arc welding gun is set at a 30° angle to the vertical. Arc shape is controlled through the coordination of an electronic controller and a welding power source.

[0051] Laser: A device that generates a laser beam. Lasers generate laser beams through stimulated emission of radiation and possess characteristics such as high energy density, high directionality, and high monochromaticity. In this invention, the laser transmits laser light to the laser head via optical fiber, with the laser power set to 2000 to 5000 W.

[0052] Laser head: An optical device used to focus the laser beam onto the weld area. It typically consists of optical components such as lenses, reflectors, and collimators. In this application, the laser head is positioned perpendicular to the weld surface, with a laser power of 2000-5000W and a welding speed of 1-2 m / min. Laser heads are widely used in welding processes such as laser welding and laser-arc hybrid welding.

[0053] In order to solve the technical defect of the existing technology in controlling the arc shape, which is the lack of effective control means, and to achieve the technical effect of accurately controlling the arc shape, effectively improving the welding quality, reducing the post-weld processing cost, and improving the production efficiency, the embodiment of the present invention discloses a single-wire laser-arc hybrid welding device, see Figure 1 , including: an electronic controller 101, three circuits 106, 107, 108, a laser head 103, a laser 104 and an arc welding gun 102.

[0054] The three circuits 106, 107, and 108 are connected to the left wall, right wall, and lower portion of the weld, respectively; this connection method enables the welding current to flow to different parts of the weld through different paths, thereby achieving precise control of the arc shape. Specifically, Figure 1 As shown, circuit 106 is connected to the left wall of the weldment, circuit 107 is connected to the lower portion of the weld seam of the weldment, and circuit 108 is connected to the right wall of the weldment. In actual use, it can also be adjusted according to specific circumstances.

[0055] Furthermore, one end of the three circuits 106 , 107 , and 108 are respectively connected to the geometric center of the left wall of the weld, the geometric center of the right wall of the weld, and the geometric center of the part below the weld, and the other end of the three circuits 106 , 107 , and 108 are connected in parallel to the electronic controller 101 .

[0056] The connection wires of the three circuits 106, 107, and 108 and the weldment are connected by multi-strand soft wires of the Southwire SOOW FlexiblePortable Cord type, and the specification is selected as 4 / 0 AWG (can carry about 380A) to ensure the circuit flow and safety during the welding process.

[0057] Among them, the weld is the core part of the weld joint, which directly connects two or more weldments to achieve a firm bond between them. The quality and performance of the weld have a decisive influence on the strength, sealing, corrosion resistance, etc. of the entire welded structure. Figure 1 As shown, the weld area in this embodiment has a V-shaped groove structure with a groove angle of 60°.

[0058] Electronic controller 101 is connected to welding power source 105 and three circuits 106, 107, and 108, respectively, to control the switching of these three circuits. Electronic controller 101 is the core control unit of the entire welding system, responsible for controlling the switching of the three circuits 106, 107, and 108 according to a predetermined logic and frequency (e.g., 200 Hz). Electronic controller 101 receives signals from welding power source 105, generates control signals, and transmits these signals to the three circuits 106, 107, and 108, thereby achieving circuit switching control.

[0059] Laser 104 transmits laser light to laser head 103 via optical fiber. Laser head 103 is located above the weld seam of the weldment and is used to direct the laser light toward the weld seam. Laser 104 is a crucial component of the entire welding system, responsible for generating a high-energy-density laser beam. The output power and beam quality of laser 104 directly impact the welding effect. Laser head 103 is the output end of laser 104 and is responsible for focusing the laser beam generated by laser 104 and directing it toward the weld seam. The high energy density of the laser rapidly heats the weld seam, facilitating the welding process.

[0060] Alternatively, laser 104 may be a Raycus RFL-C6000 laser system, with a HansLaser WWH10 scanning welding laser head 103 selected, with laser head 103 positioned perpendicular to the weld surface and laser power set to 3000 W. Laser head 103 may be a HansLaser WWH10 scanning welding laser head 103, and welding may be performed perpendicular to the weld surface. Laser power may be set to 2000 to 5000 W, and welding speed may be set to 1 to 2 m / min.

[0061] The arc welding gun 102 is located above the weld seam of the weldment and is connected to a welding power source 105. The arc welding gun 102 is a key device for generating and maintaining an arc, and is responsible for converting the electrical energy of the welding power source 105 into heat energy of the arc, thereby heating the weld seam area and promoting the welding process.

[0062] The arc welding gun 102 and the welding power source 105 are further connected via a protection circuit 109. The protection circuit 109 may include a short circuit protection circuit 109, an overvoltage protection circuit 109, and an overcurrent protection circuit 109.

[0063] The welding power source 105 and the welding gun were Fronius tps 400i welding machines, the arc current was set to 200 A, the arc usage mode was selected as the double pulse mode, and the angle between the welding gun and the vertical direction was set to 30°.

[0064] Optionally, pure argon is selected as the shielding gas during the welding process, with a gas flow rate of 20 L / min.

[0065] Select 10 mm thick 6005A aluminum alloy as the weldment, and use 1.6 mm diameter ER5356 welding wire. Clean the welding area to remove oil, rust, and other impurities. Then properly connect and debug the laser 104, laser head 103, electronic controller 101, welding power source 105, arc welding gun, and multiple power cables.

[0066] The laser 104 and the welding power supply 105 are started, so that the laser head 103 directs the laser toward the weld, and the arc welding gun 102 simultaneously strikes an arc. Under the control of the motion mechanism, the arc welding gun 102 and the laser head 103 perform cyclic welding along the weld. During the welding process, the electronic controller 101 periodically controls the switching of the three circuits 106, 107, and 108 to achieve control of the arc shape to the left, right, and center of the weld during the welding process.

[0067] Alternatively, a three-layer, three-pass welding method can be selected based on a thickness of 10 mm. It should be noted that the N-layer, N-pass welding method refers to the use of N weld seams during the welding process, with each weld seam comprising N weld paths (weld passes). Multiple weld passes are stacked sequentially to form the final weld seam. For each weld pass, the arc welding gun 102 and laser head 103 are controlled by a motion mechanism to move in a unidirectional, circular motion along the weld seam, rather than in a reciprocating motion.

[0068] Optionally, the positive electrode of the welding power source 105 is connected to the arc welding gun, and the negative electrode is connected to the welding workpiece through the electronic controller 101 and multiple wires.

[0069] Optionally, the electronic controller 101 generates 200 control signals in each cycle, and the control time of each control signal is 5ms, so as to achieve 200 controls per second, and perform cyclic control according to the control logic in the multi-layer and multi-pass welding process.

[0070] In the single-wire laser-arc hybrid welding device and method provided by the present invention, under the control of a motion mechanism, an arc welding gun 102 and a laser head 103 perform cyclic welding along the weld seam; and during the welding process, the electronic controller 101 periodically controls the switching of the three circuits 106, 107, and 108 to achieve control of the arc shape to the left, right, and directly toward the center of the weld seam during the welding process, thereby achieving precise control of the arc shape, effectively improving the welding quality, reducing the post-weld processing cost, and improving production efficiency.

[0071] Alternatively, see Figure 2 , Figure 2 Schematic diagram of the electronic controller 101 in this embodiment. The electronic controller 101 includes:

[0072] Microcontroller 201: An Arduino Uno R3 microcontroller 201 serves as the core control unit. It features multiple digital input / output pins and analog input pins, enabling the acquisition and control of various signals during the welding process. Microcontroller 201 is programmed to precisely control the welding process, including real-time adjustment of parameters such as welding current, voltage, and speed, as well as coordinated control of other components within the electronic controller 101.

[0073] Power Supply: A Mean Well LRS-75-12 standalone power supply 205 provides a stable power source for the electronic controller 101. This power supply module features high efficiency, low ripple, and excellent load regulation, ensuring a stable 12V DC power supply for the microcontroller 201 and other components. The power supply module utilizes an LM7805 voltage regulator chip for voltage regulation, providing a stable 5V voltage for the microcontroller 201.

[0074] Regulated voltage input interface: This includes the input and output interfaces of the LM7805 voltage regulator module, which converts the 12V output voltage of the power module into a stable 5V voltage, providing a stable power supply for microcontroller 201. The regulated voltage input interface also has overvoltage protection and overcurrent protection functions to ensure that microcontroller 201 and other sensitive electronic components will not be damaged in the event of power supply abnormalities.

[0075] Solid-state relay 202: This unit utilizes a G3MB-202P SSR solid-state relay. It receives control signals from microcontroller 201 and converts them into high-power switching signals, which are used to control the on / off state of welding power source 105 and multiple circuits. Solid-state relay 202 offers advantages such as fast response, long life, and the absence of mechanical contacts, enabling rapid control and precise switching during the welding process.

[0076] Single-pole, three-way switch 203: A Panasonic EVQP1A1J single-pole, three-way, high-frequency switch is selected, enabling high-speed switching of the three circuits 106, 107, and 108. Single-pole, three-way switch 203 is connected to microcontroller 201 via solid-state relay 202. Based on control signals from microcontroller 201, it switches the welding current loop to the left or right wall of the weldment, or directly below the weld groove, during different welding phases, thereby achieving precise control of the arc shape.

[0077] Communication interface: This includes interfaces for communicating with external computers or other devices, such as USB, RS-232, or Ethernet. Through these interfaces, operators can remotely monitor the welding process, download / upload welding programs, and adjust welding parameters, enabling automated control and remote management of the welding process.

[0078] User interface: This includes a display screen, buttons, and knobs, used for the operator to interact with the electronic controller 101. The display screen can display the welding status, welding parameters, and alarm information in real time, such as welding current, voltage, welding speed, welding layers / passes, etc. The buttons and knobs are used to manually control various operations during the welding process, such as starting / stopping welding, selecting welding programs, and adjusting welding parameters.

[0079] The electronic controller 101 receives a signal from the welding power source 105 , generates a control signal, and outputs the control signal to the single-pole three-way switch 203 via the solid-state relay 202 to control the single-pole three-way switch 203 to conduct one circuit.

[0080] Specifically, a Mean Well LRS-75-12 power supply is selected as the independent power supply 205 of electronic controller 101; a G3MB-202P SSR solid-state relay 202 is selected as solid-state relay 202; and a Panasonic EVQP1A1J single-pole, three-way, high-frequency switch is selected as single-pole, three-way switch 203. An Arduino UnoR3 microcontroller 201 is used for programming electronic controller 101, and both the acquisition speed of microcontroller 201 and the switching frequency of single-pole, three-way switch 203 are set to 200 Hz.

[0081] Digital pin D8 of the Arduino Uno R3 microcontroller 201 is connected to the input terminal (IN) of the solid-state relay 202, and digital pin GND is connected to the input terminal (GND) of the solid-state relay 202. Microcontroller 201 controls the on and off of solid-state relay 202 by outputting digital signals, thereby controlling welding power source 105 and the multi-channel circuit.

[0082] The output terminal (COM) of solid-state relay 202 is connected to the negative terminal (-) of welding power source 105, and the output terminal (NO) is connected to the control line of single-pole three-way switch 203. When solid-state relay 202 is turned on, the negative terminal of welding power source 105 is connected to different parts of the weldment through single-pole three-way switch 203, thus controlling the arc shape.

[0083] The three output terminals of single-pole three-position switch 203 are connected to three circuits 106, 107, and 108, which are connected to the left and right walls of the weldment and the portion directly below the weld groove, respectively. By switching single-pole three-position switch 203, the current loops at different welding positions can be controlled.

[0084] The 12V output of the power module provides a stable 5V voltage to the microcontroller 201 through the LM7805 voltage regulator 204. The input terminal (+) of the LM7805 voltage regulator 204 is connected to the 12V output of the power module, the input terminal (-) is connected to the ground (GND) of the power module, the output terminal (+) is connected to the 5V power supply pin of the microcontroller 201, and the output terminal (-) is connected to the GND pin of the microcontroller 201.

[0085] Serial communication pins (e.g., RX and TX) of microcontroller 201 are connected to an external computer or other device via a communication interface chip (e.g., a MAX232 chip). The MAX232 chip converts the TTL level signals of microcontroller 201 into RS-232 level signals, enabling communication with other devices.

[0086] The digital and analog pins of the microcontroller 201 are connected to the display, buttons, and knobs in the user interface. For example, the microcontroller 201 is connected to an LCD display via an I2C interface or an SPI interface; the digital pins are connected to buttons and knobs for inputting control signals and adjusting parameters.

[0087] Optionally, when the welding process begins, the microcontroller 201 (Arduino Uno R3) in the electronic controller 101 precisely controls the on / off switching of multiple circuits according to programmed timing and logic. Specifically, during the welding process, the microcontroller 201 outputs digital or pulse signals to control the solid-state relay 202 or other electronic switch, thereby rapidly switching the three circuits 106, 107, and 108. This sequential control ensures that the arc shape is precisely adjusted according to pre-set logic (e.g., left, right, or directly in the center of the weld) during each welding cycle, thereby optimizing the weld profile.

[0088] In this embodiment, through the coordinated work of components such as the microcontroller 201, the solid-state relay 202, and the single-pole three-way switch 203, precise control of the welding process is achieved, including real-time adjustment of welding parameters and fine control of arc shape. This can effectively solve problems such as lack of side wall fusion and poor weld formation in traditional welding methods, improve welding quality and production efficiency, and has broad application prospects and promotion value.

[0089] Furthermore, within each time period, the arc welding gun 102 and the laser head 103 are controlled by the motion mechanism to perform cyclic motion along the weld using an N-layer N-pass welding method, and multiple control signals are generated by the electronic controller 101 to periodically control the switching of the three circuits 106, 107, and 108; wherein N is an integer greater than 1.

[0090] When using the three-layer three-pass welding method: the first weld pass ensures complete fusion of the weld root by precisely controlling the arc shape, providing a good foundation for subsequent weld passes; the second weld pass ensures sufficient filling of the weld and forms a uniform weld height by adjusting the arc shape; the third weld pass forms a smooth and flat weld surface by precisely controlling the arc shape, reducing the weld excess height and reducing stress concentration.

[0091] During the first weld bead welding, in each first cycle, the electronic controller 101 switches the circuit to connect to the lower portion of the weld seam and maintains the connection for a first time period through a control signal, then switches the circuit to connect to the left wall of the weldment and maintains the connection for a second time period through a control signal, and then switches the circuit to connect to the right wall of the weldment and maintains the connection for a third time period through a control signal;

[0092] During the second weld bead welding, in each second cycle, the electronic controller 101 switches the circuit to connect to the left wall of the weldment through a control signal and maintains the connection for a fourth time period, then switches the circuit to connect to the lower portion of the weld through a control signal and maintains the connection for a fifth time period, and then switches the circuit to connect to the right wall of the weldment through a control signal and maintains the connection for a sixth time period.

[0093] When welding the third weld, in each third cycle, the electronic controller 101 switches the circuit to connect with the lower part of the weld through a control signal and maintains it for the seventh time period, then switches the circuit to connect with the left wall of the weldment through a control signal and maintains it for the eighth time period, and then switches the circuit to connect with the right wall of the weldment through a control signal and maintains it for the ninth time period.

[0094] Take a control logic as an example. The three circuits 106, 107, and 108 are switched according to a set program, with each 100ms being a cycle:

[0095] During the first weld, the control unit of electronic controller 101 generates control signals 200 times per cycle, each cycle lasting 1 second, to achieve 200 on / off changes per second. Within every 100 milliseconds, the valve is connected to the bottom of the weld for the first 35 milliseconds. Then, it takes 5 milliseconds to switch the circuit to the left wall of the weld and maintain this connection for 25 milliseconds. Then, it takes 5 milliseconds to switch the circuit to the right wall of the weld and maintain this connection for 25 milliseconds. The final 5 milliseconds are reserved for the next switching cycle. This cycle repeats 10 times per second.

[0096] 2) During the second weld, the electronic controller 101 switches the valve to the left wall of the weld for the first 35 ms within every 100 ms. It then takes 5 ms to switch the circuit to the bottom of the weld and maintains this state for 15 ms. It then takes 5 ms to switch the circuit to the right wall of the weld and maintains this state for 35 ms. The last 5 ms is reserved for the next switching cycle. This cycle is repeated 10 times per second.

[0097] 3) During the third weld, the electronic controller 101 switches the valve to connect to the bottom of the weld for the first 45 ms within every 100 ms. It then takes 5 ms to switch the circuit to connect to the left wall of the weld and maintain this state for 20 ms. It then takes 5 ms to switch the circuit to connect to the right wall of the weld and maintain this state for 20 ms. The last 5 ms is reserved for the next switching cycle. This cycle is repeated 10 times per second.

[0098] By adding a multi-channel circuit, a single-pole three-position switch 203 and an electronic controller 101 to the welding circuit, the arc shape of the single-wire laser-arc hybrid welding of medium and thick plates is periodically controlled. Different control strategies are adopted in different welding passes, which can greatly improve the defect of unfused side walls of medium and thick plates and adjust the welding height. It can effectively reduce the workload of post-weld machining and painting, and improve production efficiency.

[0099] In this embodiment, a three-layer, three-pass welding method is employed. By optimizing the control logic of the electronic controller 101 and utilizing the characteristics of each weld pass, a different arc shape control strategy is employed to precisely control the shape of each weld seam. This ultimately results in a smoother weld surface with a moderate excess height, significantly reducing the risk of stress concentration. This not only improves the weld's appearance quality but also extends the service life of the welded structure, reduces the difficulty of subsequent machining and painting, and further enhances production efficiency and economic benefits.

[0100] Furthermore, the single-wire laser-arc hybrid welding device of this embodiment improves the welding quality of medium and thick plates, significantly reduces the occurrence of side wall unfusion defects, and ensures high-quality and efficient completion of welding of medium and thick plates.

[0101] The embodiment of the present invention also discloses a single-wire laser-arc hybrid welding method, which is used for the single-wire laser-arc hybrid welding device as described above. Figure 3 As shown, the method includes:

[0102] 301. Start the laser and welding power supply, so that the laser head shoots the laser toward the weld, and the arc welding gun starts arcing at the same time.

[0103] Before welding begins, the operator activates the laser and welding power supply through the user interface or remote control device. The activation signals from the laser and welding power supply are transmitted to the electronic controller via the communication interface. Upon receiving the activation signals, the electronic controller immediately begins executing the preset welding program.

[0104] By activating the laser and welding power supply simultaneously, the laser and arc work synchronously during the welding process, improving welding efficiency and quality. The high energy density of the laser and the stability of the arc combine to quickly heat the weld area and promote weld fusion.

[0105] The laser head directs the laser light toward the weld seam: The laser transmits the laser light to the laser head via optical fiber, and the laser head welds perpendicularly to the weld surface. The position and angle of the laser head can be precisely adjusted using a motion mechanism to ensure accurate laser light targeting the weld seam. The high energy density of the laser rapidly heats the weld seam, promoting fusion and improving welding speed and quality. Precise adjustment of the laser head ensures accurate laser alignment, reducing weld defects.

[0106] The arc welding guns are simultaneously struck: The arc welding guns are connected to the positive terminal of the welding power source, while the negative terminal of the welding power source is connected to the workpiece via an electronic controller and multiple wires. When the welding power source is activated, the arc welding guns generate an arc in the welding area. The position and angle of the arc welding guns can also be precisely adjusted by the motion mechanism, ensuring that the arc is accurately applied to the weld seam.

[0107] The stability of the arc can ensure the continuity and stability of the welding process and improve the welding quality. The precise adjustment of the arc welding gun ensures the accurate alignment of the arc and reduces welding defects.

[0108] 302. The arc welding gun and the laser head are controlled by a motion mechanism to move in a circular motion along the welding direction of the weld, and during the welding process, the electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right and center of the weld during the welding process.

[0109] The motion mechanism precisely controls the arc welding gun and laser head to circulate along the weld seam according to the preset welding path and speed. The motion mechanism can use a robotic arm, linear slide, or other precision motion control equipment to ensure the continuity and stability of the welding process.

[0110] Through precise control of the motion mechanism, the arc welding gun and laser head can perform stable cyclic motion along the welding direction of the weld, improving the accuracy and quality of welding. High-precision control of the motion mechanism can reduce errors in the welding process and improve the consistency of welding.

[0111] The electronic controller periodically controls the switching of the three circuits: Based on pre-set control logic, the electronic controller generates multiple control signals within each time period to periodically control the switching of the three circuits. Specifically, within each cycle, the electronic controller uses control signals to switch the circuits to connect to the lower portion of the weld seam, the left wall, and the right wall of the weldment, and maintains these connections for the specified time.

[0112] The electronic controller's periodic control allows for precise control of the arc shape, allowing the arc to deflect left, right, and even directly toward the center of the weld during welding. This precise control ensures complete weld fusion, reduces incomplete fusion defects, and improves weld quality.

[0113] Optionally, the arc welding gun and the laser head are controlled by a motion mechanism to move cyclically along the welding direction of the weld, and during the welding process, the electronic controller periodically controls the switching of the three circuits, including: within each time period, the arc welding gun and the laser head are controlled by the motion mechanism to move cyclically along the weld using an N-layer N-pass welding method, and during the welding process, the electronic controller generates multiple control signals to periodically control the switching of the three circuits; wherein N is an integer greater than 1.

[0114] Optionally, in the case of a three-layer three-pass welding method, the electronic controller generates multiple control signals to periodically control the switching of the three circuits, specifically including:

[0115] During the welding of the first weld bead, in each first cycle, the electronic controller switches the circuit to connect to the lower portion of the weld seam and maintains the connection for a first time period through the control signal, then switches the circuit to connect to the left wall of the weldment and maintains the connection for a second time period through the control signal, and then switches the circuit to connect to the right wall of the weldment and maintains the connection for a third time period through the control signal;

[0116] During the second weld bead welding, in each second cycle, the electronic controller switches the circuit to connect to the left wall of the weldment through the control signal and maintains the connection for a fourth time period, then switches the circuit to connect to the lower portion of the weld through the control signal and maintains the connection for a fifth time period, and then switches the circuit to connect to the right wall of the weldment through the control signal and maintains the connection for a sixth time period;

[0117] When welding the third weld, in each third cycle, the electronic controller switches the circuit to connect with the lower part of the weld through the control signal and maintains it for the seventh time period, then switches the circuit to connect with the left wall of the weldment through the control signal and maintains it for the eighth time period, and then switches the circuit to connect with the right wall of the weldment through the control signal and maintains it for the ninth time period.

[0118] The single-wire laser-arc hybrid welding method provided by an embodiment of the present invention performs cyclic welding along the weld seam using an arc welding gun and a laser head under the control of a motion mechanism. During the welding process, the electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right, and center of the weld seam during the welding process, thereby achieving precise control of the arc shape, effectively improving the welding quality, reducing the cost of post-weld processing, and improving production efficiency.

[0119] Compared with the prior art, the present invention has the following innovations:

[0120] (1) The embodiment of the present invention achieves dynamic control of the arc shape through an electronic controller. The electronic controller generates 200 control signals in each cycle, with each control signal lasting 5 ms, thereby achieving high-frequency control 200 times per second. This high-frequency control allows the arc shape to be precisely adjusted according to the different requirements of the welding process, ensuring complete fusion of the weld sidewalls and reducing lack of fusion defects.

[0121] (2) The embodiment of the present invention adopts an N-layer N-pass welding method, in which the first, second, and third welding sequences form a weld pass cycle. By optimizing the control logic of the electronic controller, detailed control is performed based on the characteristics of each weld pass in the cycle.

[0122] (3) The embodiment of the present invention utilizes a high-frequency control signal of 200 Hz to achieve rapid response and precise control of the arc shape. This high-frequency control not only improves welding efficiency, but also ensures the quality and consistency of the weld, reduces the difficulty of subsequent machining and painting, and improves production efficiency. Conventional welding methods are generally unable to achieve such high control accuracy and response speed.

[0123] Figure 4 An example of a physical structure diagram of an electronic device is shown below. Figure 4 As shown, the electronic device may include: a processor 410, a communications interface 420, a memory 430, and a communications bus 440. The processor 410, the communications interface 420, and the memory 430 communicate with each other via the communications bus 440. The processor 410 may call logic instructions in the memory 430 to execute a single-wire laser-arc hybrid welding method, which includes: activating the laser and the welding power supply, causing the laser head to emit laser light toward the weld seam, and simultaneously igniting the arc welding gun; controlling the arc welding gun and the laser head to cyclically move along the welding direction of the weld seam via a motion mechanism, and periodically controlling the switching of the three circuits via the electronic controller during the welding process to control the arc shape to deviate to the left, right, or directly toward the center of the weld seam during welding.

[0124] Furthermore, the logic instructions in the aforementioned memory 430 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the portion that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product, stored in a storage medium, includes instructions for enabling a computer device (which can be a personal computer, server, or network device, etc.) to perform all or part of the steps of the methods described in various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, a mobile hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0125] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, i.e., they may be located in one location or distributed across multiple network units. Some or all of the modules may be selected based on actual needs to achieve the objectives of the present embodiment. Persons of ordinary skill in the art will be able to understand and implement the present invention without inventive effort.

[0126] Through the above description of the embodiments, those skilled in the art will clearly understand that each embodiment can be implemented using software plus a necessary general-purpose hardware platform, or of course, hardware. Based on this understanding, the essence of the above technical solution, or the portion that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, a magnetic disk, or an optical disk, and includes a number of instructions for causing a computer device (such as a personal computer, server, or network device) to execute the methods described in each embodiment or certain portions of the embodiments.

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A single-wire laser-arc hybrid welding device, characterized in that: include: Three circuits are connected to the left wall, right wall and lower part of the weld respectively; An electronic controller, connected to the welding power source and the three circuits respectively, for controlling switching of the three circuits; a laser head, the laser head being located above the weld of the weldment and being used to direct laser light toward the weld; A laser that transmits laser light to the laser head via an optical fiber; An arc welding gun, the arc welding gun is located above the weld seam of the weldment and is connected to a welding power source; The laser and the welding power supply are started, so that the laser head directs the laser toward the weld seam and the arc welding gun simultaneously strikes the arc. Under the control of the motion mechanism, the arc welding gun and the laser head perform cyclic welding along the weld seam. During the welding process, the electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right, and center of the weld seam during the welding process. In each time period, the motion mechanism controls the arc welding gun and the laser head to perform cyclic motion along the weld using an N-layer, N-pass welding method, and the electronic controller generates multiple control signals to periodically control the switching of the three circuits; wherein N is an integer greater than 1; In the case of three-layer three-pass welding: During the welding of the first weld bead, in each first cycle, the electronic controller switches the circuit to connect to the lower portion of the weld seam and maintains the connection for a first time period through the control signal, then switches the circuit to connect to the left wall of the weldment and maintains the connection for a second time period through the control signal, and then switches the circuit to connect to the right wall of the weldment and maintains the connection for a third time period through the control signal; During the second weld bead welding, in each second cycle, the electronic controller switches the circuit to connect to the left wall of the weldment through the control signal and maintains the connection for a fourth time period, then switches the circuit to connect to the lower portion of the weld through the control signal and maintains the connection for a fifth time period, and then switches the circuit to connect to the right wall of the weldment through the control signal and maintains the connection for a sixth time period; When welding the third weld, in each third cycle, the electronic controller switches the circuit to connect with the lower part of the weld through the control signal and maintains it for the seventh time period, then switches the circuit to connect with the left wall of the weldment through the control signal and maintains it for the eighth time period, and then switches the circuit to connect with the right wall of the weldment through the control signal and maintains it for the ninth time period.

2. The single-wire laser-arc hybrid welding device according to claim 1, characterized in that: The electronic controller includes a microcontroller, a solid-state relay and a single-pole three-way switch, wherein the microcontroller is connected to the solid-state relay and the single-pole three-way switch in sequence, and the single-pole three-way switch is connected to the three circuits respectively; The microcontroller generates a control signal and outputs the control signal to the single-pole three-way switch via the solid-state relay to control the single-pole three-way switch to be connected to one of the circuits.

3. The single-wire laser-arc hybrid welding device according to claim 1, characterized in that: One end of the three-way circuit is connected to the geometric center of the left wall of the weld, the geometric center of the right wall of the weld and the geometric center of the lower part of the weld respectively, and the other end of the three-way circuit is connected in parallel with the electronic controller.

4. The single-wire laser-arc hybrid welding device according to claim 1, characterized in that: The current of the welding power supply is 150~250A, and the welding is performed in double pulse mode; The angle between the arc welding gun and the vertical direction is set to 30°; The laser head is perpendicular to the welding surface for welding, the laser power of the laser head is set to 2000 ~ 5000 W, and the welding speed is set to 1 ~ 2 m / min.

5. A single-wire laser-arc hybrid welding method, used for the single-wire laser-arc hybrid welding device according to any one of claims 1 to 4, characterized in that: The method comprises: Starting the laser and the welding power supply so that the laser head emits the laser toward the weld and the arc welding gun simultaneously strikes the arc; The arc welding gun and the laser head are controlled by a motion mechanism to move cyclically along the welding direction of the weld, and during the welding process, the electronic controller periodically controls the switching of the three circuits to achieve control of the arc shape to the left, right and center of the weld during the welding process.

6. The single-wire laser-arc hybrid welding method according to claim 5, characterized in that: The arc welding gun and the laser head are controlled to cyclically move along the welding direction of the weld by a motion mechanism, and the switching of the three circuits is periodically controlled by the electronic controller during the welding process, including: In each time period, the motion mechanism controls the arc welding gun and the laser head to perform cyclic motion along the weld using an N-layer, N-pass welding method, and during the welding process, the electronic controller generates multiple control signals to periodically control the switching of the three circuits; wherein N is an integer greater than 1.

7. The single-wire laser-arc hybrid welding method according to claim 6, characterized in that: In the case of a three-layer three-pass welding method, the electronic controller generates multiple control signals to periodically control the switching of the three circuits, specifically including: During the welding of the first weld bead, in each first cycle, the electronic controller switches the circuit to connect to the lower portion of the weld seam and maintains the connection for a first time period through the control signal, then switches the circuit to connect to the left wall of the weldment and maintains the connection for a second time period through the control signal, and then switches the circuit to connect to the right wall of the weldment and maintains the connection for a third time period through the control signal; During the second weld bead welding, in each second cycle, the electronic controller switches the circuit to connect to the left wall of the weldment through the control signal and maintains the connection for a fourth time period, then switches the circuit to connect to the lower portion of the weld through the control signal and maintains the connection for a fifth time period, and then switches the circuit to connect to the right wall of the weldment through the control signal and maintains the connection for a sixth time period; When welding the third weld, in each third cycle, the electronic controller switches the circuit to connect with the lower part of the weld through the control signal and maintains it for the seventh time period, then switches the circuit to connect with the left wall of the weldment through the control signal and maintains it for the eighth time period, and then switches the circuit to connect with the right wall of the weldment through the control signal and maintains it for the ninth time period.

8. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein: When the processor executes the program, the single-wire laser-arc hybrid welding method according to any one of claims 5 to 7 is implemented.

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