Deep penetration TIG (Tungsten Inert Gas) welding treatment system and method, electronic equipment and medium

Abstract

The embodiment of the invention provides a deep penetration TIG welding treatment system and method, electronic equipment and a medium, and belongs to the technical field of welding. The system is characterized in that a three-phase commutator module outputs received smooth direct-current electric energy converted from three-phase alternating current to each sub-module; the welding module converts the smooth direct-current electric energy into first direct-current electric energy and outputs the first direct-current electric energy to welding equipment; the coupling module converts the smooth direct-current electric energy into sine alternating-current electric energy and outputs the sine alternating-current electric energy to the composite coil; the digital control module controls the wire feeding motor to feed a welding wire into a welding area through the composite coil, the welding wire is heated, when the composite coil is close to welding equipment to a preset distance range, a magnetic field generated by sine alternating current acts on the welding area, electric arcs are promoted to swing, a molten pool in the welding area is stirred, and the welding wire is heated. And efficient connection of the workpieces to be welded is achieved. By means of the system, heat input in the welding process is reduced, and the welding efficiency is improved.

Description

Technical Field

[0001] The present application relates to the field of welding technology, and in particular, to a keyhole TIG welding processing system, method, electronic device and medium. Background Art

[0002] Keyhole TIG welding can penetrate titanium alloys less than 16 mm and stainless steels less than 12 mm without beveling in one pass, with the advantages of high welding efficiency, energy saving and material saving. For thicker plates, due to the limitation of arc penetration, beveling is required and keyhole TIG welding is used for root pass welding first, followed by filler wire welding. If filler wire welding is carried out simultaneously during root pass welding, since melting the filler wire consumes a part of energy, a larger welding current is required, resulting in excessive heat input during welding, coarse grains in the formed welded joint and poor mechanical properties. At the same time, if the welding current is too large, the heat generated by the arc increases, the temperature rises, resulting in a decrease in the surface tension of the molten pool, so the molten pool metal will leak, forming welding defects, greatly limiting the improvement of welding efficiency. Not only can welding not be achieved, but also a cutting effect may be formed. Summary of the Invention

[0003] In order to solve the above technical problems, embodiments of the present application provide a keyhole TIG welding processing system, method, electronic device and medium.

[0004] In a first aspect, embodiments of the present application provide a keyhole TIG welding processing system, the system includes:

[0005] A digital control module, a welding module, a coupling module, a composite coil, a wire feeding motor and a welding device;

[0006] The welding module includes: a three-phase commutator module, a first power switch module, a first high-frequency transformer module and a first high-frequency rectifier and filter module;

[0007] The three-phase commutator module, the first power switch module, the first high-frequency transformer module and the first high-frequency rectifier and filter module are electrically connected in sequence;

[0008] The three-phase commutator module is configured to convert the received three-phase alternating current into smooth direct current electrical energy and output the smooth direct current electrical energy to the first power switch module and the coupling module;

[0009] The digital control module is configured to generate a first high-frequency signal and control the first power switch module to convert the smooth direct current electrical energy into first high-frequency square wave alternating current electrical energy according to the first high-frequency signal;

[0010] The first high-frequency transformer sub-module is used to convert the first high-frequency square-wave AC electrical energy into first low-voltage high-frequency square-wave AC electrical energy and output it to the first high-frequency rectification and filtering sub-module;

[0011] The first high-frequency rectification and filtering sub-module is electrically connected to the welding device and is used to convert the first low-voltage high-frequency square-wave AC electrical energy into first DC electrical energy and output the first DC electrical energy to the welding device;

[0012] The coupling module is respectively electrically connected to the three-phase rectifier sub-module and the composite coil and is used to convert the smooth DC electrical energy into a sine AC current and output it to the composite coil;

[0013] The wire feeding motor is respectively electrically connected to the composite coil and the digital control module. The digital control module is used to control the wire feeding motor to feed the welding wire into the welding area via the composite coil through a second high-frequency control signal, heat the welding wire. When the composite coil approaches the welding device within a preset distance range, the changing magnetic field generated by the sine AC current passing through the composite coil acts on the welding area to stir the molten pool in the welding area and weld the welding wire to the workpiece to be welded in the welding area.

[0014] In one embodiment, the digital control module is electrically connected to the welding module and is used to collect the first DC electrical energy of the welding module, compare the first DC electrical energy value with a target welding current value, and obtain a welding current error value;

[0015] The digital control module is used to perform a closed-loop operation on the welding current error value to obtain an output duty ratio;

[0016] The first power switch sub-module is used to control the welding current value of the welding device within a target preset current value range according to the output duty ratio.

[0017] In one embodiment, the coupling module includes: a second power switch sub-module, a second high-frequency transformer sub-module, a second high-frequency rectification and filtering sub-module, and a third power switch sub-module;

[0018] The second power switch sub-module, the second high-frequency transformer sub-module, the second high-frequency rectification and filtering sub-module, and the third power switch sub-module are electrically connected in sequence;

[0019] The second power switch sub-module is electrically connected to the three-phase rectifier sub-module and is used to obtain the smooth DC electrical energy and transmit the smooth DC electrical energy to the second power switch sub-module;

[0020] The digital control module is used to generate a third high-frequency signal and control the second power switch sub-module according to the third high-frequency signal to convert the smoothed DC electrical energy into second high-frequency square-wave AC electrical energy;

[0021] The second high-frequency transformer sub-module is used to convert the second high-frequency square-wave AC electrical energy into second low-voltage high-frequency square-wave AC electrical energy and transmit the second low-voltage high-frequency square-wave AC electrical energy to the second high-frequency rectification and filtering sub-module;

[0022] The second high-frequency rectification and filtering sub-module is used to convert the second low-voltage high-frequency square-wave AC electrical energy into second DC electrical energy and transmit the second DC electrical energy to the third power switch sub-module;

[0023] The digital control module is used to generate a fourth high-frequency signal and control the third power switch sub-module through the fourth high-frequency signal to convert the second DC electrical energy into the sinusoidal AC current.

[0024] In one embodiment, the digital control module is electrically connected to the second high-frequency rectification and filtering sub-module and is used to collect the second DC electrical energy of the second high-frequency rectification and filtering sub-module and compare the second DC electrical energy with a target voltage value to obtain a voltage error value;

[0025] The digital control module is used to perform a closed-loop operation on the voltage error value to obtain an output phase-shift angle value;

[0026] The second power switch sub-module is used to stabilize the second DC electrical energy within a preset target voltage range according to the output phase-shift angle value.

[0027] In one embodiment, the digital control module is electrically connected to the third power switch sub-module and is further used to collect the sinusoidal AC current value and compare the sinusoidal AC current value with a target AC current value to obtain an AC current error value;

[0028] The digital control module is used to perform a closed-loop operation on the AC current error value to obtain an output pulse-width modulation value;

[0029] The third power switch sub-module is used to stabilize the current frequency and magnitude of the output AC current of the welding equipment within a preset target AC current range according to the output pulse-width modulation value.

[0030] In one embodiment, the digital control module is further used to collect the voltage across the welding wire and the workpiece to be welded and determine whether the voltage value exceeds a preset voltage threshold range;

[0031] If the voltage value exceeds the upper limit of the preset voltage threshold, the wire feeding speed of the wire feeding motor is increased by increasing the duty cycle of the second high-frequency signal;

[0032] If the voltage value is lower than the lower limit of the preset voltage threshold, the wire feeding speed of the wire feeding motor is decreased by decreasing the duty cycle of the second high-frequency signal.

[0033] In a second aspect, an embodiment of the present application provides a keyhole TIG welding processing method, and the keyhole TIG welding processing method includes:

[0034] The three-phase commutator module converts the received three-phase alternating current into smooth direct current energy and outputs the smooth direct current energy to the first power switch module and the coupling module;

[0035] The digital control module generates a first high-frequency signal and controls the first power switch module to convert the smooth direct current energy into first high-frequency square-wave alternating current energy according to the first high-frequency signal;

[0036] The first high-frequency transformer module converts the first high-frequency square-wave alternating current energy into first low-voltage high-frequency square-wave alternating current energy and outputs it to the first high-frequency rectification and filtering module;

[0037] The first high-frequency rectification and filtering module converts the first low-voltage high-frequency square-wave alternating current energy into first direct current energy and outputs the first direct current energy to the welding device;

[0038] The coupling module converts the smooth direct current energy into a sinusoidal alternating current and outputs it to the composite coil;

[0039] The digital control module controls the wire feeding motor to feed the welding wire into the welding area via the composite coil through a second high-frequency signal, and heats the welding wire. When the composite coil approaches the welding device within a preset distance range, the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil acts on the welding area to stir the molten pool in the welding area, and weld the welding wire to the workpiece to be welded in the welding area.

[0040] In an embodiment, the digital control module collects the first direct current energy of the welding module, compares the first direct current energy value with the target welding current value, and obtains a welding current error value;

[0041] The digital control module performs a closed-loop operation on the welding current error value to obtain an output duty cycle;

[0042] The first power switch module controls the welding current value of the welding device within the range of the target preset current value according to the output duty cycle.

[0043] In a third aspect, an embodiment of the present application provides an electronic device, including a memory and a processor. The memory is used to store a computer program, and the computer program executes the keyhole TIG welding processing method provided in the second aspect when running on the processor.

[0044] In a fourth aspect, an embodiment of the present application provides a computer-readable storage medium, which stores a computer program, and the computer program executes the keyhole TIG welding processing method provided in the second aspect when running on a processor.

[0045] The deep penetration TIG welding processing system, method, electronic device and medium provided by the present application described above, the system includes: a digital control module, a welding module, a coupling module, a composite coil, a wire feeding motor and a welding device; the welding module includes: a three-phase commutator module, a first power switch sub-module, a first high-frequency transformer sub-module and a first high-frequency rectification and filtering sub-module; the three-phase commutator module, the first power switch sub-module, the first high-frequency transformer sub-module and the first high-frequency rectification and filtering sub-module are electrically connected in sequence; the three-phase commutator module is used to convert the received three-phase alternating current into smooth direct current electrical energy and output the smooth direct current electrical energy to the first power switch sub-module and the coupling module; the digital control module is used to generate a first high-frequency signal and control the first power switch sub-module to convert the smooth direct current electrical energy into first high-frequency square-wave alternating current electrical energy according to the first high-frequency signal; the first high-frequency transformer sub-module is used to convert the first high-frequency square-wave alternating current electrical energy into first low-voltage high-frequency square-wave alternating current electrical energy and output it to the first high-frequency rectification and filtering sub-module; the first high-frequency rectification and filtering sub-module is electrically connected to the welding device and is used to convert the first low-voltage high-frequency square-wave alternating current electrical energy into first direct current electrical energy and output the first direct current electrical energy to the welding device; the coupling module is respectively electrically connected to the three-phase commutator module and the composite coil and is used to convert the smooth direct current electrical energy into sinusoidal alternating current and output it to the composite coil; the wire feeding motor is respectively electrically connected to the composite coil and the digital control module, and the digital control module is used to control the wire feeding motor to feed the welding wire into the welding area via the composite coil through a second high-frequency control signal, generate a heating effect on the welding wire. When the composite coil approaches the welding device within a preset distance range, the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil acts on the welding area to generate a stirring effect on the molten pool in the welding area, and weld the welding wire to the workpiece to be welded in the welding area. This system uses the composite coil to play the role of induction heating and generating a magnetic field, which can not only preheat the welding wire, without the need for multiple weldings or using a large welding current, significantly reducing the heat input during the welding process and improving the welding efficiency; at the same time, the generated alternating magnetic field prompts the arc to swing, which helps to generate an oscillating effect on the molten pool, thereby achieving grain refinement and improving the mechanical properties of the welded joint; and the oscillation of the molten pool can accelerate the penetration of the base material, reduce the penetration current of the base material, and further reduce the welding heat input. Description of the Drawings

[0046] In order to more clearly illustrate the technical solutions of the present application, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present application and should not be regarded as limiting the protection scope of the present application. In each drawing, similar components are numbered similarly.

[0047] Figure 1 Shows a structural schematic diagram of a keyhole TIG welding processing system;

[0048] Figure 2 Shows a symmetry schematic diagram of a pair of composite coils provided by an embodiment of the present application;

[0049] Figure 3 Shows a deflection schematic diagram of a composite coil provided by an embodiment of the present application;

[0050] Figure 4 Shows another deflection schematic diagram of a composite coil provided by an embodiment of the present application;

[0051] Figure 5 Shows an overall circuit diagram of a keyhole TIG welding processing system provided by an embodiment of the present application;

[0052] Figure 6 Shows a schematic diagram of a closed-loop digital operation model provided by an embodiment of the present application;

[0053] Figure 7 Shows a flow schematic diagram of a keyhole TIG welding processing method;

[0054] Figure 8 Shows a structural schematic diagram of an electronic device provided by an embodiment of the present application.

[0055] Icons: 10 - Digital control module; 20 - Welding module; 30 - Wire feeding motor; 40 - Coupling module; 50 - Composite coil; 60 - Welding equipment, 800 - Electronic device, 801 - Transceiver, 802 - Processor, 803 - Memory. Detailed implementation manners

[0056] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments.

[0057] Generally, the components of the embodiments of the present application described and shown in the accompanying drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the claimed present application, but merely represents selected embodiments of the present application. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without creative efforts belong to the scope of protection of the present application.

[0058] As used hereinafter, the terms "including", "having" and their cognates that may be used in various embodiments of the present application are only intended to indicate specific features, numbers, steps, operations, elements, components or combinations of the foregoing items, and should not be construed as precluding the existence of one or more other features, numbers, steps, operations, elements, components or combinations of the foregoing items or as precluding the possibility of adding one or more features, numbers, steps, operations, elements, components or combinations of the foregoing items.

[0059] In addition, the terms "first", "second", "third", etc. are only used for distinguishing descriptions and should not be construed as indicating or implying relative importance.

[0060] Unless otherwise defined, all terms (including technical terms and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art to which various embodiments of the present application pertain. The terms (such as those defined in commonly used dictionaries) will be interpreted as having the same meaning as the contextual meaning in the relevant technical field and will not be interpreted as having an idealized meaning or an overly formal meaning unless clearly defined in various embodiments of the present application.

[0061] Embodiment 1

[0062] An embodiment of the present application provides a keyhole TIG welding processing system. The system provided by the present application can be used in the field of narrow-gap welding. Compared with the traditional resistance preheating wire method, the system provided by the present application heats the wire when it is about to enter the arc, effectively avoiding the disadvantages of easy softening of the wire and blockage of the wire feeding hose in the traditional method. Moreover, by integrating induction heating and a magnetic field into a whole, the volume of the structure is reduced.

[0063] See Figure 1 , the keyhole TIG welding processing system includes: a digital control module 10, a welding module 20, a coupling module 40, a composite coil 50, a wire feeding motor 30 and a welding device;

[0064] The welding module 20 includes: a three-phase commutator module, a first power switch sub-module, a first high-frequency transformer sub-module, and a first high-frequency rectification and filtering sub-module; the three-phase commutator module, the first power switch sub-module, the first high-frequency transformer sub-module, and the first high-frequency rectification and filtering sub-module are electrically connected in sequence; the three-phase commutator module is configured to convert the received three-phase alternating current into smooth direct current electrical energy and output the smooth direct current electrical energy to the first power switch sub-module and the coupling module; the digital control module is configured to generate a first high-frequency signal and control the first power switch sub-module to convert the smooth direct current electrical energy into first high-frequency square-wave alternating current electrical energy according to the first high-frequency signal; the first high-frequency transformer sub-module is configured to convert the first high-frequency square-wave alternating current electrical energy into first low-voltage high-frequency square-wave alternating current electrical energy and output it to the first high-frequency rectification and filtering sub-module; the first high-frequency rectification and filtering sub-module is electrically connected to the welding device and is configured to convert the first low-voltage high-frequency square-wave alternating current electrical energy into first direct current electrical energy and output the first direct current electrical energy to the welding device; the coupling module is respectively electrically connected to the three-phase commutator module and the composite coil and is configured to convert the smooth direct current electrical energy into sinusoidal alternating current and output it to the composite coil; the wire feeding motor is respectively electrically connected to the composite coil and the digital control module, and the digital control module is configured to control the wire feeding motor to feed the welding wire into the welding area via the composite coil through a second high-frequency control signal, generate a heating effect on the welding wire, and when the composite coil approaches the welding device within a preset distance range, act on the welding area through the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil to generate a stirring effect on the molten pool in the welding area and weld the welding wire to the workpiece to be welded in the welding area.

[0065] In this embodiment, the digital control module 10, the welding module 20, the coupling module 40, the composite coil 50, the wire feeding motor 30, and the welding device 60 are interconnected to achieve the coordinated control of the entire welding system, including current and voltage detection, fault detection, and control signal output, and at the same time achieve the human-machine interaction with the user.

[0066] It should be noted that the coupling module 40 outputs sinusoidal alternating current and acts on the composite coil 50. According to the electromagnetic principle, it can not only generate a heating effect on the welding wire and help preheat the welding wire; at the same time, the composite coil 50 passes through sinusoidal alternating current, and as the current direction changes, the magnetic field direction also changes accordingly. Therefore, an alternating magnetic field can be generated to act on the welding arc; as the magnetic field direction changes, it promotes the arc to generate a swinging effect, which helps to generate a stirring effect on the molten pool area.

[0067] Furthermore, the composite coil 50 is placed within a certain area close to the welding equipment 60, which can heat the welding wire about to be fed into the arc area, preventing the welding wire from overheating and softening at a distance and causing blockage of the wire feeding hose. At the same time, the composite coil 50 being close to the welding equipment 60 helps to introduce the magnetic field into the welding area, achieving the effect of promoting the arc to swing.

[0068] For example, as Figure 2 shown, when no current passes through the composite coil 50, no magnetic field is generated. At this time, the welding arc is vertically downward and centrosymmetric.

[0069] As Figure 3 shown, when current flows into the A end and out of the B end of the composite coil 50, a magnetic field is generated along the axis direction of the composite coil 50, slanting downward to the right. After interacting with the charged ions in the arc, the arc deflects to the right.

[0070] As Figure 4 shown, when current flows out of the A end and into the B end of the composite coil 50, a magnetic field is generated along the axis direction of the composite coil 50, slanting upward to the left. After interacting with the charged ions in the arc, the arc deflects to the left.

[0071] Furthermore, as Figure 5 shown, Figure 5 is the overall circuit diagram of the keyhole TIG welding processing system. The three-phase rectifier module includes: three-phase rectifier bridge BR1, input filter inductor L1, input filter capacitor C1; the first power switch module includes: power switch tubes Q1, Q2, Q3, Q4, the first high-frequency transformer module includes: high-frequency transformer T1, the first high-frequency rectification and filtering module includes: high-frequency rectifier diodes D1, D2, output filter inductor L2, output filter capacitor C2.

[0072] It should be noted that the three-phase rectifier bridge BR1 converts the input three-phase AC electrical energy into pulsating DC electrical energy in the positive half cycle, and in cooperation with the input filter inductor L1 and input filter capacitor C1, it is converted into smooth DC electrical energy. The power switch tubes Q1, Q2, Q3, and Q4 respectively realize the conversion of smooth DC electrical energy into high-frequency square-wave AC electrical energy under the control of the first high-frequency signals PWM1, PWM2, PWM3, and PWM4.

[0073] Among them, when the first high-frequency signals PWM1 and PWM4 are both at high level, the power switching transistors Q1 and Q4 are turned on. At this time, the smooth DC power can flow through the high-frequency transformer T1, and the voltage across its two ends is positive at the top and negative at the bottom. When the first high-frequency signals PWM2 and PWM3 are both at high level, the power switching transistors Q2 and Q3 are turned on. At this time, the smooth DC power can flow through the high-frequency transformer T1, and the voltage across its two ends is negative at the top and positive at the bottom. Under the control of the first high-frequency signal PWM1, the first high-frequency signal PWM2, the first high-frequency signal PWM3, and the first high-frequency signal PWM4 in a cycle, the conversion of the smooth DC power into the first high-frequency square-wave AC power is thus realized.

[0074] Furthermore, the high-frequency transformer T1 steps down and isolates the high-frequency square-wave AC power into the first low-voltage high-frequency square-wave AC power. At the same time, under the action of the high-frequency rectifying diode D1 and the high-frequency rectifying diode D2, it is converted into the first low-voltage high-frequency DC square-wave power, and then is converted into DC power through the output filter inductor L2 and the output filter capacitor C2 to supply the welding device 60. Among them, in this embodiment, the welding device 60 is a keyhole welding torch. In other embodiments, other welding devices 60 can be used.

[0075] In one embodiment, the coupling module 40 includes: a second power switching sub-module, a second high-frequency transformer sub-module, a second high-frequency rectifying and filtering sub-module, and a third power switching sub-module; the second power switching sub-module, the second high-frequency transformer sub-module, the second high-frequency rectifying and filtering sub-module, and the third power switching sub-module are electrically connected in sequence; the second power switching sub-module is electrically connected to the three-phase rectifying sub-module for obtaining the smooth DC power and transmitting the smooth DC power to the second power switching sub-module; the digital control module is used for generating a third high-frequency signal and controlling the second power switching sub-module to convert the smooth DC power into the second high-frequency square-wave AC power according to the third high-frequency signal; the second high-frequency transformer sub-module is used for converting the second high-frequency square-wave AC power into the second low-voltage high-frequency square-wave AC power and transmitting the second low-voltage high-frequency square-wave AC power to the second high-frequency rectifying and filtering sub-module; the second high-frequency rectifying and filtering sub-module is used for converting the second low-voltage high-frequency square-wave AC power into the second DC power and transmitting the second DC power to the third power switching sub-module; the digital control module is used for generating a fourth high-frequency signal and controlling the third power switching sub-module to convert the second DC power into the sinusoidal alternating current through the fourth high-frequency signal.

[0076] In this embodiment, as Figure 5As shown, the second power switch sub-module includes: power switch Q5, power switch Q6, power switch Q7, power switch Q8, and resonant inductor L3; the second high-frequency transformer sub-module includes: resonant inductor L3 and high-frequency transformer T2; the second high-frequency rectification and filtering sub-module includes: high-frequency rectifier diodes D3, D4, D5, D6, and output filter capacitor C2; the third power switch sub-module includes: power switch Q9, power switch Q10, power switch Q11, power switch Q12, output filter inductor L4, and output filter capacitor C4.

[0077] It should be noted that when the third high-frequency signals PWM5 and PWM8 are both at high level, power switches Q5 and Q8 are turned on. At this time, the smooth DC power can flow through power switch Q5, high-frequency transformer T2, resonant inductor L3, and power switch Q8. Therefore, the voltage across the transformer is positive at the top and negative at the bottom. When the third high-frequency signals PWM6 and PWM7 are both at high level, power switches Q6 and Q7 are turned on. At this time, the smooth DC power can flow through power switch Q6, high-frequency transformer T2, resonant inductor L3, and power switch Q7. Therefore, the voltage across the transformer is negative at the top and positive at the bottom, that is, the smooth DC power is converted into the second high-frequency square-wave AC power.

[0078] At the same time, under the action of the resonant inductor L3, zero-voltage turn-on of the power switches Q5, Q6, Q7, and Q8 is achieved, and it is converted into the second low-voltage high-frequency square-wave AC power through the high-frequency transformer T2. Under the action of the high-frequency rectifier diodes D3, D4, D5, and D6, it is converted into the second low-voltage high-frequency square-wave DC power, and becomes DC power after being filtered by the output filter capacitor C3.

[0079] Furthermore, the power switches Q9, Q10, Q11, and Q12 convert DC power into the third low-voltage high-frequency square-wave AC power respectively under the control of the fourth high-frequency signals PWM9, PWM10, PWM11, and PWM12, and are filtered into sinusoidal AC current output under the action of the output filter inductor L4 and output filter capacitor C4.

[0080] In one embodiment, the digital control module is electrically connected to the welding module, and is configured to collect the first DC electrical energy of the welding module, compare the first DC electrical energy value with a target welding current value to obtain a welding current error value; the digital control module is configured to perform a closed-loop operation on the welding current error value to obtain an output duty ratio; the first power switch sub-module is configured to control the welding current value of the welding device within a target preset current value range according to the output duty ratio.

[0081] It should be noted that, as Figure 6 shown, Figure 6 is a unified model for closed-loop digital operation. The digital control module 10 collects the output current I of the welding power supply module wf i.e., the welding current, compares it with the set current I w to obtain an error value e w , and performs a closed-loop digital calculation to obtain an output duty ratio δ, which is then assigned to the first high-frequency signal PWM1, the first high-frequency signal PWM2, the first high-frequency signal PWM3, and the first high-frequency signal PWM4 to achieve the control of the welding current, and it operates in the duty ratio adjustment mode.

[0082] In one embodiment, the digital control module 10 is electrically connected to the second high-frequency rectification and filtering sub-module, and is configured to collect the second DC electrical energy of the second high-frequency rectification and filtering sub-module, compare the second DC electrical energy with a target voltage value to obtain a voltage error value; the digital control module 10 is configured to perform a closed-loop operation on the voltage error value to obtain an output phase shift angle value; the second power switch sub-module is configured to stabilize the second DC electrical energy within a preset target voltage range according to the output phase shift angle value.

[0083] It should be noted that, as Figure 6 shown, the digital control module 10 collects the output voltage V mf , compares it with the set voltage V m to obtain an error value e m , and performs a closed-loop digital calculation to obtain an output phase shift angle θ, which is then assigned to the third high-frequency signal PWM5, the third high-frequency signal PWM6, the third high-frequency signal PWM7, and the third high-frequency signal PWM8 to stabilize the output voltage and make it operate in the phase shift angle adjustment mode.

[0084] In one embodiment, the digital control module 10 is electrically connected to the third power switch sub-module, and is further configured to collect the sinusoidal alternating current value, compare the sinusoidal alternating current value with a target alternating current value to obtain an alternating current error value; the digital control module 10 is configured to perform a closed-loop operation on the alternating current error value to obtain an output quantity pulse width modulation value; the third power switch sub-module is configured to stabilize the current frequency and magnitude of the output alternating current of the welding device within a preset target alternating current range according to the output quantity pulse width modulation value.

[0085] It should be noted that, as Figure 6 shown, the digital control module 10 collects the sinusoidal alternating current I output by the coupling module 40 of the digital control module 10 sf , compares it with the set current I s to obtain an error value e s , and performs a closed-loop digital calculation to obtain an output quantity SVPWM, and thus assigns it to the fourth high-frequency signal PWM9, the fourth high-frequency signal PWM10, the fourth high-frequency signal PWM11, and the fourth high-frequency signal PWM12 to achieve the control of the output current frequency and magnitude.

[0086] The specific sinusoidal alternating current calculation formula is as follows: Is = Imsin(2πft);

[0087] where Is is the set sinusoidal output current, Im is the peak current of the output sine wave, f is the output frequency, and its adjustment process formula is es = Is - Isf, so as to obtain an error and send it to the digital control module 10 for closed-loop digital calculation to obtain a second high-frequency signal.

[0088] In one embodiment, the digital control module 10 is further configured to collect the voltages at both ends of the welding wire and the workpiece to be welded, and determine whether the voltage value exceeds a preset voltage threshold range; if the voltage value exceeds the upper limit of the preset voltage threshold, the wire feeding speed of the wire feeding motor 30 is increased by increasing the duty ratio of the second high-frequency signal; if the voltage value is lower than the lower limit of the preset voltage threshold, the wire feeding speed of the wire feeding motor 30 is decreased by decreasing the duty ratio of the second high-frequency signal.

[0089] It should be noted that by detecting the voltage between the welding wire and the base material, it is determined whether the voltage value exceeds a preset voltage threshold range, and the wire feeding speed of the wire feeding motor 30 is controlled within a certain range to achieve the matching of the melting and feeding of the welding wire.

[0090] The keyhole TIG welding processing system provided by this embodiment uses the composite coil 50 to play the roles of induction heating and generating a magnetic field. It can not only preheat the welding wire, eliminating the need for multiple welds or using a large welding current, significantly reducing the heat input during welding and improving the welding efficiency. At the same time, the generated alternating magnetic field causes the arc to swing, which helps to oscillate the molten pool, thereby achieving grain refinement and improving the mechanical properties of the welded joint. Moreover, the oscillation of the molten pool can accelerate the penetration of the base material, reduce the penetration current of the base material, and further reduce the welding heat input.

[0091] Embodiment 2

[0092] In addition, the embodiment of the present application provides a keyhole TIG welding processing method.

[0093] As Figure 7 shown, S701, the three-phase commutator module converts the received three-phase alternating current into smooth direct current electrical energy and outputs the smooth direct current electrical energy to the first power switch module and the coupling module.

[0094] S702, the digital control module generates a first high-frequency signal and controls the first power switch module according to the first high-frequency signal to convert the smooth direct current electrical energy into first high-frequency square-wave alternating current electrical energy.

[0095] S703, the first high-frequency transformer module converts the first high-frequency square-wave alternating current electrical energy into first low-voltage high-frequency square-wave alternating current electrical energy and outputs it to the first high-frequency rectification and filtering module.

[0096] S704, the first high-frequency rectification and filtering module converts the first low-voltage high-frequency square-wave alternating current electrical energy into first direct current electrical energy and outputs the first direct current electrical energy to the welding equipment.

[0097] S705, the coupling module converts the smooth direct current electrical energy into a sinusoidal alternating current and outputs it to the composite coil.

[0098] S706, the digital control module controls the wire feeding motor to feed the welding wire through the composite coil into the welding area via a second high-frequency signal, heating the welding wire. When the composite coil is close to the welding equipment within a preset distance range, the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil acts on the welding area to stir the molten pool in the welding area, and weld the welding wire to the workpiece to be welded in the welding area.

[0099] In one embodiment, the digital control module collects the first DC electrical energy of the welding module, compares the first DC electrical energy value with the target welding current value to obtain a welding current error value; the digital control module performs a closed-loop operation on the welding current error value to obtain an output duty ratio; the first power switch sub-module controls the welding current value of the welding device within the range of the target preset current value according to the output duty ratio.

[0100] The keyhole TIG welding processing method provided in this embodiment is applied to the keyhole TIG welding processing system provided in Embodiment 1. To avoid repetition, it will not be elaborated here.

[0101] The keyhole TIG welding processing method provided in this embodiment is applied to a keyhole TIG welding processing system. The system uses a composite coil to play the roles of induction heating and generating a magnetic field. It can not only preheat the welding wire, eliminating the need for multiple welds or using a large welding current, significantly reducing the heat input during the welding process and improving the welding efficiency; at the same time, the generated alternating magnetic field causes the arc to swing, which helps to oscillate the molten pool, thereby achieving grain refinement and improving the mechanical properties of the welded joint; and the oscillation of the molten pool can accelerate the penetration of the base material, reduce the penetration current of the base material, and further reduce the welding heat input.

[0102] Embodiment 3

[0103] In addition, an embodiment of the present application provides an electronic device, including a memory and a processor. The memory stores a computer program, and when the computer program runs on the processor, it executes the keyhole TIG welding processing method provided in Embodiment 2.

[0104] Specifically, refer to Figure 8, the electronic device 800 includes: a transceiver 801, a bus interface, and a processor 802. The processor 802 is configured to: The three-phase commutator module converts the received three-phase alternating current into smooth direct current electrical energy, and outputs the smooth direct current electrical energy to the first power switch module and the coupling module; the digital control module generates a first high-frequency signal, and controls the first power switch module according to the first high-frequency signal to convert the smooth direct current electrical energy into first high-frequency square-wave alternating current electrical energy; the first high-frequency transformer module converts the first high-frequency square-wave alternating current electrical energy into first low-voltage high-frequency square-wave alternating current electrical energy, and outputs it to the first high-frequency rectification and filtering module; the first high-frequency rectification and filtering module converts the first low-voltage high-frequency square-wave alternating current electrical energy into first direct current electrical energy, and outputs the first direct current electrical energy to the welding device; the coupling module converts the smooth direct current electrical energy into a sinusoidal alternating current and outputs it to the composite coil; the digital control module controls the wire feeding motor to feed the welding wire through the composite coil into the welding area via a second high-frequency signal, heating the welding wire. When the composite coil approaches the welding device within a preset distance range, the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil acts on the welding area, so as to stir the molten pool in the welding area, and weld the welding wire to the workpiece to be welded in the welding area.

[0105] In one embodiment, the processor 802 is further configured to: the digital control module collects the first direct current electrical energy of the welding module, compares the first direct current electrical energy value with a target welding current value, and obtains a welding current error value; the digital control module performs a closed-loop operation on the welding current error value to obtain an output duty ratio; the first power switch module controls the welding current value of the welding device within the target preset current value range according to the output duty ratio.

[0106] In the embodiment of the present application, the electronic device 800 further includes: a memory 803. In Figure 8 , the bus architecture may include any number of interconnected buses and bridges, specifically various circuits of one or more processors represented by the processor 802 and the memory represented by the memory 803 are linked together. The bus architecture can also link together various other circuits such as peripheral devices, voltage regulators, and power management circuits, which are well known in the art, and therefore, will not be further described herein. The bus interface provides an interface. The transceiver 801 may be a plurality of components, that is, including a transmitter and a receiver, and provides a unit for communicating with various other devices on the transmission medium. The processor 802 is responsible for managing the bus architecture and general processing, and the memory 803 can store the data used by the processor 802 when performing operations.

[0107] The electronic device 800 provided by the embodiments of the present application can execute the steps of the keyhole TIG welding processing method provided in Embodiment 2 of the above method. To avoid repetition, it will not be described in detail here.

[0108] Embodiment 4

[0109] The present application further provides a computer-readable storage medium. A computer program is stored on the computer-readable storage medium, and when the computer program is executed by a processor, it implements the keyhole TIG welding processing method provided in Embodiment 2.

[0110] In this embodiment, the computer-readable storage medium can be a read-only memory (ROM), a random access memory (RAM), a magnetic disk, an optical disc, or the like.

[0111] The computer-readable storage medium provided in this embodiment can implement the keyhole TIG welding processing method provided in Embodiment 2. To avoid repetition, it will not be described in detail here.

[0112] It should be noted that in this article, the term "including", "comprising" or any other variant thereof is intended to cover a non-exclusive inclusion, such that a process, method, article or terminal including a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or terminal. Without further limitation, an element defined by the phrase "including a..." does not exclude the existence of additional identical elements in the process, method, article or terminal including the element.

[0113] Through the description of the above embodiments, those skilled in the art can clearly understand that the above-described embodiment methods can be implemented by means of software plus a necessary general hardware platform. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation. Based on such an understanding, the technical solution of the present application, in essence, or the part that contributes to the prior art can be embodied in the form of a software product. The computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disc) and includes several instructions for causing a terminal (which can be a mobile phone, a computer, a server, an air conditioner, or a network device, etc.) to execute the methods described in various embodiments of the present application.

[0114] The embodiments of the present application have been described above in conjunction with the accompanying drawings. However, the present application is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present application, those of ordinary skill in the art can also make many forms without departing from the purpose of the present application and the scope protected by the claims, and all of them fall within the protection scope of the present application.

Claims

1. A keyhole TIG welding processing system, characterized in that, The system includes: a digital control module, a welding module, a coupling module, a composite coil, a wire feeding motor, and a welding device; The welding module includes: a three-phase commutator module, a first power switch sub-module, a first high-frequency transformer sub-module, and a first high-frequency rectifying and filtering sub-module; The three-phase commutator module, the first power switch sub-module, the first high-frequency transformer sub-module, and the first high-frequency rectifying and filtering sub-module are electrically connected in sequence; The three-phase commutator module is configured to convert the received three-phase alternating current into smooth direct current electrical energy, and output the smooth direct current electrical energy to the first power switch sub-module and the coupling module; The digital control module is configured to generate a first high-frequency signal, and control the first power switch sub-module to convert the smooth direct current electrical energy into first high-frequency square-wave alternating current electrical energy according to the first high-frequency signal; The first high-frequency transformer sub-module is configured to convert the first high-frequency square-wave alternating current electrical energy into first low-voltage high-frequency square-wave alternating current electrical energy, and output it to the first high-frequency rectifying and filtering sub-module; The first high-frequency rectifying and filtering sub-module is electrically connected to the welding device, and is configured to convert the first low-voltage high-frequency square-wave alternating current electrical energy into first direct current electrical energy, and output the first direct current electrical energy to the welding device; The coupling module is respectively electrically connected to the three-phase commutator module and the composite coil, and is configured to convert the smooth direct current electrical energy into sinusoidal alternating current and output it to the composite coil; The wire feeding motor is respectively electrically connected to the composite coil and the digital control module. The digital control module is configured to control the wire feeding motor to feed the welding wire into the welding area via the composite coil through a second high-frequency control signal, and generate a heating effect on the welding wire. When the composite coil approaches the welding device within a preset distance range, the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil acts on the welding area to stir the molten pool in the welding area, and weld the welding wire to the workpiece to be welded in the welding area.

2. The keyhole TIG welding processing system according to claim 1, wherein The digital control module is electrically connected to the welding module, and is configured to collect the first direct current electrical energy of the welding module, and compare the first direct current electrical energy value with a target welding current value to obtain a welding current error value; The digital control module is configured to perform a closed-loop operation on the welding current error value to obtain an output duty ratio; The first power switch sub-module is configured to control the welding current value of the welding device within the target preset current value range according to the output duty ratio.

3. The keyhole TIG welding processing system according to claim 1, wherein, The coupling module includes: a second power switch sub-module, a second high-frequency transformer sub-module, a second high-frequency rectifying and filtering sub-module, and a third power switch sub-module; The second power switch sub-module, the second high-frequency transformer sub-module, the second high-frequency rectifying and filtering sub-module, and the third power switch sub-module are electrically connected in sequence; The second power switch sub-module is electrically connected to the three-phase commutator module, and is configured to obtain the smooth direct current electrical energy, and transmit the smooth direct current electrical energy to the second power switch sub-module; The digital control module is configured to generate a third high-frequency signal and control the second power switch sub-module according to the third high-frequency signal to convert the smoothed DC electrical energy into second high-frequency square-wave AC electrical energy; The second high-frequency transformer sub-module is configured to convert the second high-frequency square-wave AC electrical energy into second low-voltage high-frequency square-wave AC electrical energy and transmit the second low-voltage high-frequency square-wave AC electrical energy to the second high-frequency rectification and filtering sub-module; The second high-frequency rectification and filtering sub-module is configured to convert the second low-voltage high-frequency square-wave AC electrical energy into second DC electrical energy and transmit the second DC electrical energy to the third power switch sub-module; The digital control module is configured to generate a fourth high-frequency signal and control the third power switch sub-module through the fourth high-frequency signal to convert the second DC electrical energy into the sinusoidal AC current.

4. The keyhole TIG welding processing system according to claim 3, wherein, The digital control module is electrically connected to the second high-frequency rectification and filtering sub-module and is configured to collect the second DC electrical energy of the second high-frequency rectification and filtering sub-module and compare the second DC electrical energy with a target voltage value to obtain a voltage error value; The digital control module is configured to perform a closed-loop operation on the voltage error value to obtain an output phase-shift angle value; The second power switch sub-module is configured to stabilize the second DC electrical energy within a preset target voltage range according to the output phase-shift angle value.

5. The keyhole TIG welding processing system according to claim 3, characterized in that, The digital control module is electrically connected to the third power switch sub-module and is further configured to collect the sinusoidal AC current value and compare the sinusoidal AC current value with a target AC current value to obtain an AC current error value; The digital control module is configured to perform a closed-loop operation on the AC current error value to obtain an output pulse-width modulation value; The third power switch sub-module is configured to stabilize the current frequency and magnitude of the output AC current of the welding device within a preset target AC current range according to the output pulse-width modulation value.

6. The keyhole TIG welding processing system according to claim 1, characterized in that The digital control module is further configured to collect the voltage across the welding wire and the workpiece to be welded and determine whether the voltage value exceeds a preset voltage threshold range; If the voltage value exceeds the upper limit of the preset voltage threshold, the wire feeding speed of the wire feeding motor is increased by increasing the duty cycle of the second high-frequency signal; If the voltage value is lower than the lower limit of the preset voltage threshold, the wire feeding speed of the wire feeding motor is decreased by reducing the duty cycle of the second high-frequency signal.

7. A keyhole TIG welding treatment method, characterized in that Applied to the keyhole TIG welding processing system according to any one of 1-6, the method includes: The three-phase rectifier sub-module converts the received three-phase alternating current into smoothed DC electrical energy and outputs the smoothed DC electrical energy to the first power switch sub-module and the coupling module; The digital control module generates a first high-frequency signal and controls the first power switch sub-module according to the first high-frequency signal to convert the smoothed DC electrical energy into first high-frequency square-wave AC electrical energy; The first high-frequency transformer sub-module converts the first high-frequency square-wave AC electrical energy into first low-voltage high-frequency square-wave AC electrical energy and outputs it to the first high-frequency rectification and filtering sub-module; The first high-frequency rectification and filtering sub-module converts the first low-voltage high-frequency square-wave AC electrical energy into first DC electrical energy and outputs the first DC electrical energy to the welding device; The coupling module converts the smoothed DC electrical energy into a sinusoidal alternating current and outputs it to the composite coil; The digital control module controls the wire feeding motor through a second high-frequency signal to feed the welding wire into the welding area via the composite coil, heating the welding wire. When the composite coil approaches the welding device within a preset distance range, the changing magnetic field generated by the sinusoidal alternating current passing through the composite coil acts on the welding area to stir the molten pool in the welding area, and welds the welding wire to the workpiece to be welded in the welding area.

8. The keyhole TIG welding treatment method according to claim 7, characterized in that The method includes: The digital control module collects the first DC electrical energy of the welding module, compares the first DC electrical energy value with the target welding current value, and obtains a welding current error value; The digital control module performs a closed-loop operation on the welding current error value to obtain an output duty cycle; The first power switch sub-module controls the welding current value of the welding device within the range of the target preset current value according to the output duty cycle.

9. An electronic device, characterized in that, It includes a memory and a processor. The memory stores a computer program, and the computer program executes the keyhole TIG welding processing method according to claim 7 or 8 when running on the processor.

10. A computer-readable storage medium, characterized in that, It stores a computer program, and the computer program executes the keyhole TIG welding processing method according to claim 7 or 8 when running on the processor.

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