GMAW-gtaw hybrid aluminum alloy narrow gap welding system based on arc sensing

Abstract

The present application relates to the field of aluminum alloy narrow gap welding, and is a GMAW-GTAW composite aluminum alloy narrow gap welding system and method based on arc sensing. In view of the problems such as incomplete fusion of the side wall in aluminum alloy narrow gap welding, a GMAW-GTAW composite aluminum alloy narrow gap welding system and method is proposed. The GMAW-GTAW composite aluminum alloy narrow gap welding wire filling position control method based on arc sensing is used to control the wire filling position; the GMAW-GTAW composite aluminum alloy narrow gap welding swing amplitude control method based on arc sensing is used to control the swing amplitude of the double guns; and the GMAW-GTAW composite aluminum alloy narrow gap welding double gun position relationship control method based on arc sensing is used to control the position relationship of the double guns.

Description

Technical Field

[0001] This invention relates to the field of narrow gap welding of aluminum alloys, and is a GMAW-GTAW composite aluminum alloy narrow gap welding system and method based on arc sensing. Background Technology

[0002] In recent years, with the increasing demands for lightweight and high-strength structures in high-end equipment, narrow-gap welding has become an important process for joining thick-walled aluminum alloys due to its advantages such as low heat input, high welding efficiency, and small weld shrinkage deformation. However, problems such as poor sidewall fusion during narrow-gap welding pose a severe challenge to the automated control capabilities of the welding system. GTAW-GMAW hybrid welding technology, leveraging the synergistic advantages of GTAW (Gas Metal Arc Welding) with its low heat input and excellent weld formation, combined with GMAW (Gas Metal Arc Welding) with its high deposition efficiency and strong penetration capability, provides a reliable method for narrow-gap welding of aluminum alloys. This invention discloses a GMAW-GTAW hybrid aluminum alloy narrow-gap welding system based on arc sensing. By controlling the welding wire, welding torch, and arc during the welding process, it achieves functions such as independent movement of the two torches, weld tracking, full fusion of sidewalls, welding of zigzag welds, and adaptive weld slope, ultimately improving the quality of narrow-gap welding of aluminum alloys. Summary of the Invention

[0003] A narrow-gap welding system for GMAW-GTAW composite aluminum alloys based on arc sensing is characterized by comprising: a slide table system, a dual-welding-torch adjustable torque ratio slide rail system, a GMAW welding torch adjustment mechanism, a GTAW welding torch adjustment mechanism, a welding power supply system, a welding wire system, an arc signal acquisition system, and a communication and control system; the slide table system comprises X-direction guide rails, Y-direction guide rails, and Z-direction guide rails; the dual-welding-torch adjustable torque ratio slide rail system comprises a boom, a boom rotating slider, and an adjustable torque ratio slide rail; the adjustable torque ratio slide rail system comprises: a boom, a boom rotating slider, and an adjustable torque ratio slide rail; the GMAW-GTAW composite aluminum alloy narrow-gap welding system is characterized by: a slide table system, a dual-welding-torch adjustable torque ratio slide rail system, a GMAW welding torch adjustment mechanism, a GTAW welding torch adjustment mechanism, a welding power supply system, a welding wire system, an arc signal acquisition system, and a communication and control system; the slide table system comprises X-direction guide rails, Y-direction guide rails, and Z-direction guide rails; the dual-welding-torch adjustable torque ratio slide rail system comprises: a boom, a boom rotating slider, and an adjustable torque ratio slide rail; the GMAW-GTAW composite aluminum alloy narrow-gap welding system is characterized by: a slide table system, a dual-welding-torch adjustable torque ratio slide rail ... The torque ratio guide rail includes a boom mounting position above it and GTAW wire feeding mechanism, GTAW welding torch adjustment mechanism, and GMAW welding torch adjustment mechanism mounting positions below it. The GTAW welding torch adjustment mechanism consists of a GTAW rotary guide rail, a GTAW telescopic guide rail, a GTAW telescopic slider, a GTAW rotating arm, a GTAW welding torch rotary joint, and a GTAW welding torch. The GMAW welding torch adjustment mechanism consists of a GMAW rotary guide rail, a GMAW telescopic guide rail, a GMAW telescopic slider, a GMAW rotating arm, a GMAW welding torch rotary joint, and a GMAW welding torch. The welding power system consists of an AC GTAW welding power supply and a DC GTAW welding torch. The MAW welding power supply consists of: a GMAW wire feeder, a GMAW built-in wire feed tube, a GTAW wire feeder, and a GTAW wire feeding mechanism; the GTAW wire feeding mechanism consists of a GTAW wire feeding telescopic slide rail, a GTAW wire feeding telescopic slider, a 5-axis adjustment mechanism, and a wire feed tube; the arc signal acquisition system consists of a Hall voltage sensor, a Hall current sensor, and a data acquisition card; the arc signal acquisition system is used to acquire the tungsten extreme arc signal of the GTAW welding torch and the GMAW welding current signal; the communication and control system consists of an electrical control cabinet and a control cabinet; the electrical control cabinet is used to distribute and convert external power, supply power to various components, and ensure power safety. The control cabinet precisely controls welding process parameters, coordinates welding timing, and links various mechanisms and components via PLC; the arc signal acquisition system and the communication and control system establish a data interaction channel through a communication bus to realize the acquisition of arc signals; the communication and control system realizes the overall displacement of the dual welding torch adjustable torque ratio slide rail system, GMAW welding torch adjustment mechanism, GTAW welding torch adjustment mechanism, and GTAW wire feeding mechanism in the X, Y, and Z directions through the control slide table system; the communication and control system realizes the movement of the GMAW welding torch adjustment mechanism, GTAW welding torch adjustment mechanism, and GTAW wire feeding mechanism on the slide rail through the dual welding torch adjustable torque ratio slide rail system. The arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding system is as follows... Figure 1 As shown.

[0004] The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is characterized in that: one end of the boom is mounted on the Z-direction guide rail of the slide table system, enabling displacement in the X, Y, and Z directions; one end of the boom rotating slider is mounted above the adjustable torque ratio slide rail, allowing movement along the adjustable torque ratio slide rail; the other end of the boom rotating slider is connected to the shaft seat at the other end of the boom, allowing the adjustable torque ratio slide rail to rotate 360° around the Z direction; the GTAW wire feeding telescopic slide rail is mounted below the adjustable torque ratio slide rail, allowing movement along the adjustable torque ratio slide rail; the GTAW wire feeding telescopic slide rail... The telescopic slider is nested inside the GTAW wire feeding telescopic slide rail and can move along the Z direction; the 5-axis adjustment mechanism is installed below the GTAW wire feeding telescopic slider and can rotate 360° around the Z direction; the GTAW wire feeding tube is fixed to the end of the 5th axis, with an angle of 90° with it, and can rotate 180°; the GTAW rotary slide rail is installed below the adjustable torque ratio slide rail and can move along the adjustable torque ratio slide rail and rotate 360° around the Z direction; the GTAW telescopic slide rail is installed on the rotary slide rail and can move along the GTAW rotary slide rail; the GTAW telescopic slider is nested inside the G... The GTAW telescopic slide rail is located inside the GTAW telescopic slide rail and can move along the Z-direction. One end of the GTAW rotating arm is fixedly connected to the GTAW telescopic slider, and the other end of the shaft is connected to the GTAW welding torch rotary joint. The GTAW welding torch is fixedly connected to the GTAW welding torch rotary joint and can rotate 180°. The GMAW rotary slide rail is installed below the adjustable torque ratio slide rail and can move along the adjustable torque ratio slide rail and rotate 360° around the Z-direction. The GMAW telescopic slide rail is installed on the GMAW rotary slide rail and can move along the GMAW rotary slide rail. The GMAW telescopic slider is nested within the GMAW telescopic slide rail. The inner side of the rail allows movement along the Z-direction; one end of the GMAW rotating arm is fixedly connected to the GMAW telescopic slider, and the other end's shaft is connected to the GMAW welding torch rotary joint; the GMAW welding torch is fixedly connected to the GMAW welding torch rotary joint and can rotate 180°; the GMAW welding torch has a built-in wire feed tube installed inside, allowing for simultaneous wire feeding; the GTAW wire feeding mechanism, GTAW welding torch adjustment mechanism, and GMAW welding torch adjustment mechanism are installed in a front-to-back sequence below the adjustable torque ratio slide rail, each moving independently, with the welding sequence being GTAW first, then GMAW. The welding torch installation details of the arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding system are as follows... Figure 2 As shown.

[0005] The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is characterized in that: the filler wire position in the GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is controlled by a GMAW-GTAW composite aluminum alloy narrow gap welding filler wire position control method based on arc sensing; the GMAW-GTAW composite filler wire position control method adjusts the GTAW wire feeding mechanism, the GTAW welding torch adjustment mechanism, and the GMAW welding torch adjustment mechanism through an arc signal acquisition system and a communication and control system. The mechanism controls the filler wire position. After welding begins, the GTAW welding torch adjustment mechanism first ignites the arc. Once successful, the communication and control system, through the arc signal acquisition system, uses the tungsten electrode arc voltage U to raise the GTAW welding torch to a designated height H0. At height H0, the tungsten electrode arc length is L1. After the voltage stabilizes at U0, the GTAW welding torch moves forward along the welding direction and swings to the left. When the tungsten electrode approaches the sidewall position P1, the arc climbs to the sidewall, causing U to decrease from U0 to U1. Then, the GTAW welding torch swings to the right, increasing U from U1 to U0. At position P2 on the other sidewall, U decreases from U0 to U1. The perpendicular bisector of the line connecting P1 and P2 serves as the initial weld seam. The GTAW welding torch begins to move along the direction of the initial weld seam and oscillates left and right. The tungsten electrode arc voltage U is the voltage between the tungsten electrode and the workpiece, which is positively correlated with the arc length L. The height H is the distance between the tungsten electrode and the workpiece. Both sidewall positions P1 and P2 are separated from the sidewall by a distance D1, and the tungsten electrode does not directly contact the sidewall. D1 is the minimum distance between the GTAW welding torch and the sidewall. During GTAW welding, multiple movements from one sidewall to the other are considered. The trend line formed by the midpoints of the trajectory is used to adjust the weld position; after the GTAW welding torch adjustment mechanism enters the broken weld, it turns according to the angle between the line connecting the midpoints of the first two trajectory segments and the previous trend line, and welds along the broken weld; the GTAW wire feeding mechanism fills the wire at the midpoint of each trajectory line that moves from one side of the sidewall to the other; the GTAW welding torch adjustment mechanism establishes a simple harmonic waveform trajectory with the opposite phase based on the simple harmonic waveform trajectory of the GTAW welding torch in front of the welding direction for welding.

[0006] The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is characterized in that: the oscillation amplitude of the dual torches in the GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is controlled by an GMAW-GTAW composite aluminum alloy narrow gap welding oscillation amplitude control method based on arc sensing; the GMAW-GTAW composite aluminum alloy narrow gap welding oscillation amplitude control method based on arc sensing realizes the identification of the sidewall and the control of the minimum distance between the GTAW welding torch and the sidewall; the arc voltage U of the GTAW tungsten electrode changes with the arc length during the GTAW welding torch oscillation, and the slope of the arc voltage change with time is K = ΔU / Δt. Whenever K ≥ K1, the position of the tungsten electrode is the sidewall position, and the time T at this time is recorded. n Then the narrow gap bevel width D0 = V0·(T) n+1 -T n ), n≥1 and n∈Z; K1 is the slope of the arc voltage change with time when the arc climbs to the sidewall, and V0 is the speed of the GTAW welding torch swinging left and right; the minimum distance between the GTAW welding torch and the sidewall is controlled by the arc signal acquisition system and the communication and control system at the minimum distance D1=2mm corresponding to the tungsten end arc voltage U1, with a dwell time T1=0.5s, to preheat the sidewall; the minimum distance between the GMAW welding torch and the sidewall is smaller than that between the GTAW welding torch and the sidewall, and is controlled by the arc signal acquisition system and the communication and control system at the minimum distance D2=1mm corresponding to the tungsten end arc voltage U2, to fully fuse the sidewall; the GTAW welding torch and the GMAW welding torch swing in opposite directions to create a 180° phase difference in the welding trajectory, which crosses symmetrically along the weld.

[0007] The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is characterized in that: the positional relationship of the two torches in the GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is controlled by a GMAW-GTAW composite aluminum alloy narrow gap welding dual torch positional relationship control method based on arc sensing; the GMAW-GTAW composite aluminum alloy narrow gap welding dual torch positional relationship control method includes a GMAW welding torch and GTAW welding torch path difference S control method on the weld seam and an adaptive weld seam slope method; the GMAW welding torch and GTAW welding torch path difference S control method is controlled by a GMAW welding torch adjustment mechanism, a GTAW welding torch adjustment mechanism, a GTAW wire feeding mechanism, a slide table system and a dual welding torch adjustable torque ratio slide rail system to control the path difference S of the two welding torches on the weld seam; after welding starts, the GTAW welding torch adjustment mechanism and the GTAW wire feeding mechanism first move synchronously on the weld seam at welding speed V1, identify the sidewall position and the weld seam position for oscillating welding, and preheat the sidewall; GM The GMAW welding torch adjustment mechanism waits for a time T2 before performing reverse-phase oscillating welding at a welding speed V2 on the weld seam according to the movement trajectory of the GTAW welding torch adjustment mechanism. The waiting time T2 = S0 / V1, where S0 is the initial path difference between the two welding torches, set according to the GMAW-GTAW ratio and heat input. The GMAW welding torch adjustment mechanism, GTAW welding torch adjustment mechanism, and GTAW wire feeding mechanism can all move independently, adjusting their respective speeds. The GMAW welding torch adjustment mechanism and GTAW welding torch adjustment mechanism... When entering the zigzag weld seam, the slide table system and the dual welding torch adjustable torque ratio slide rail system keep V1 and V2 on the weld seam constant, respectively. The boom rotating slider above the adjustable torque ratio slide rail changes its distance between the GMAW welding torch adjustment mechanism and the GTAW welding torch adjustment mechanism to dynamically adjust the torque ratio K2 between the two. The rotating shaft at one end of the boom causes the adjustable torque ratio slide rail to rotate around the boom rotating slider by an angle β, so that the GTAW welding torch adjustment mechanism and the GMAW welding torch adjustment mechanism have opposite velocity components V in the direction perpendicular to the adjustable torque ratio slide rail. 11 =sinβ·V1,V 21 =sin(θ-β)·V2, respectively adjust the component velocity V of the GTAW welding torch adjustment mechanism and the GMAW welding torch adjustment mechanism on the adjustable torque ratio slide rail. 12 =cosβ·V1, V 22 = (θ-β)·V2, so that the resultant velocities V1 and V2 of the two welding torches on the weld seam remain constant according to the set parameters, and can enter the broken weld seam at an angle θ; the torque ratio K2 = V 11 / V 21θ is the included angle of the broken-line weld, and β is the included angle between the adjustable torque ratio slide rail and the broken-line weld. Both are obtained by weld tracking based on arc sensing by the GTAW welding torch adjustment mechanism, and 0≤β≤θ. The process of β decreasing from θ to 0 is the process from the GTAW welding torch entering the broken-line weld to the GMAW welding torch also entering the broken-line weld. The adaptive weld slope method is implemented through the GMAW welding torch adjustment mechanism, the GTAW welding torch adjustment mechanism, the GTAW wire feeding mechanism, the arc signal acquisition system, and the communication and control system. When the GTAW welding torch is welding between the side walls, the arc length L between the tungsten electrode and the workpiece changes due to the weld slope of the unwelded weld. The pressure U fluctuates around U0. When U≤U0, the height of the GTAW welding torch and GTAW wire feed tube is increased; when U≥U0, the height of the GTAW welding torch and GTAW wire feed tube is decreased to stabilize L at L1. When the GMAW welding torch welds between sidewalls, the arc length L between the GMAW welding wire and the workpiece changes due to the weld slope of the already welded weld. The welding current I fluctuates around I0. When I≤I0, the height of the GMAW welding torch is decreased; when I≥I0, the height of the GMAW welding torch is increased to stabilize L at L2. U0 is the arc voltage corresponding to the set arc length L1 of the GTAW welding torch, and I0 is the welding current corresponding to the set arc length L2 of the GMAW welding torch. The schematic diagram of the movement of the GTAW welding torch entering the broken line weld is shown below. Figure 3 As shown.

[0008] Beneficial effects of the invention

[0009] This invention relates to the field of narrow-gap welding of aluminum alloys, and specifically to a GMAW-GTAW composite aluminum alloy narrow-gap welding system and method based on arc sensing. Addressing problems such as incomplete sidewall fusion in narrow-gap welding of aluminum alloys, a GMAW-GTAW composite aluminum alloy narrow-gap welding system and method are proposed. The system utilizes an arc-sensor-based GMAW-GTAW composite aluminum alloy narrow-gap welding filler wire position control method to control the filler wire position; an arc-sensor-based GMAW-GTAW composite aluminum alloy narrow-gap welding oscillation amplitude control method to control the dual-torch oscillation amplitude; and an arc-sensor-based GMAW-GTAW composite aluminum alloy narrow-gap welding dual-torch position relationship control method to control the dual-torch position relationship. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of a GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing.

[0011] In the diagram, 1 is the X-direction guide rail, 2 is the Y-direction guide rail, 3 is the Z-direction guide rail, 4 is the boom, 5 is the boom rotating slider, 6 is the adjustable torque ratio guide rail, 7 is the GTAW welding torch adjustment mechanism, 8 is the GMAW welding torch adjustment mechanism, 9 is the GTAW wire feeding mechanism, 10 is the GTAW welding machine, 11 is the GMAW welding machine, 12 is the Hall voltage sensor, 13 is the Hall current sensor, 14 is the GTAW wire feeder, 15 is the GMAW wire feeder, 16 is the electrical control cabinet, and 17 is the control cabinet.

[0012] Figure 2 Detailed diagram of welding torch installation.

[0013] In the diagram, 18 is the GTAW rotary slide rail, 19 is the GTAW telescopic slide rail, 20 is the GTAW telescopic slider, 21 is the GTAW rotary arm, 22 is the GTAW welding torch rotary joint, 23 is the GTAW welding torch, 24 is the GMAW rotary slide rail, 25 is the GMAW telescopic slide rail, 26 is the GMAW telescopic slider, 27 is the GMAW rotary arm, 28 is the GMAW welding torch rotary joint, 29 is the GMAW welding torch, 30 is the GTAW wire feeding telescopic slide rail, 31 is the GTAW wire feeding telescopic slider, 32 is the 5-axis adjustment mechanism, and 33 is the GTAW wire feeding tube.

[0014] Figure 3 This is a schematic diagram of the movement of the GTAW welding torch entering the zigzag weld seam.

[0015] Figure 4 This is a flowchart of a narrow-gap welding method for GMAW-GTAW composite aluminum alloys based on arc sensing. Detailed Implementation

[0016] To better illustrate the technical solution and beneficial effects of this invention, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. The implementation methods of this invention are not limited thereto.

[0017] Step 1: Controlling the position of the filler wire.

[0018] In the narrow gap welding process of GMAW-GTAW composite aluminum alloy based on arc sensing, it is necessary to locate the weld position to determine the filler wire position. This invention discloses a filler wire position control method for narrow gap welding of GMAW-GTAW composite aluminum alloy based on arc sensing. Because the arc voltage of the GTAW tungsten electrode is proportional to the arc length, during the left-right swinging process of the GTAW welding torch, the arc rises from the workpiece to positions P1, P2, etc., which are a certain distance away from the sidewall, causing a change in the arc length L. This results in a decrease in voltage from U0 to U1. The weld position is adjusted based on the trend line formed by multiple midpoints of the trajectory from one side of the sidewall to the other, such as the midpoint of P1P2. The GTAW filler wire position is the weld position where the midpoint of every two sidewall positions, such as the midpoint of P1P2, is located. The GMAW welding is performed on a simple harmonic waveform trajectory that is out of phase with the trajectory of the GTAW welding torch.

[0019] Step 2: Control the swing amplitude of the two guns.

[0020] In the narrow-gap welding process of GMAW-GTAW composite aluminum alloys based on arc sensing, it is necessary to identify the sidewall to calculate the narrow-gap groove width, and simultaneously control the oscillation amplitude of the two welding torches to limit the minimum distance between the two welding torches and the sidewall. This ensures sufficient fusion of the sidewall while preventing collision between the welding torches and the sidewall. This invention discloses a method for controlling the oscillation amplitude of the two welding torches in narrow-gap welding of GMAW-GTAW composite aluminum alloys based on arc sensing. When the slope K of the arc voltage change over time during the GTAW welding torch oscillation is greater than or equal to K1, the position of the tungsten electrode is the sidewall position, and the time T at this moment is recorded. n Then the narrow gap bevel width D0 = V0·(T) n+1 -T n ), n≥1 and n∈Z. The minimum distance between the GTAW welding torch and the sidewall is controlled at D1 and held at T1 to preheat the sidewall. The minimum distance between the GMAW welding torch and the sidewall is controlled at an even smaller D2 to fully fuse the sidewall. The motion trajectories of the two welding torches are simple harmonic waveform trajectories with opposite phases.

[0021] Step 3: Controlling the positional relationship between the two guns.

[0022] In the narrow-gap welding process of GMAW-GTAW composite aluminum alloys based on arc sensing, GTAW welding is performed first, followed by GMAW welding. When entering the zigzag weld seam, the welding speeds of the two welding torches on the weld seam need to be kept constant according to the set parameters to control the path difference S between the two welding torches on the weld seam. Changes in the weld seam slope affect the weld quality. To address these two issues, this invention discloses a method for controlling the positional relationship of two welding torches in narrow-gap welding of GMAW-GTAW composite aluminum alloys based on arc sensing. The GTAW welding torch performs welding first, identifies the weld seam, and preheats the sidewalls. The GMAW welding torch waits for T2 before welding, and the welding speeds V1 and V2 of the two welding torches are controlled to control the path difference S. When entering the zigzag weld seam, the torque ratio K2 between the GTAW and GMAW welding torches is adjusted in real time via an adjustable torque ratio slide rail. This ensures that the two torches achieve appropriate component velocities in the direction perpendicular to and along the adjustable torque ratio slide rail, maintaining the resultant velocities V1 and V2 on the weld seam constant, thereby controlling the path difference S between the two torches. To maintain the arc lengths at L1 and L2 respectively during GTAW and GMAW welding, achieving an adaptive slope, the height of the GTAW welding torch and GTAW wire feed tube decreases or increases when the arc voltage increases or decreases relative to U0; similarly, the height of the GMAW welding torch increases or decreases when the welding current increases or decreases relative to I0.

Claims

1. A GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing, used for GMAW-GTAW composite aluminum alloy narrow gap welding, characterized in that: The arc-sensing-based GMAW-GTAW composite aluminum alloy narrow-gap welding system comprises a slide table system, a dual-torch adjustable torque ratio slide rail system, a GMAW torch adjustment mechanism, a GTAW torch adjustment mechanism, a welding power supply system, a welding wire system, an arc signal acquisition system, and a communication and control system. The slide table system consists of X-direction guide rails, Y-direction guide rails, and Z-direction guide rails. The dual-torch adjustable torque ratio slide rail system consists of a boom, a boom rotating slider, and an adjustable torque ratio slide rail. The adjustable torque ratio slide rail includes a boom mounting position above and a GTAW wire feeding mechanism mounting position, a GTAW torch adjustment mechanism mounting position, and a GMAW torch adjustment mechanism mounting position below. The GTAW torch adjustment mechanism consists of a GTAW rotating slide rail, a GTAW telescopic slide rail, a GTAW telescopic slider, a GTAW rotating arm, a GTAW torch rotary joint, and a GTAW torch. The GMAW torch adjustment mechanism consists of a GMAW... The system comprises an AW rotary slide rail, a GMAW telescopic slide rail, a GMAW telescopic slider, a GMAW rotary arm, a GMAW welding torch rotary joint, and a GMAW welding torch; the welding power system consists of an AC GTAW welding power supply and a DC GMAW welding power supply; the welding wire system consists of a GMAW wire feeder, a GMAW built-in wire feed tube, a GTAW wire feeder, and a GTAW wire feeding mechanism; the GTAW wire feeding mechanism consists of a GTAW wire feeding telescopic slide rail, a GTAW wire feeding telescopic slider, a 5-axis adjustment mechanism, and a GTAW wire feeding tube; the arc signal acquisition system consists of a Hall voltage sensor, a Hall current sensor, and a data acquisition card; the arc signal acquisition system is used to acquire the tungsten extreme arc signal of the GTAW welding torch and the GMAW welding current signal; the communication and control system consists of an electrical control cabinet and a control cabinet; the electrical control cabinet is used to distribute and convert external power, supply power to various components, and ensure power safety; the control cabinet is connected via a PLC. The system precisely controls welding process parameters, coordinates welding timing, and links various mechanisms and components. A data exchange channel is established between the arc signal acquisition system and the communication and control system via a communication bus to enable the acquisition of arc signals. The communication and control system controls the slide table system to achieve overall displacement of the dual-welding-torch adjustable torque ratio slide rail system, GMAW welding torch adjustment mechanism, GTAW welding torch adjustment mechanism, and GTAW wire feeding mechanism in the X, Y, and Z directions. The communication and control system also controls the movement of the GMAW welding torch adjustment mechanism, GTAW welding torch adjustment mechanism, and GTAW wire feeding mechanism on the slide rail via the dual-welding-torch adjustable torque ratio slide rail system.The arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding system controls the position relationship of the two welding torches using an arc-sensing-based dual-torch position relationship control method. This includes a method for controlling the path difference S between the GMAW and GTAW welding torches on the weld seam and an adaptive weld seam slope method. Specifically, the GTAW welding torch first performs welding, identifies the weld seam, and preheats the sidewall. The GMAW welding torch waits for a set time before welding. When entering the zigzag weld seam, the torque ratio between the GTAW and GMAW welding torches is adjusted in real time using an adjustable torque ratio slide rail. This ensures that the two welding torches obtain appropriate component velocities in the direction perpendicular to the adjustable torque ratio slide rail and in the direction of the adjustable torque ratio slide rail, thereby maintaining a constant resultant velocity on the weld seam and controlling the path difference between the two welding torches. To achieve an adaptive weld slope, the height of the GTAW welding torch and the GTAW wire feed tube is lowered or raised accordingly when the arc voltage increases or decreases relative to the set voltage in GTAW; similarly, the height of the GMAW welding torch is raised or lowered accordingly when the welding current increases or decreases relative to the set current in GMAW.

2. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing according to claim 1, characterized in that: One end of the boom is mounted on the Z-direction guide rail of the slide system, enabling displacement in the X, Y, and Z directions. One end of the boom rotating slider is mounted above the adjustable torque ratio slide rail, allowing it to move along the slide rail. The other end of the boom rotating slider is connected to the shaft seat at the other end of the boom, allowing the adjustable torque ratio slide rail to rotate 360° around the Z-direction. The GTAW wire feeding telescopic slide rail is mounted below the adjustable torque ratio slide rail, allowing it to move along the slide rail. The GTAW wire feeding telescopic slider is nested inside the GTAW wire feeding telescopic slide rail, allowing it to move along the Z-direction. The 5-axis adjustment mechanism is installed below the GTAW wire feeding telescopic slider and can rotate 360° around the Z direction; the GTAW wire feeding tube is fixed to the end of the 5th axis, with an angle of 90° with it, and can rotate 180°; the GTAW rotary slide rail is installed below the adjustable torque ratio slide rail, can move along the adjustable torque ratio slide rail, and can rotate 360° around the Z direction; the GTAW telescopic slide rail is installed on the rotary slide rail and can move along the GTAW rotary slide rail; the GTAW telescopic slider is nested inside the GTAW telescopic slide rail and can move along the Z direction; One end of the GTAW rotating arm is fixedly connected to the GTAW telescopic slider, and the other end of the shaft is connected to the GTAW welding torch rotary joint; the GTAW welding torch is fixedly connected to the GTAW welding torch rotary joint and can rotate 180°; the GMAW rotating slide rail is installed below the adjustable torque ratio slide rail, and can move along the adjustable torque ratio slide rail and rotate 360° around the Z direction; the GMAW telescopic slide rail is installed on the GMAW rotating slide rail and can move along the GMAW rotating slide rail; the GMAW telescopic slider is nested inside the GMAW telescopic slide rail and can move along the Z direction. The GMAW rotating arm is fixedly connected at one end to the GMAW telescopic slider, and at the other end, the shaft seat is connected to the GMAW welding gun rotary joint. The GMAW welding gun is fixedly connected to the GMAW welding gun rotary joint and can rotate 180°. The GMAW welding gun is equipped with a built-in wire feeding tube, which can feed wire simultaneously. The GTAW wire feeding mechanism, GTAW welding gun adjustment mechanism, and GMAW welding gun adjustment mechanism are installed in a front-to-back sequence below the adjustable torque ratio slide rail, and each moves independently. The welding sequence is GTAW first, then GMAW.

3. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing according to claim 1, characterized in that: The filler wire position in the arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding system is controlled by an arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding filler wire position control method. This method uses an arc signal acquisition system and a communication and control system to adjust the GTAW wire feeding mechanism, the GTAW welding torch adjustment mechanism, and the GMAW welding torch adjustment mechanism to control the filler wire position. After welding begins, the GTAW welding torch... The adjustment mechanism first ignites the arc. After successful arc ignition, the communication and control system raises the GTAW welding torch to a designated height H0 based on the tungsten electrode arc voltage U acquired by the arc signal acquisition system. At height H0, the tungsten electrode arc length is L1. After the voltage stabilizes at U0, the GTAW welding torch moves forward along the welding direction and swings to the left. When the tungsten electrode approaches position P1 on one side of the sidewall, the arc climbs to the sidewall, causing U to decrease from U0 to U1. At this point, the GTAW welding torch swings to the right, increasing U from U1 to U0. When it approaches position P2 on the other sidewall, U decreases again from U0. As shown in U1, the perpendicular bisector of the line connecting P1 and P2 serves as the initial weld seam. The GTAW welding torch begins to move along the direction of the initial weld seam and oscillates left and right. The tungsten electrode arc voltage U is the voltage between the tungsten electrode and the workpiece, which is positively correlated with the arc length L. The height H is the distance between the tungsten electrode and the workpiece. The positions P1 and P2 are both separated from the sidewall by a distance D1, and the tungsten electrode does not directly contact the sidewall. D1 is the minimum distance between the GTAW welding torch and the sidewall. During GTAW welding, the GTAW torch is formed by the midpoints of multiple trajectories moving from one side of the sidewall to the other. The trend line adjusts the weld position; after the GTAW welding torch adjustment mechanism enters the broken weld, it turns according to the angle between the line connecting the midpoints of the first two trajectory segments and the previous trend line, and welds along the broken weld; the GTAW wire feeding mechanism fills the wire at the midpoint of each trajectory line moving from one side of the sidewall to the other; the GTAW welding torch adjustment mechanism establishes a simple harmonic waveform trajectory in opposite phase to the simple harmonic waveform trajectory traversed by the GTAW welding torch in the welding direction for welding.

4. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing according to claim 1, characterized in that: The dual-gun oscillation amplitude in the arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding system is controlled by the arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding dual-gun oscillation amplitude control method; the arc-sensing-based GMAW-GTAW composite aluminum alloy narrow gap welding oscillation amplitude control method realizes the identification of the sidewall and the control of the minimum distance between the GTAW welding gun, the GMAW welding gun and the sidewall. The arc voltage U of the GTAW tungsten electrode changes with the arc length during the GTAW welding torch oscillation. The slope of the arc voltage change with time is K = ΔU / Δt. Whenever K ≥ K1, the position of the tungsten electrode, i.e., the sidewall position, is recorded at this time, and the time T is recorded. n Then the narrow gap bevel width D0 = V0·(T) n+1 -T n ), n≥1 and n∈Z; K1 is the slope of the arc voltage change with time when the arc climbs to the sidewall, and V0 is the speed of the GTAW welding torch swinging left and right; the minimum distance between the GTAW welding torch and the sidewall is controlled by the arc signal acquisition system and the communication and control system at the minimum distance D1=2mm corresponding to the tungsten end arc voltage U1, with a dwell time T1=0.5s, to preheat the sidewall; the minimum distance between the GMAW welding torch and the sidewall is smaller than that between the GTAW welding torch and the sidewall, and is controlled by the arc signal acquisition system and the communication and control system at the minimum distance D2=1mm corresponding to the GTAW tungsten end arc voltage U2, to fully fuse the sidewall; the GTAW welding torch and the GMAW welding torch swing in opposite directions to create a 180° phase difference in the welding trajectory, which crosses symmetrically along the weld.

5. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing according to claim 1, characterized in that: The method for controlling the path difference S between the GMAW and GTAW welding torches on the weld seam utilizes a GMAW torch adjustment mechanism, a GTAW torch adjustment mechanism, a GTAW wire feeding mechanism, a slide system, and a dual-torch adjustable torque ratio slide rail system to control the path difference S between the two torches on the weld seam. After welding begins, the GTAW torch adjustment mechanism and the GTAW wire feeding mechanism first move synchronously on the weld seam at welding speed V1, identifying the sidewall position and the weld seam position for oscillating welding and preheating the sidewall. The GMAW torch adjustment mechanism waits for time T2 before performing anti-phase oscillating welding on the weld seam according to the movement trajectory of the GTAW torch adjustment mechanism. The waiting time T2 = S0 / V1, where S0 is the initial path difference set between the two torches, determined according to the GMAW-GTAW... The AW ratio and heat input settings are configured; the GMAW welding torch adjustment mechanism, GTAW welding torch adjustment mechanism, and GTAW wire feeding mechanism can all move independently and adjust their respective speeds; when the GMAW welding torch adjustment mechanism and GTAW welding torch adjustment mechanism enter the zigzag weld seam, the slide table system and the dual welding torch adjustable torque ratio slide rail system keep V1 and V2 on the weld seam constant, respectively. The boom rotating slider above the adjustable torque ratio slide rail changes its distance between the GMAW welding torch adjustment mechanism and the GTAW welding torch adjustment mechanism to dynamically adjust the torque ratio K2 between the two. The rotating shaft at one end of the boom causes the adjustable torque ratio slide rail to rotate around the boom rotating slider by an angle β, so that the GTAW welding torch adjustment mechanism and the GMAW welding torch adjustment mechanism have opposite velocity components V in the direction perpendicular to the adjustable torque ratio slide rail. 11 =sinβ·V1、V 21 =sin(θ-β)·V2, respectively adjust the component velocity V of the GTAW welding torch adjustment mechanism and the GMAW welding torch adjustment mechanism in the direction of the adjustable torque ratio slide rail. 12 =cosβ·V1、V 22 =(θ-β)·V2, so that the resultant velocities V1 and V2 of the two welding torches on the weld seam remain constant according to the set parameters, and can enter the broken weld seam at an angle θ; the torque ratio K2=V 11 / V 21 θ is the included angle of the broken-line weld, and β is the included angle between the adjustable torque ratio slide rail and the broken-line weld. Both are obtained by weld tracking based on arc sensing by the GTAW welding torch adjustment mechanism, and 0≤β≤θ. The process of β decreasing from θ to 0 is the process from the GTAW welding torch entering the broken-line weld to the GMAW welding torch also entering the broken-line weld. The adaptive weld slope method is implemented through the GMAW welding torch adjustment mechanism, the GTAW welding torch adjustment mechanism, the GTAW wire feeding mechanism, the arc signal acquisition system, and the communication and control system. When the GTAW welding torch is welding between the side walls, the arc length L between the tungsten electrode and the workpiece changes due to the weld slope of the unwelded weld. The pressure U fluctuates around U0. When U≤U0, the height of the GTAW welding torch and GTAW wire feed tube is increased; when U≥U0, the height of the GTAW welding torch and GTAW wire feed tube is decreased to stabilize L at L1. When the GMAW welding torch is welding between the side walls, the arc length L between the GMAW welding wire and the workpiece changes due to the weld slope of the already welded weld. The welding current I fluctuates around I0. When I≤I0, the height of the GMAW welding torch is decreased; when I≥I0, the height of the GMAW welding torch is increased to stabilize L at L2. U0 is the arc voltage of the GTAW welding torch at the set arc length L1, and I0 is the welding current of the GMAW welding torch at the set arc length L2.

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