Pulse welding control method and system and storage medium
By adjusting welding parameters in real time and dynamically adjusting the wire feed rate and melting amount, the problem of insufficient adaptability of the sub-pulse cycle during welding was solved, thus achieving stability and controllability of the welding process and improving welding quality.
Patent Information
- Application Number
- CN202511505832.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-21
- Publication Date
- 2026-01-16
AI Technical Summary
In existing welding technologies, the sub-pulse period of pulse welding is difficult to adapt to dynamic changes under different welding conditions, resulting in insufficient arc stability and affecting welding quality.
By collecting real-time parameters during the welding process and dynamically adjusting the sub-pulse cycle, the wire feed rate and melting amount are adjusted in real time using the energy balance principle, the wire resistance thermal correlation coefficient, and the arc thermal efficiency correlation coefficient to ensure the balance of wire energy input and achieve the stability and controllability of the welding process.
It improves the stability and controllability of the welding process, ensures welding quality, is suitable for various welding scenarios, and has good application prospects.
Smart Images
Figure CN121348965A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a pulse welding control method, system, and storage medium, belonging to the field of welding technology, and is mainly applied to gas metal arc welding (GMAW) and is suitable for pulse welding modes. Background Technology
[0002] In existing welding technologies, pulse welding is widely used because it can effectively control heat input and improve weld formation quality. However, during the welding process, the period of the secondary pulse often depends on empirical settings, making it difficult to adapt to dynamic changes under different welding conditions, resulting in insufficient arc stability and affecting weld quality. Summary of the Invention
[0003] The purpose of this invention is to provide a pulse welding control method, system, and storage medium, which achieves stability and controllability of the welding process by calculating and adjusting the sub-pulse period.
[0004] To achieve the above objectives / to solve the above technical problems, the present invention is implemented using the following technical solution.
[0005] On one hand, the present invention provides a pulse welding control method, comprising:
[0006] Collect real-time welding parameters during the welding process;
[0007] Based on the real-time welding parameters, the end time of the sub-pulse cycle is determined for pulse welding control.
[0008] Optional real-time welding parameters include: wire feed speed v (unit: mm / s), welding time t (unit: s), mass of welding wire per unit length a (unit: g / mm), current I (unit: A), voltage U (unit: V), equivalent resistance R (unit: Ω), welding wire resistance thermal correlation coefficient b, and arc thermal efficiency correlation coefficient c.
[0009] Optionally, based on the energy balance principle, the end time of the sub-pulse cycle is determined. The energy balance principle is that the sub-pulse cycle ends when the amount of welding wire fed S and the amount of welding wire melted M are equal.
[0010] Optionally, the formula for calculating the amount of welding wire fed is as follows: The formula for calculating the amount of welding wire melted is: When the energy required to melt the welding wire is equal to the portion of electrical energy converted into heat energy in the electric arc, that is, when the amount of welding wire fed equals the amount of melting, then... This indicates that the energy input of the current sub-pulse has met the requirements for melting the welding wire, and the sub-pulse cycle ends at this time.
[0011] Optionally, the pulse welding control includes: dynamically adjusting the sub-pulse period according to the welding wire resistance thermal correlation coefficient b and the arc thermal efficiency correlation coefficient c, wherein the welding wire resistance thermal correlation coefficient b and the arc thermal efficiency correlation coefficient c are related to the wire extension and the arc length.
[0012] Optionally, the dynamic adjustment of the sub-pulse period includes:
[0013] When the wire extension increases, the arc length increases instantaneously, the correlation coefficient b of the welding wire resistance heat increases, and the correlation coefficient c of the arc thermal efficiency decreases. During the pulse peak, the overall heat generation of the arc and the resistance heat increase, so the extension of the sub-pulse period makes the amount of welding wire melted equal to the amount of welding wire fed.
[0014] When the wire extension shortens, the arc length shortens instantaneously, the correlation coefficient b of the welding wire resistance heat decreases, and the correlation coefficient c of the arc thermal efficiency increases. During the pulse peak, the heat generation and resistance heat decrease as a whole. Therefore, the shortening of the arc sub-pulse period makes the amount of welding wire melted equal to the amount of welding wire fed.
[0015] Within the pulse cycle, the peak period is the primary heat-generating phase due to the high peak current and voltage. During this phase, the amount of welding wire melted is significantly greater than the amount of wire fed during the same period. During the pulse base phase, the current and voltage are low, resulting in less heat generation, far less than the amount of wire fed during the same period. After the start of a pulse, the amount of melting increases sharply, then decreases after the peak ends, until it reaches equilibrium with the amount of welding wire fed.
[0016] In a second aspect, the present invention provides a pulse welding control system, comprising:
[0017] The data acquisition module is configured to acquire real-time welding parameters during the welding process.
[0018] The sub-pulse cycle determination module is configured to determine the end time of the sub-pulse cycle based on the real-time welding parameters for pulse welding control.
[0019] Optional, the sub-pulse period determination module includes:
[0020] The energy calculation unit is used to calculate the amount of welding wire fed S and the amount of welding wire melted M.
[0021] The cycle judgment unit is used to compare the relative magnitudes of the wire feed amount S and the wire melting amount M, as a basis for judging the end of the sub-pulse cycle.
[0022] Optionally, the pulse welding control system may also include: a control output module, used to adjust the period of the sub-pulse based on the judgment result of the sub-pulse period judgment module.
[0023] Thirdly, the present invention provides a computer-readable storage medium having a computer program / instructions stored thereon, characterized in that, when the computer program / instructions are executed by a processor, they implement the steps of the pulse welding control method described in the first aspect.
[0024] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:
[0025] This invention dynamically adjusts the period of the sub-pulse based on real-time welding parameters, which can improve the stability and controllability of the welding process, effectively ensure the quality of welding, and is applicable to a variety of welding scenarios. It has good application prospects and promotion value. Attached Figure Description
[0026] Figure 1 This is a schematic diagram of a pulse welding control method provided in an embodiment of the present invention;
[0027] Figure 2 This is a schematic diagram illustrating the changes in the welding wire feed rate and melting amount provided in an embodiment of the present invention;
[0028] Figure 3 This is a schematic diagram of the welding cycle variation provided in an embodiment of the present invention. Detailed Implementation
[0029] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical solution of the present invention, rather than limitations thereof. In the absence of conflict, the embodiments of the present invention and the technical features in the embodiments can be combined with each other.
[0030] The term "and / or" simply describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. Additionally, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.
[0031] Example 1
[0032] This embodiment introduces a pulse welding control method, such as... Figure 1 As shown.
[0033] Collect real-time welding parameters during the welding process;
[0034] Based on the real-time welding parameters, the end time of the sub-pulse cycle is determined for pulse welding control.
[0035] The calculation of some parameters in this embodiment is explained as follows:
[0036] Under the same electrode extension conditions, different combinations of peak and base currents can be approximated by the fact that the wire resistance thermal correlation coefficient b and the arc thermal efficiency correlation coefficient c are fixed, provided that the arc length remains the same. This is because, during the main pulse, with a sufficient number of pulses, it is possible to obtain the electrode extension characteristic P and the arc length characteristic Q.
[0037] Under the same dry extension P1 and arc length Q1, b and c can be calculated by using different welding currents and voltages.
[0038]
[0039]
[0040] Solving the equations yields b1 and c1 under the conditions of stem elongation P1 and arc length Q1. By changing the stem elongation and arc length in this way, a series of data can be obtained, ultimately leading to b = f ( P ) and c = g ( Q ).
[0041] The first method: b = f ( P ) and c = g(Q) are equations in terms of P and Q, for example b = 0.000006P; c = 1 - 0.0555555Q.
[0042] The second method: b = f ( P ) and c = g ( Q ) are obtained by looking up tables. Table 1 shows the table corresponding to b = f ( P ) and Table 2 shows the table corresponding to c = g ( Q ).
[0043] Table 1. Correspondence table for b = f(P)
[0044]
[0045] Table 2 Correspondence Table of c = g( Q)
[0046]
[0047] In this embodiment, during the welding process, the system collects real-time welding parameters every 10µs. The initial parameters are set as follows:
[0048] Wire feeding speed v = 167 mm / s;
[0049] The mass of the welding wire per unit length is a = 0.01 g / mm;
[0050] Current I = 200A;
[0051] Voltage U = 25V;
[0052] The equivalent resistance R = 0.1Ω;
[0053] Based on the principle of energy balance, the end time of the sub-pulse cycle is determined. The principle of energy balance is that the sub-pulse cycle ends when the amount of welding wire fed S and the amount of welding wire melted M are equal.
[0054] Specifically, the formula for calculating the amount of welding wire fed is as follows: The formula for calculating the amount of welding wire melted is: When the energy required to melt the welding wire is equal to the portion of electrical energy converted into heat energy in the electric arc, that is, when the amount of welding wire fed equals the amount of melting, then... This indicates that the energy input of the current sub-pulse has met the requirements for melting the welding wire, and the sub-pulse cycle ends at this time.
[0055] The pulse welding control includes: dynamically adjusting the sub-pulse period according to the wire resistance thermal correlation coefficient b and the arc thermal efficiency correlation coefficient c, wherein the wire resistance thermal correlation coefficient b and the arc thermal efficiency correlation coefficient c are related to the wire extension and the arc length.
[0056] When the arc elongation increases, the arc length increases instantaneously, the correlation coefficient between resistance heat (b) and arc thermal efficiency (c) increases, and the correlation coefficient between resistance heat generation (b) and arc thermal efficiency (c) decreases. During the pulse peak, both arc heat generation and resistance heat generation increase overall, such as... Figure 2 As shown in M1, the pulse cycle ends when the melting amount and the wire feeding amount S are balanced. Therefore, the pulse cycle increases as the wire extension length increases.
[0057] When the arc extension decreases, the arc length shortens instantaneously, the correlation coefficient between resistance heat (b) and arc thermal efficiency (c) decreases, and the correlation coefficient between resistance heat generation and arc thermal efficiency increases. During the pulse peak, both arc heat generation and resistance heat generation decrease overall, such as... Figure 2 In the pulse cycle M2, the pulse period ends when the melting amount and the wire feed rate S are balanced. Therefore, as the wire elongation decreases, the pulse period decreases.
[0058] Based on the above principles, this embodiment provides three different operating conditions to illustrate the system's workflow.
[0059] Condition 1: In the initial condition, welding begins during the main pulse. At this time, the wire extension P = 0.04 and the arc length Q = 18 are calculated. Based on P and Q, b = 0.00000024 and c = 0.00000011 are calculated. Then, the amount of welding wire melted is calculated. When the amount of welding wire melted is 0.0143g, it is exactly equal to the amount of welding wire fed. The pulse period is 9.3ms. Figure 3 As shown in curve 2, Figure 3 In the diagram, the horizontal axis represents time (for ease of plotting, the unit for time on the horizontal axis is 10µs), and the vertical axis represents the amount of wire fed and the amount of metal melted (unit: g); a straight line represents uniform wire feeding.
[0060] Changes in weld extension during welding affect b and c. Based on the new weld extension, the period of the sub-pulse is adjusted. This embodiment is explained in two cases.
[0061] Condition 2: When the wire extension shortens, the arc length will be adjusted during the main pulse stage, and the wire extension P=0.03 and arc length Q=17.5 will be calculated. Based on P and Q, b=0.00000021 and c=0.00000013 will be calculated, and the amount of welding wire melted will be calculated. When the amount of welding wire melted is 0.0122g, it is exactly equal to the amount of welding wire fed. Figure 3 As shown in curve 3, the pulse period is 8.5ms.
[0062] Operating Condition 3:
[0063] When the wire extension increases, the arc length is adjusted during the main pulse stage, and the wire extension P=0.05 and arc length Q=18.5 are calculated. Based on P and Q, b=0.00000027 and c=0.00000009 are calculated to determine the amount of welding wire melted. When the amount of welding wire melted is 0.0169g, it is exactly equal to the amount of welding wire fed. Figure 3 As shown in curve 1, the pulse period is 11.2ms.
[0064] Example 2
[0065] Based on the same inventive concept as Embodiment 1, this embodiment introduces a pulse welding control system, including:
[0066] The data acquisition module is configured to acquire real-time welding parameters during the welding process.
[0067] The sub-pulse cycle determination module is configured to determine the end time of the sub-pulse cycle based on the real-time welding parameters for pulse welding control.
[0068] Specifically, the sub-pulse period determination module includes:
[0069] The energy calculation unit is used to calculate the amount of welding wire fed S and the amount of welding wire melted M.
[0070] The cycle judgment unit is used to compare the relative magnitudes of the wire feed amount S and the wire melting amount M, as a basis for judging the end of the sub-pulse cycle.
[0071] The pulse welding control system also includes a control output module, which is used to adjust the period of the sub-pulse based on the judgment result of the sub-pulse period judgment module.
[0072] The specific functions of each module described above are explained in the relevant content of the method in Embodiment 1, and will not be repeated here.
[0073] Example 3
[0074] Based on the same inventive concept as other embodiments, this embodiment introduces a computer-readable storage medium storing a computer program / instructions thereon, characterized in that, when the computer program / instructions are executed by a processor, they implement the steps of the pulse welding control method described in Embodiment 1.
[0075] In summary, the present invention dynamically adjusts the period of the sub-pulse according to real-time welding parameters, which can improve the stability and controllability of the welding process, effectively ensure the quality of welding, and is applicable to a variety of welding scenarios, with good application prospects and promotional value.
[0076] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.
[0077] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.
[0078] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.
[0079] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1The steps of the function specified in one or more boxes.
[0080] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.
Claims
1. A method of controlling a pulse welding, characterized by, The method comprises the following steps: collecting real-time welding parameters during welding; determining the end time of a sub-pulse period according to the real-time welding parameters, for pulse welding control.
2. The pulsed welding control method of claim 1, wherein, The real-time welding parameters include wire feeding speed v, welding time t, mass per unit length of wire a, current I, voltage U, equivalent resistance R, wire resistance heat correlation coefficient b, and arc heat efficiency correlation coefficient c.
3. The pulsed welding control method of claim 2, wherein, The end time of the sub-pulse period is determined based on the principle of energy balance, i.e., when the wire feeding amount S is equal to the wire melting amount M, the sub-pulse period ends.
4. The pulsed welding control method of claim 3, wherein, The formula for calculating the wire feed rate is ; The calculation formula of the melting amount of the welding wire is: .
5. The pulsed welding control method of claim 4, wherein, The pulse welding control comprises dynamically adjusting the sub-pulse period according to the wire resistance heat correlation coefficient b and the arc heat efficiency correlation coefficient c, which are related to dry elongation and arc length.
6. The pulsed welding control method of claim 5, wherein, The dynamic adjustment of the sub-pulse period comprises: when the dry elongation becomes longer, the wire resistance heat correlation coefficient b increases and the arc heat efficiency correlation coefficient c decreases, and the sub-pulse period is extended; when the dry elongation becomes shorter, the wire resistance heat correlation coefficient b decreases and the arc heat efficiency correlation coefficient c increases, and the sub-pulse period is shortened.
7. A pulsed welding control system characterized by, The method comprises the following steps: a data collection module configured to collect real-time welding parameters during welding; a sub-pulse period determination module configured to determine the end time of a sub-pulse period according to the real-time welding parameters, for pulse welding control.
8. The pulsed welding control system of claim 7, wherein, The sub-pulse period determination module comprises: an energy calculation unit for calculating the wire feeding amount S and the wire melting amount M; a period determination unit for comparing the relative size of the wire feeding amount S and the wire melting amount M as a basis for determining the end of the sub-pulse period.
9. The pulsed welding control system of claim 7, wherein, Further comprising: a control output module for adjusting the period of the sub-pulse according to the determination result of the sub-pulse period determination module.
10. A computer readable storage medium having stored thereon computer programs / instructions, characterized in that, The computer program / instructions are executed by the processor to implement the steps of the pulse welding control method of any one of claims 1 to 6.