A method, apparatus, system, and welding device for controlling a wire feed
By real-time monitoring and dynamic adjustment of the negative retraction speed and positive wire feed speed during the droplet transition period and short-circuit phase duration, the problems of arc length consistency and arc stability during welding were solved, thus improving welding quality and efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- PANASONIC WELDING SYST TANGSHAN
- Filing Date
- 2026-04-09
- Publication Date
- 2026-06-09
AI Technical Summary
During the welding process, the instability of the droplet transfer period and the duration of the short-circuit phase leads to poor arc length consistency and arc stability, which affects the welding quality.
By monitoring the droplet transition period and the duration of the short-circuit phase in real time, the transition slope between the negative pullback speed and the positive wire feeding speed is dynamically adjusted to ensure the consistency of the droplet transition period and arc length. Adjustment coefficients λ1, λ2, λ3, λ4, λ5, and λ6 are used for flexible adjustment.
It has improved the stability and efficiency of the welding process, reduced welding defects such as porosity and cracks, and improved welding quality and production automation.
Smart Images
Figure CN122164988A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of intelligent welding technology, and in particular to a wire drawing welding control method, device, system, and welding equipment. Background Technology
[0002] In practical applications, when welding conditions change, such as welding materials of different thicknesses, different welding positions, or welding speeds, the energy during the welding process changes, leading to different cooling rates of the molten pool. This, in turn, alters the droplet transfer period and the duration of the short-circuit phase, resulting in poorer arc length consistency and droplet transfer period consistency, ultimately deteriorating arc stability. Therefore, controlling the droplet transfer period and the duration of the short-circuit phase during wire drawing welding remains a challenge. The short-circuit phase duration refers to the duration during which the molten droplet at the wire tip contacts the base material and forms a short circuit. This duration directly affects the droplet arc length, droplet transfer frequency, and arc stability. Therefore, the droplet transfer period and the duration of the short-circuit phase have a significant impact on arc length stability and consistency. When the droplet transfer period is unstable or the short-circuit phase duration is too long, it can lead to poor arc length consistency and an unstable droplet transfer period, and even cause welding defects such as lack of fusion, porosity, spatter, or other welding defects. Therefore, precise control of the droplet transfer period and the duration of the short-circuit phase is required, and corresponding adjustment measures should be taken when the preset values are exceeded to ensure the consistency of arc length and arc stability during the welding process. In the prior art, the forward wire feeding and reverse wire drawing speeds are usually fixed. This method is difficult to adapt to dynamic changes that occur under different welding conditions, which may lead to poor arc consistency during the welding process and affect the welding quality. Summary of the Invention
[0003] The purpose of this invention is to provide a method, apparatus, system, and welding equipment for controlling wire drawing welding, so as to solve the problem of poor arc length consistency and droplet transfer cycle consistency, which leads to poor arc stability.
[0004] To solve the above problems, the present invention is implemented using the following technical solution:
[0005] In a first aspect, the present invention provides a method for controlling wire drawing welding, comprising:
[0006] Obtain the droplet transition period T and the duration T of the short-circuit phase. S ;
[0007] The droplet transition period T is compared with the preset period T0, and the transition slope between the negative retraction speed and the positive wire feeding speed is adjusted according to the comparison result so that the droplet transition period T approaches the preset period T0.
[0008] The duration T of the short-circuit phase S With preset short-circuit time T S0 Comparison, in response to T S >T S0 To control arc length consistency, the negative retraction speed is reduced and the positive wire feeding speed is increased.
[0009] By monitoring the droplet transition period and short-circuit time in real time, the transition slope and speed value of the retraction and wire feeding speeds are dynamically adjusted to achieve period stability and consistent arc length.
[0010] Furthermore, in response to the droplet transition period T > T0, the transition slope is increased.
[0011] When the droplet transition period is detected to exceed the preset threshold T0, the system automatically adjusts the transition slope to optimize the welding process. This dynamic adjustment ensures stability and efficiency during the welding process, while reducing welding defects and improving welding quality.
[0012] Further, the transition slope includes a negative-to-positive wire feed speed transition slope ACC1 and a positive-to-negative wire feed speed transition slope ACC2; in response to T > T0, the adjusted negative-to-positive wire feed speed transition slope... Adjusted transition slope of wire feed speed from positive to negative direction Where λ1 and λ2 are adjustment coefficients.
[0013] The system can automatically adjust based on real-time feedback, ensuring the stability and accuracy of the welding process, reducing the need for manual intervention, and improving the level of production automation.
[0014] Furthermore, in response to the droplet transition period T < T0, the transition slope is reduced.
[0015] Further, the transition slope includes a negative-to-positive wire feed speed transition slope ACC1 and a positive-to-negative wire feed speed transition slope ACC2; in response to T < T0, the adjusted negative-to-positive wire feed speed transition slope... Adjusted transition slope of wire feed speed from positive to negative direction Where λ3 and λ4 are adjustment coefficients.
[0016] This control method ensures a smoother transition in wire feed speed under different welding conditions, improving welding quality and stability. The system can automatically adjust the transition slope based on real-time feedback to adapt to changing welding environments, thus achieving more precise welding control. Furthermore, this method can reduce welding defects such as porosity and cracks, improving welding efficiency.
[0017] Furthermore, in response to T S >TS0 Adjusted negative pullback speed Adjusted forward wire feed speed Where S2 is the initial negative retraction speed, S1 is the initial positive wire feeding speed, and λ5 and λ6 are adjustment coefficients.
[0018] By introducing adjustment coefficients λ5 and λ6, the system can be flexibly adjusted for different operating conditions, thereby improving overall control accuracy and efficiency. This control strategy not only helps improve the response speed of the equipment but also reduces energy consumption to a certain extent and extends the service life of the equipment.
[0019] Furthermore, the preset period T0 and the preset short-circuit time T S0 The transition slope, the negative retraction speed, and the positive wire feeding speed are set based on the wire diameter, wire type, shielding gas type, and welding current value.
[0020] By flexibly adjusting these parameters, we can better adapt to the needs of different welding scenarios and improve welding efficiency and weld quality.
[0021] Secondly, the present invention also provides a welding device that employs the wire drawing welding control method as described in any of the above claims for welding control.
[0022] Thirdly, the present invention also provides a wire drawing welding control device, comprising:
[0023] The acquisition module is used to obtain the droplet transition period T and the duration T of the short-circuit phase. S ;
[0024] The judgment module is used to compare the droplet transition period T with the preset period T0, and adjust the transition slope between the negative retraction speed and the positive wire feeding speed according to the comparison result, so that the droplet transition period T approaches the preset period T0.
[0025] The response module is used to determine the duration T of the short-circuit phase. S With preset short-circuit time T S0 Comparison, in response to T S >T S0 To control arc length consistency, the negative retraction speed is reduced and the positive wire feeding speed is increased.
[0026] The control device enables precise control of the droplet transition period and the duration of the short-circuit phase during welding, thereby effectively improving welding quality and efficiency. Specifically, the acquisition module monitors and acquires the droplet transition period T and the duration T of the short-circuit phase in real time during the welding process. SThe judgment module compares the collected droplet transition period T with the preset period T0. If a deviation is found, it will quickly adjust the transition slope between the negative retraction speed and the positive wire feeding speed to make the droplet transition period T gradually approach the preset period T0, thus ensuring the stability of the welding process.
[0027] At the same time, the response module will record the duration T of the short-circuit phase. S With the preset short-circuit time T S0 Compare them. Once T is detected... S Greater than T S0 The system will respond immediately, reducing the negative retraction speed and increasing the positive wire feed speed to maintain a stable and consistent arc length. This control mechanism can effectively avoid welding defects caused by fluctuations in welding parameters, such as uneven welds and porosity.
[0028] Furthermore, this device possesses adaptive learning capabilities, automatically adjusting relevant parameters based on different welding materials and environmental conditions to achieve optimal welding results. In practical applications, whether for automated production lines or manual welding operations, this device significantly improves the reliability and consistency of welding quality, reduces welding defect rates, and increases production efficiency and economic benefits.
[0029] Fourthly, the present invention also provides a wire drawing welding control system, including a storage medium and a processor;
[0030] The storage medium is used to store instructions;
[0031] The processor is configured to operate according to the instructions to execute the wire drawing welding control method according to any of the preceding claims.
[0032] The control system enables precise control of the welding process, improving welding quality and efficiency. Specifically, the processor can monitor various parameters during the welding process in real time, such as current, voltage, and welding speed, and adjust them according to preset instructions. Furthermore, the control system can record data during the welding process, facilitating subsequent quality analysis and process improvement.
[0033] Compared with the prior art, the beneficial effects achieved by the wire drawing welding control method, device, system, and welding equipment of the present invention are as follows:
[0034] 1. This invention overcomes the shortcomings of existing technologies that use a fixed wire feed speed and have difficulty adapting to dynamic changes in welding conditions by real-time monitoring and dynamic closed-loop control of two key parameters: droplet transition period and short-circuit duration. This achieves stable control of droplet transition period and consistent arc length, effectively avoiding welding defects such as spatter, lack of fusion, and porosity caused by fluctuations in transition period or changes in arc length.
[0035] 2. The present invention adopts a method of linearly adjusting the overslope of the ratio, enabling the switching of the wire feeding speed to accurately match the deviation degree of difficult droplet transfer, thereby achieving precise control of the droplet transfer cycle and further improving the stability of the welding process. 3. By coordinately adjusting the negative back-drawing speed and the positive wire feeding speed, the present invention effectively solves the problem of poor arc length consistency caused by an overly long short-circuit stage, significantly improving the welding quality.
[0036] BRIEF DESCRIPTION OF THE DRAWINGS
[0037] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or in the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.
[0038] Figure 1 FIG. is a waveform diagram of parameter adjustment for the droplet transfer cycle T>T0 of a draw wire welding control method in some embodiments provided by the present invention;
[0039] Figure 2 FIG. is a schematic flow diagram of parameter adjustment for the droplet transfer cycle T>T0 of a draw wire welding control method in some embodiments provided by the present invention;
[0040] Figure 3 FIG. is a waveform diagram of parameter adjustment for the droplet transfer cycle T<T0 of a draw wire welding control method in some embodiments provided by the present invention;
[0041] Figure 4 FIG. is a schematic flow diagram of parameter adjustment for the droplet transfer cycle T<T0 of a draw wire welding control method in some embodiments provided by the present invention;
[0042] Figure 5 FIG. is the short-circuit stage duration T S >T S0 parameter adjustment waveform diagram of a draw wire welding control method in some embodiments provided by the present invention;
[0043] Figure 6 FIG. is the short-circuit stage duration T S >T S0 parameter adjustment flow schematic diagram of a draw wire welding control method in some embodiments provided by the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use.
[0045] Example 1:
[0046] like Figure 1-6 As shown, this embodiment provides a method for controlling wire drawing welding, including:
[0047] Obtain the droplet transition period T and the duration T of the short-circuit phase. S The wire-drawing arc welding process includes a short-circuit stage and an arc-ignition stage. After the short-circuit contact, the welding wire is drawn back to reduce the instability of the arc. At the same time, the molten droplets are transferred into the weld through the forward wire feeding action.
[0048] The droplet transition period T is compared with a preset period T0, and the transition slope between the negative retraction speed and the positive wire feed speed is adjusted according to the comparison result to make the droplet transition period T approach the preset period T0. The controller identifies the droplet transition moment by monitoring the waveform change of the welding current, and the time interval between two adjacent droplet transition moments is the droplet transition period T. By adjusting the transition slope between the negative retraction speed and the positive wire feed speed, the motion characteristics of the welding wire can be changed, thereby affecting the rhythm of the droplet transition and making T approach T0.
[0049] The duration T of the short-circuit phase S With preset short-circuit time T S0 Comparison, in response to T S >T S0 The negative retraction speed is reduced and the positive wire feed speed is increased to control arc length consistency. The controller identifies the short-circuit phase by monitoring the waveform of the welding voltage. When the welding voltage drops below a preset threshold, the short-circuit phase is determined to begin; when the welding voltage rises back above the preset threshold, the short-circuit phase is determined to end. The duration T of the short-circuit phase is... S This is the time interval between the start and end of the short circuit.
[0050] In summary, the wire-drawing welding control method provided in this embodiment monitors two key parameters in real time: the droplet transition period and the duration of the short-circuit phase, and employs differentiated control strategies for each. On one hand, the transition slope between the negative retraction speed and the positive wire feed speed is dynamically adjusted based on the deviation between the droplet transition period and the preset period, ensuring that the switching rhythm of the wire feed speed precisely matches the changing trend of the preset period, thereby achieving stable control of the droplet transition period. On the other hand, when the duration of the short-circuit phase exceeds a preset threshold, the negative retraction speed is reduced in a coordinated manner to limit the wire retraction height, and the positive wire feed speed is increased to maintain the arc energy input, effectively suppressing arc length fluctuations. These technical means work together to solve the technical problems of unstable droplet transition periods and poor arc length consistency caused by changes in welding conditions in existing technologies. This significantly reduces the generation of welding defects such as spatter, lack of fusion, and porosity, improves the stability and quality of the welding process, and also possesses good process adaptability.
[0051] In some embodiments, the transition slope is increased in response to the droplet transition period T > T0. Optionally, the transition slope includes a negative-to-positive wire feed speed transition slope ACC1 and a positive-to-negative wire feed speed transition slope ACC2; the adjusted negative-to-positive wire feed speed transition slope is adjusted in response to T > T0. Adjusted transition slope of wire feed speed from positive to negative direction Where λ1 and λ2 are adjustment coefficients. This can be understood as follows: Figure 1 As shown, during wire drawing welding, when the droplet transition period output time is long (i.e., droplet transition period T > T0), the slopes ACC1 and ACC2 can be switched by increasing the wire feed speed to ensure that the droplet transition period remains constant. The controller will then adjust the increased speed... and The wire is fed to the wire feeding drive circuit, where the wire feeding motor switches speeds according to the new acceleration, thereby increasing the positive wire feeding speed and the negative wire drawing speed, accelerating the droplet transfer cycle, and making T approach T0. λ1 and λ2 can be preset according to process parameters such as wire diameter, shielding gas type, or welding current value.
[0052] In some embodiments, the transition slope is reduced in response to the droplet transition period T < T0. Optionally, the transition slope includes a negative-to-positive wire feed speed transition slope ACC1 and a positive-to-negative wire feed speed transition slope ACC2; the adjusted negative-to-positive wire feed speed transition slope is adjusted in response to T < T0. Adjusted transition slope of wire feed speed from positive to negative direction Where λ3 and λ4 are adjustment coefficients. This can be understood as... Figure 3As shown, during the drawing and welding process, when the output time of the droplet transfer cycle is short, that is, when the droplet transfer cycle T < T0, by reducing the wire feeding speed switching slopes ACC1 and ACC2, the droplet transfer cycle can be ensured to remain unchanged. The controller will reduce the and and deliver them to the wire feeding drive circuit. The wire feeding motor switches its speed according to the new acceleration, thereby reducing the forward wire feeding speed and the reverse wire drawing speed, slowing down the droplet transfer cycle, and making T approach T0.
[0053] In some embodiments, in response to T S > T S0 , the adjusted reverse wire drawing speed , the adjusted forward wire feeding speed ; where S2 is the initial reverse wire drawing speed, S1 is the initial forward wire feeding speed, and λ5, λ6 are adjustment coefficients. It can be understood that, as Figure 5 shown, during the drawing and welding process, when the duration of the short - circuit stage is long, that is, when the short - circuit stage duration Ts > Ts0, by reducing the reverse wire drawing speed of the welding wire and increasing the forward wire feeding speed, the arc length consistency can be ensured. The controller pre - stores the initial reverse wire drawing speed S2 and the initial forward wire feeding speed S1, as well as the preset short - circuit time T S0 . When the short - circuit stage starts, the controller starts timing. When the timing time reaches T S0 , regardless of whether the short - circuit stage has ended, the controller starts to execute the adjustment operation. Since T S > T S0 , therefore < 1, , that is, the reverse wire drawing speed decreases; at the same time > 1, , that is, the forward wire feeding speed increases. The controller outputs the adjusted reverse wire drawing speed to the wire drawing drive circuit, and the wire drawing motor drives the welding wire to be drawn back according to , reducing the height of the welding wire leaving the molten pool and avoiding the occurrence of a long arc length due to a long wire drawing time.
[0054] At the same time, the controller delivers the adjusted forward wire feeding speed to the wire feeding drive circuit, and the wire feeding motor drives the welding wire to be fed in according to during the next droplet transfer to ensure that the duration of the arc ignition stage of the next droplet transfer remains unchanged and maintain the energy stability of the welding process.
[0055] In some embodiments, the preset cycle T0, the preset short - circuit time T S0The transition slope, negative retraction speed, and positive wire feed speed are set based on the wire diameter, wire type, shielding gas type, and welding current value. It is understood that different wire diameters and types, shielding gases, or current values may result in different welding current waveform designs during the short-circuit and arc-ignition phases. S0 S1, S2, T0, ACC1, ACC2, λ1, λ2, λ3, λ4, λ5, and λ6 also differ. Operators can select the welding wire diameter, welding wire type, shielding gas type, and welding current value through the control panel of the welding equipment. The controller automatically retrieves the corresponding preset parameters based on the selection.
[0056] Example 2:
[0057] This embodiment provides a welding device that employs the wire-drawing welding control method as described in any one of Embodiment 1 for welding control. It can be understood that the welding device provided in this embodiment, by adopting the control method of Embodiment 1, can adapt to dynamic changes under different welding conditions, ensuring the stability of the welding process, reducing spatter, and improving welding quality.
[0058] Example 3:
[0059] This embodiment provides a wire drawing welding control device, including:
[0060] The acquisition module is used to obtain the droplet transition period T and the duration T of the short-circuit phase. S ;
[0061] The judgment module is used to compare the droplet transition period T with the preset period T0, and adjust the transition slope between the negative retraction speed and the positive wire feeding speed according to the comparison result, so that the droplet transition period T approaches the preset period T0.
[0062] The response module is used to determine the duration T of the short-circuit phase. S With preset short-circuit time T S0 Comparison, in response to T S >T S0 To control arc length consistency, the negative retraction speed is reduced and the positive wire feeding speed is increased.
[0063] It is understood that this embodiment, through its modular device structure, can be integrated into the control system of a digital welding machine. The device divides the control logic into three functional modules: acquisition, judgment, and response, thereby realizing the automated control of the wire drawing welding process and facilitating system integration and maintenance.
[0064] Example 4:
[0065] This embodiment provides a wire drawing welding control system, including a storage medium and a processor;
[0066] The storage medium is used to store instructions;
[0067] The processor is configured to operate according to the instructions to execute the wire drawing welding control method according to any one of Embodiment 1.
[0068] It is understood that this embodiment provides a wire drawing welding control system, which can be implemented using a computer program and is suitable for control platforms of various digital welding equipment. The software-based approach, implemented through storage media and a processor, offers advantages such as high flexibility and ease of upgrade and maintenance.
[0069] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A method for controlling wire drawing welding, characterized in that, include: Obtain the droplet transition period T and the duration T of the short-circuit phase. S ; The droplet transition period T is compared with the preset period T0, and the transition slope between the negative retraction speed and the positive wire feeding speed is adjusted according to the comparison result so that the droplet transition period T approaches the preset period T0. The duration T of the short-circuit phase S With preset short-circuit time T S0 Comparison, in response to T S >T S0 To control arc length consistency, the negative retraction speed is reduced and the positive wire feeding speed is increased.
2. The wire drawing welding control method according to claim 1, characterized in that, In response to the droplet transition period T > T0, the transition slope is increased.
3. The wire drawing welding control method according to claim 2, characterized in that, The transition slope includes the negative to positive wire feed speed transition slope ACC1 and the positive to negative wire feed speed transition slope ACC2. In response to T > T0, the adjusted transition slope of the negative to positive wire feed speed Adjusted transition slope of wire feed speed from positive to negative direction Where λ1 and λ2 are adjustment coefficients.
4. The wire drawing welding control method according to claim 1, characterized in that, In response to the droplet transition period T < T0, the transition slope is reduced.
5. The wire drawing welding control method according to claim 4, characterized in that, The transition slope includes the negative to positive wire feed speed transition slope ACC1 and the positive to negative wire feed speed transition slope ACC2. In response to T < T0, the adjusted transition slope of the negative to positive wire feed speed Adjusted transition slope of wire feed speed from positive to negative direction Where λ3 and λ4 are adjustment coefficients.
6. The wire drawing welding control method according to claim 1, characterized in that, Response to T S >T S0 Adjusted negative pullback speed Adjusted forward wire feed speed Where S2 is the initial negative retraction speed, S1 is the initial positive wire feeding speed, and λ5 and λ6 are adjustment coefficients.
7. The wire drawing welding control method according to claim 1, characterized in that, The preset period T0, the preset short-circuit time T S0 The transition slope, the negative retraction speed, and the positive wire feeding speed are set based on the wire diameter, wire type, shielding gas type, and welding current value.
8. A welding device, characterized in that, Welding control is performed using the wire drawing welding control method as described in any one of claims 1 to 7.
9. A wire drawing welding control device, characterized in that, include: The acquisition module is used to obtain the droplet transition period T and the duration T of the short-circuit phase. S ; The judgment module is used to compare the droplet transition period T with the preset period T0, and adjust the transition slope between the negative retraction speed and the positive wire feeding speed according to the comparison result, so that the droplet transition period T approaches the preset period T0. The response module is used to determine the duration T of the short-circuit phase. S With preset short-circuit time T S0 Comparison, in response to T S >T S0 To control arc length consistency, the negative retraction speed is reduced and the positive wire feeding speed is increased.
10. A wire drawing welding control system, characterized in that, Including storage media and processor; The storage medium is used to store instructions; The processor is configured to operate according to the instructions to execute the wire drawing welding control method according to any one of claims 1 to 7.