A push-pull wire feeder, a wire feeding control method, and a laser processing system

Abstract

This invention discloses a push-pull wire feeder, a wire feeding control method, and a laser processing system. The push-pull wire feeder includes: a wire spool for winding welding wire; a rear wire pusher for pushing the welding wire on the spool into the wire feeding tube; a front wire puller for pulling the welding wire into the welding gun wire tube and monitoring the welding wire movement in real time to obtain welding wire movement status information; and a wire feeding control device for using a preset algorithm to calculate the torque change of the front wire puller and the welding wire movement status information, respectively, and outputting control commands to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire puller, controlling the rear wire pusher and the front wire puller to rotate collaboratively. This controls the coordinated rotation of the rear wire pusher and the front wire puller, achieving precise welding wire output control, realizing high-precision closed-loop control, possessing extremely fast dynamic response speed, adapting to complex working conditions, and improving the wire feeding stability and welding quality during the welding process.

Description

Technical Field

[0001] This invention relates to the field of laser welding technology, and in particular to a push-pull wire feeder, a wire feeding control method, and a laser processing system. Background Technology

[0002] In welding processes, the welding wire feeding system is a core component of automated laser processing systems. Its wire feeding accuracy, motor synchronization, dynamic response capability, and adaptive performance directly determine the stability of the welding process, the controllability of the molten pool, and the quality of the final weld formation.

[0003] Currently, to balance working range and stability, push-pull wire feeding has emerged. This method involves placing a wire puller at the welding torch end as an auxiliary power source, rotating in tandem with the base's wire pusher. However, existing push-pull wire feeding systems have several shortcomings: poor speed synchronization between the pusher and pull motors easily leads to wire accumulation, warping, or breakage, compromising feeding stability and affecting weld formation; the system's dynamic response is slow, unable to quickly compensate for changes in wire feeding resistance, robot movement, and other disturbances, resulting in large fluctuations in wire feeding speed, making it difficult to meet the requirements of high-end welding processes; the control strategy is coarse, lacking closed-loop control based on real-time feedback, unable to adapt to changes in parameters such as wire characteristics and wire spool weight, resulting in poor adaptability; during long-distance wire feeding, the wire is prone to serpentine bending, increasing friction, reducing feeding stability, and limiting the robot's working range; insufficient wire feeding and trajectory accuracy make it difficult to meet the stringent requirements of high-power laser welding, thin-plate welding, and other high-end processes for wire feeding speed stability and trajectory accuracy.

[0004] Therefore, a high-precision, fast-response, and highly adaptive push-pull wire feeder is needed to solve the above-mentioned technical problems. Summary of the Invention

[0005] In view of this, the present invention provides a push-pull wire feeder, a wire feeding control method, and a laser processing system to solve the problems of poor speed synchronization accuracy of the push motor and the draw motor, slow dynamic response, and lack of closed-loop control based on real-time feedback in the existing push-pull wire feeding system.

[0006] To solve the above-mentioned technical problems, the first aspect of the present invention provides the following technical solution: a push-pull type wire feeder, comprising a welding wire spool, welding wire, a rear wire pusher, a wire feeding tube, a wire feeding control device, a front wire drawing machine, and a welding gun wire tube, wherein the wire feeding control device is electrically connected to the rear wire pusher and the front wire drawing machine respectively; wherein: The welding wire spool is used to wind the welding wire; The rear wire pusher is used to push the welding wire on the welding wire spool into the wire feeding tube according to the control command of the wire feeding control device. The front-end wire drawing machine is used to pull the welding wire into the welding gun wire tube according to the control command of the wire feeding control device; and to monitor the movement of the welding wire in real time to obtain the welding wire movement status information and transmit it to the wire feeding control device. The wire feeding control device is used to calculate the torque change of the front wire drawing machine and the motion state information of the welding wire using a preset algorithm, and output control commands to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire drawing machine, thereby controlling the rear wire pusher and the front wire drawing machine to rotate in coordination.

[0007] Optionally, the wire feeding control device includes a central controller, a rear-end motor driver, and a front-end motor driver; wherein: The central controller is electrically connected to the rear motor driver and the front motor driver respectively, and is used to calculate the torque change of the front wire drawing machine and the motion state information of the welding wire using a preset algorithm, and output control commands to the rear motor driver and the front motor driver respectively. The rear-end motor driver is used to drive the rear-end wire pusher, which is electrically connected to it, to operate according to the control instructions of the central controller. The front-end motor driver is used to drive the front-end wire drawing machine, which is electrically connected to it, to operate according to the control instructions of the central controller.

[0008] Optionally, the rear wire pusher includes a rear wire pusher motor and a wire pusher roller assembly, wherein: The rear wire pusher motor is electrically connected to the rear motor driver and is used to operate under the drive of the rear motor driver. The welding wire on the welding wire spool is in close contact with the wire pusher roller assembly, which is connected to the rear wire pusher motor and is used to transport the welding wire under the drive of the rear wire pusher motor, feeding the welding wire into the wire feeding tube.

[0009] Optionally, the front-end wire drawing machine includes a front-end wire drawing motor, a wire drawing roller assembly, and a welding wire encoder; wherein: The front-end wire drawing motor is electrically connected to the front-end motor driver and is used to operate under the drive of the front-end motor driver; The wire drawing roller assembly is connected to the front-end wire drawing motor and is used to operate under the drive of the front-end wire drawing motor to draw the welding wire and feed the welding wire into the welding gun wire tube. The welding wire encoder is located at the wire exit point behind the wire drawing roller assembly. It rotates with the movement of the welding wire to monitor the movement of the welding wire in real time, obtain the welding wire movement status information, and transmit the welding wire movement status information to the central controller.

[0010] Optionally, the preset algorithm is a PID control algorithm; the central controller uses the PID control algorithm to calculate the torque change of the front-end wire drawing machine and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pushing motor.

[0011] Optionally, the preset algorithm is a PID control algorithm; the central controller uses the PID control algorithm to calculate the motion state information of the welding wire and outputs control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing motor.

[0012] Accordingly, the second aspect of the present invention provides the following technical solution: a wire feeding control method, comprising: Output control commands to control the back-end wire pusher to push the welding wire wound on the welding wire spool into the wire feeding tube; Output control commands to control the front-end wire drawing machine to pull the welding wire into the welding gun wire tube; The preset algorithm is used to calculate the torque change of the front wire drawing machine and the welding wire motion status information, and outputs control commands to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire drawing machine, so as to control the rear wire pusher and the front wire drawing machine to rotate in coordination. The welding wire motion status information is obtained by the front wire drawing machine from real-time monitoring of the welding wire motion.

[0013] Optionally, the preset algorithm is a PID control algorithm; the step of using the preset algorithm to calculate the welding wire motion state information and outputting control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing machine includes: S3A1 sends a control command to the front-end motor driver to drive the front-end wire drawing motor to start running at the set target wire feeding speed to feed the welding wire. S3A2: Obtain the actual wire feeding speed collected in real time by the wire encoder; S3A3. Compare the actual wire feeding speed with the set target wire feeding speed, and calculate the real-time wire feeding speed error value, wherein the wire feeding speed error value is the difference between the actual wire feeding speed and the set target wire feeding speed. S3A4. Use a PID control algorithm to perform PID calculation on the wire feeding speed error value and output a control quantity to eliminate the wire feeding speed error. S3A5. Based on the control quantity, update the control command and send it to the front-end motor driver, so that the front-end motor driver drives the front-end wire drawing motor to adjust the speed according to the updated control command; S3A6. Repeat steps S3A2 to S3A5 to form a real-time closed-loop feedback compensation control.

[0014] Optionally, the preset algorithm is a PID control algorithm; the step of using the preset algorithm to calculate the torque change of the front-end wire drawing machine and outputting control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pushing machine includes: S3B1 sends a control command to the rear motor driver to drive the rear wire pusher motor to start running at the initial wire pusher torque value to feed the welding wire. S3B2: Real-time reading of the actual working torque value of the front-end wire drawing motor; S3B3. Compare the actual working torque value of the front-end wire drawing motor with the target torque value of the front-end wire drawing motor, and calculate the real-time torque error value, wherein the torque error value is the difference between the target torque value of the front-end wire drawing motor and the actual working torque value of the front-end wire drawing motor. S3B4. Use a PID control algorithm to perform PID calculation on the torque error value and output a control quantity for correcting the torque of the back-end wire pusher motor. S3B5. According to the control quantity, update the torque parameters of the back-end motor driver in real time, so that the back-end motor driver drives the back-end wire pusher motor to adjust its output working torque according to the updated torque parameters. S3B6. Repeat steps S3B2 to S3B5 to form a real-time closed-loop feedback compensation control.

[0015] Accordingly, the third aspect of the present invention provides the following technical solution: a laser processing system, including the push-pull wire feeder described in the first aspect of the present invention.

[0016] Compared with related technologies, the present invention proposes a push-pull wire feeder, a wire feeding control method, and a laser processing system. The push-pull wire feeder pushes the welding wire wound on the welding wire spool into the wire feeding tube according to the control instructions of the wire feeding control device, allowing the welding wire to reach the front wire drawing machine via the wire feeding tube. The front wire drawing machine pulls the welding wire into the welding gun wire tube according to the control instructions of the wire feeding control device, allowing the welding wire to reach the workpiece after passing through the welding gun wire tube. The system also monitors the welding wire movement in real time to obtain welding wire movement status information, which is transmitted to the wire feeding control device. The wire feeding control device uses a preset algorithm to calculate the torque change of the front wire drawing machine and the received welding wire movement status information, respectively, and outputs control instructions to perform real-time closed-loop feedback compensation control on the rear wire feeder and the front wire drawing machine, controlling the rear wire feeder and the front wire drawing machine to rotate collaboratively. By placing the front-end wire drawing machine as close as possible to the welding torch, deformation errors caused by the long wire tube are eliminated. The front-end wire drawing machine monitors the wire movement in real time to obtain wire movement status information, which is then transmitted to the wire feeding control device. The wire feeding control device uses a preset algorithm to calculate the torque changes of the front-end wire drawing machine and the wire movement status information, respectively, and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pusher and the front-end wire drawing machine. This controls the rear-end wire pusher and the front-end wire drawing machine to rotate in tandem, achieving precise wire feeding control. This enables the push-pull wire feeder to achieve high-precision closed-loop control, extremely fast dynamic response speed, and adaptability to complex working conditions, improving the wire feeding stability and weld quality during the welding process. This solves the problems of poor speed synchronization accuracy between the pusher and drawer motors, slow dynamic response, and lack of real-time feedback-based closed-loop control in existing push-pull wire feeding systems. Attached Figure Description

[0017] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0018] Figure 1 This is a schematic diagram of the structure of a push-pull type wire feeder provided by the present invention; Figure 2 A schematic flowchart of a wire feeding control method provided by the present invention; Figure 3 The present invention provides a schematic diagram of a wire feeding control method that uses a PID control algorithm to calculate the motion state information of the welding wire and outputs control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing machine. Figure 4 The present invention provides a schematic diagram of a wire feeding control method that uses a PID control algorithm to calculate the motion state information of the welding wire and outputs control commands to perform real-time closed-loop feedback compensation control on the back-end wire pusher. Figure 5 This is a schematic diagram of a laser processing system provided by the present invention. Detailed Implementation

[0019] To make the technical problems, solutions, and beneficial effects of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0020] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrative purposes and has no specific meaning in itself. Therefore, "module," "part," or "unit" may be used interchangeably.

[0021] It should be noted that the terms "first," "second," etc., in the specification, claims, and drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0022] In welding processes, the welding wire feeding system is a core component of automated laser processing systems. Its wire feeding accuracy, motor synchronization, dynamic response capability, and adaptive performance directly determine the stability of the welding process, the controllability of the molten pool, and the quality of the final weld formation. Currently, the main wire feeding methods include push-type, pull-type, and push-pull-type.

[0023] 1. Existing wire feeding methods and their limitations.

[0024] Wire feeders with pusher-type wire feeding mechanisms are simple in structure and use lightweight welding torches, making them the most widely used wire feeding method. However, the power source (wire feeder) is located far from the welding torch, requiring the welding wire to pass through a relatively long wire feeding hose. As the length of the hose increases, the frictional resistance between the welding wire and the inner wall of the hose increases significantly, easily causing the welding wire to bend or even get stuck inside the hose, severely affecting the stability of wire feeding. Therefore, the length of the wire feeding hose in pusher-type wire feeding mechanisms is usually limited to 2 to 5 meters, greatly restricting the robot's working range. In addition, the wire feeding hose itself has elastic deformation, and the longer the hose, the greater this deformation. This deformation ultimately translates into an error in the actual wire output length; the longer the hose, the greater the actual wire output error. This makes precise control of wire feeding almost impossible, ultimately making it impossible to control the quality of the weld formation.

[0025] Wire-drawing feeders integrate the wire feeding mechanism directly onto the welding torch, which solves some of the problems associated with long flexible tubes. However, wire-drawing feeders cannot balance weight and wire-drawing power: to make the welding torch lightweight and flexible, a small feeder motor must be selected and the wire feeding wheel structure simplified, which significantly reduces the wire-drawing power, making it only suitable for small-diameter welding wires and limiting the length of the wire feeding tube; to increase the wire-drawing power, a medium-to-large-sized wire feeding motor is selected and the wire feeding wheel structure is strengthened, which leads to a significant increase in the weight of the welding torch, making operation cumbersome and significantly reducing the flexibility of the robotic arm, making it difficult to meet the requirements of modern automated welding for flexibility and lightweight design.

[0026] To balance working range and stability, a push-pull wire feeding method has emerged. This method places a wire puller at the welding torch end as an auxiliary power source, rotating in tandem with the substrate's wire pusher. Theoretically, this method can extend the effective wire feeding distance to 15 meters or even 20 meters. However, existing push-pull systems have significant drawbacks: poor speed synchronization between the push and pull motors. In practice, if the wire push speed exceeds the wire pull speed, the welding wire will accumulate and arch out in the middle area, or even become blocked; if the wire pull speed exceeds the wire push speed, the welding wire may break. Although some solutions introduce simple mechanical buffers (such as crescent-shaped channels) and use limit switches for coarse adjustment (such as "stop-and-go" switch control), this control method is slow to respond and has low precision, failing to achieve true speed matching. Frequent up-and-down fluctuations of the welding wire within the buffer still cause wire feeding speed pulsations, affecting welding stability and quality.

[0027] 2. Key factors affecting wire feeding stability and shortcomings of existing control methods.

[0028] Wire feeding stability is affected by multiple factors. On the one hand, the characteristics of the welding wire itself, such as hard bends, corrosion, uneven diameter, or changes in wire spool weight, directly lead to fluctuations in wire feeding resistance. On the other hand, the dynamic characteristics of the wire feeding system are also very complex: when the robot moves, the movement of each joint causes the wire hose to sway in the air, resulting in high-frequency oscillation of the internal welding wire; changes in the welding torch posture alter the curvature of the wire feeding hose, thus affecting the wire feeding resistance; traditional open-loop wire feeders cannot sense these resistance changes and compensate for them in real time, leading to unstable wire feeding speed and directly affecting welding quality. Existing technologies attempt to improve this. For example, a buffer device is installed between the wire feeding device and the welding torch, with space inside for the lateral bending deformation of the welding wire to absorb some length changes. Another example is that the wire feeding system attempts to control the rotation of the welding wire spool through a follow-up device and a tension detection device to prevent the welding wire from being too tight or too loose. However, these methods are mostly passive mechanical compensation or local control, failing to fundamentally solve the core control problem of precise speed synchronization of push-pull dual motors in a high-dynamic welding process. Furthermore, the welding wire lacks precise, closed-loop monitoring and adjustment throughout its entire path from the wire feed spool to the welding torch.

[0029] 3. To meet the precise control requirements of high-quality welding.

[0030] For high-quality welding, especially thin-plate laser welding and multi-dimensional spatial weld welding, precise control of heat input, penetration depth, and spatter is required. This necessitates precise intervention in the droplet transfer process, which undoubtedly places extremely high demands on the dynamic response accuracy and speed synchronization of the wire feeding mechanism. Traditional wire feeding systems are ill-suited to meet the stringent dynamic performance requirements of this advanced welding process.

[0031] In summary, existing welding wire feeding technologies, especially push-pull wire feeding systems, have the following main shortcomings: 1. Problem of poor speed synchronization accuracy between the wire pusher motor and the wire drawer motor: Existing push-pull wire feeding systems lack a high-response, high-precision synchronization control strategy between the wire pusher motor and the wire drawer motor, making it difficult to achieve high-precision real-time synchronization between the two motors. This leads to wire accumulation, warping, or even breakage in the flexible hose due to speed mismatch, thereby compromising the stability of wire feeding and causing instability, directly affecting the stability of welding and the quality of weld formation.

[0032] 2. Insufficient dynamic response capability of the system, failing to effectively compensate for real-time disturbances: The existing wire feeding system has a slow dynamic response and cannot provide real-time, rapid, and accurate compensation for instantaneous changes in wire feeding resistance caused by deformation of the wire feeding hose, robot movement, and bending of the welding wire itself during the welding process. This results in fluctuations in the wire feeding speed, making it difficult to meet the stringent requirements of high-end welding processes for dynamic wire feeding performance.

[0033] 3. The control strategy is crude and lacks multi-parameter adaptive adjustment capability: The existing wire feeding system relies on fixed control parameters or simple mechanical buffer devices, and fails to form a closed-loop control based on real-time feedback. The wire feeding accuracy and consistency are difficult to guarantee. Moreover, it lacks the ability to intelligently sense and adapt parameters based on multiple elements such as the actual state of the welding robot arm, the characteristics of the welding wire, and the weight change of the welding wire spool. As a result, the wire feeding control cannot achieve optimal matching when the welding task or conditions change.

[0034] 4. Problem of difficulty in ensuring the stability of wire feeding over long distances: Especially in application scenarios that require long wire feeding hoses (e.g., more than 5 meters), the existing push-pull wire feeding system is not good at suppressing the serpentine bending of the welding wire in the hose and the resulting increase in friction, which significantly reduces the stability of wire feeding and limits the working range of the robot.

[0035] 5. Difficulty in meeting the wire feeding quality requirements of high-end welding processes: For high-requirement processes such as high-power laser welding, thin plate welding, and spatial multi-dimensional weld welding, the existing wire feeding system performs poorly in terms of wire feeding speed stability and trajectory accuracy, which restricts the further improvement of welding quality.

[0036] The aforementioned shortcomings have hindered the further application of automated laser welding technology in high-end manufacturing. Therefore, there is an urgent need for a push-pull welding wire feeder capable of high-precision closed-loop control, extremely fast dynamic response, and adaptability to complex working conditions, in order to improve the stability of the welding process and the quality of the weld.

[0037] To address this, the present invention provides a closed-loop controlled push-pull wire feeder, comprising a rear-end wire pusher, a wire feeding control device, and a front-end wire drawer. By placing the front-end wire drawer at the welding torch, deformation errors caused by the long wire tube are eliminated. The front-end wire drawer monitors the wire movement in real time to obtain wire movement status information, which is then transmitted to the wire feeding control device. The wire feeding control device uses a preset algorithm to calculate the torque change of the front-end wire drawer and the wire movement status information, respectively, and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pusher and the front-end wire drawer. This controls the rear-end wire pusher and the front-end wire drawer to rotate in tandem, achieving precise wire feeding control. This enables the push-pull wire feeder to achieve high-precision closed-loop control, extremely fast dynamic response speed, and adaptability to complex working conditions, improving the wire feeding stability and weld quality during the welding process. This solves the problems of poor speed synchronization accuracy between the pusher and drawer motors, slow dynamic response, and lack of real-time feedback-based closed-loop control in existing push-pull wire feeding systems.

[0038] Please refer to Figure 1 In one embodiment, the present invention provides a push-pull type wire feeder 600, comprising: a welding wire spool 610, welding wire 620, a rear wire pusher 630, a wire feeding control device 650, a front wire drawing machine 660, and a welding torch wire tube 670, wherein the wire feeding control device 650 is electrically connected to the rear wire pusher 630 and the front wire drawing machine 660 respectively; wherein: Wire spool 610 is used for winding welding wire 620; The rear wire pusher 630 is used to push the welding wire 620 wound on the welding wire spool 610 into the wire feeding tube 640 according to the control command of the wire feeding control device 650, so that the welding wire 620 reaches the front wire drawing machine 660 through the wire feeding tube 640. The front-end wire drawing machine 660 is used to pull the welding wire 620 into the welding gun wire tube 670 according to the control command of the wire feeding control device 650, so that the welding wire 620 reaches the workpiece 700 after passing through the welding gun wire tube 670; and to monitor the movement of the welding wire in real time to obtain the movement status information of the welding wire and transmit it to the wire feeding control device 650. The wire feeding control device 650 is used to calculate the torque change of the front wire drawing machine and the received welding wire motion status information using a preset algorithm, and output control commands to perform real-time closed-loop feedback compensation control on the back wire pusher 630 and the front wire drawing machine 660, so as to control the back wire pusher 630 and the front wire drawing machine 660 to rotate in coordination.

[0039] In this embodiment, a push-pull wire feeder is provided. The rear wire pusher, according to the control command of the wire feeding control device, pushes the welding wire wound on the welding wire spool into the wire feeding tube, allowing the welding wire to reach the front wire drawing machine via the wire feeding tube. The front wire drawing machine, according to the control command of the wire feeding control device, pulls the welding wire into the welding gun wire tube, allowing the welding wire to reach the workpiece after passing through the welding gun wire tube. The device also monitors the welding wire movement in real time to obtain welding wire movement status information, which is transmitted to the wire feeding control device. The wire feeding control device uses a preset algorithm to calculate the torque change of the front wire drawing machine and the received welding wire movement status information, respectively, and outputs control commands to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire drawing machine, controlling the rear wire pusher and the front wire drawing machine to rotate collaboratively. By placing the front-end wire drawing machine as close as possible to the welding torch, deformation errors caused by the long wire tube are eliminated. The front-end wire drawing machine monitors the wire movement in real time to obtain wire movement status information, which is then transmitted to the wire feeding control device. The wire feeding control device uses a preset algorithm to calculate the torque changes of the front-end wire drawing machine and the wire movement status information, respectively, and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pusher and the front-end wire drawing machine. This controls the rear-end wire pusher and the front-end wire drawing machine to rotate in tandem, achieving precise wire feeding control. This enables the push-pull wire feeder to achieve high-precision closed-loop control, extremely fast dynamic response speed, and adaptability to complex working conditions, improving the wire feeding stability and weld quality during the welding process. This solves the problems of poor speed synchronization accuracy between the pusher and drawer motors, slow dynamic response, and lack of real-time feedback-based closed-loop control in existing push-pull wire feeding systems.

[0040] In one embodiment, the wire feeding control device 650 is used to calculate the torque change of the front wire drawing machine and the received welding wire motion status information using a preset algorithm, and output control commands to perform real-time closed-loop feedback compensation control on the back wire pusher 630 and the front wire drawing machine 660, thereby controlling the back wire pusher 630 and the front wire drawing machine 660 to rotate in coordination.

[0041] For details, please refer to Figure 1 The wire feeding control device 650 includes a central controller 651, a rear-end motor driver 653, and a front-end motor driver 656; wherein: The central controller 651 is electrically connected to both the rear-end motor driver 653 and the front-end motor driver 656. It is used to calculate the torque changes of the front-end wire drawing machine and the received welding wire movement status information using a preset algorithm, and output control commands to the rear-end motor driver 653 and the front-end motor driver 656 respectively. Specifically, the central controller 651 is electrically connected to the rear-end motor driver 653 to calculate the torque changes of the front-end wire drawing machine using a preset algorithm and output control commands to the rear-end motor driver 653, causing the rear-end wire pusher 630 to adjust according to the torque changes of the front-end wire drawing machine; the central controller 651 is also electrically connected to the front-end motor driver 656 to calculate the received welding wire movement status information using a preset algorithm and output control commands to the front-end motor driver 656, causing the front-end wire drawing machine 660 to adjust according to the welding wire movement status. The rear motor driver 653 is used to drive the rear wire pusher motor 633 of the rear wire pusher 630, which is electrically connected to the central controller 651, to operate according to the control instructions of the central controller 651. The front-end motor driver 656 is used to drive the front-end drawing motor 666 of the front-end drawing machine 660, which is electrically connected to it, to operate according to the control instructions of the central controller 651.

[0042] As an optional embodiment, the wire feeding control device 650 can be placed independently or built into the rear wire pusher 630.

[0043] In one embodiment, the rear wire pusher 630 is used to push the welding wire 620 wound on the welding wire spool 610 into the wire feeding tube 640 according to the control command of the wire feeding control device 650, so that the welding wire 620 reaches the front wire drawing machine 660 through the wire feeding tube 640.

[0044] For details, please refer to Figure 1 The rear wire pusher 630 includes a rear wire pusher motor 633 and a wire pusher roller assembly 634.

[0045] The rear pusher motor 633 is electrically connected to the rear motor driver 653 of the wire feeding control device 650, and is used to operate under the drive of the rear motor driver 653. The welding wire 620 on the welding wire spool 610 is in close contact with the wire pusher roller assembly 634. The wire pusher roller assembly 634 is connected to the rear wire pusher motor 633 and is used to feed the welding wire 620 under the drive of the rear wire pusher motor 633. The welding wire 620 is fed into the wire feeding tube 640 and then reaches the front wire drawing machine 660 through the wire feeding tube 640.

[0046] For example, the wire pusher roller assembly 634 includes two wire pusher rollers, namely a first wire pusher roller 6341 and a second wire pusher roller 6342. The first wire pusher roller 6341 and the second wire pusher roller 6342 are arranged vertically, with the first wire pusher roller 6341 on top and the second wire pusher roller 6342 on the bottom. There is a gap between the first wire pusher roller 6341 and the second wire pusher roller 6342, and the height of the gap is equal to or slightly less than the diameter of the welding wire 620. The first wire pusher roller 6341 is connected to the rear wire pusher motor 633. The welding wire 620 on the welding wire spool 610 passes through the gap. The first wire pusher roller 6341 rotates under the drive of the rear wire pusher motor 633. Power is transmitted through the friction between the first wire pusher roller 6341 and the second wire pusher roller 6342, and the welding wire 620 between the first wire pusher roller 6341 and the second wire pusher roller 6342 is conveyed to the wire feeding tube 640.

[0047] In one embodiment, the front-end wire drawing machine 660 is used to pull the welding wire 620 into the welding gun wire tube 670 according to the control command of the wire feeding control device 650, so that the welding wire 620 reaches the workpiece 700 after passing through the welding gun wire tube 670; and to monitor the movement of the welding wire in real time to obtain the welding wire movement status information and transmit it to the wire feeding control device 650.

[0048] For details, please refer to Figure 1 The front-end wire drawing machine 660 includes a front-end wire drawing motor 666, a wire drawing roller assembly 667, and a welding wire encoder 668.

[0049] The front-end drawing motor 666 is electrically connected to the front-end motor driver 656 of the wire feeding control device 650, and is used to operate under the drive of the front-end motor driver 656. The wire drawing roller assembly 667 is connected to the front-end wire drawing motor 666 and is used to pull the welding wire 620 under the drive of the front-end wire drawing motor 666, so that the welding wire 620 is fed into the welding gun wire tube 670 and reaches the workpiece 700 after passing through the welding gun wire tube 670.

[0050] For example, the wire drawing roller assembly 667 includes two rollers, namely a first wire drawing roller 6671 and a second wire drawing roller 6672. The first wire drawing roller 6671 and the second wire drawing roller 6672 are arranged vertically, with the first wire drawing roller 6671 on top and the second wire drawing roller 6672 on the bottom. There is a gap between the first wire drawing roller 6671 and the second wire drawing roller 6672, and the height of the gap is equal to or slightly less than the diameter of the welding wire 620. The first wire drawing roller 6671 is connected to the front-end wire drawing motor 666. The welding wire 620 on the welding wire spool 610 passes through the gap. The first wire drawing roller 6671 rotates under the drive of the front-end wire drawing motor 666. Power is transmitted through the friction between the first wire drawing roller 6671 and the second wire drawing roller 6672, and the welding wire 620 between the first wire drawing roller 6671 and the second wire drawing roller 6672 is transported to the welding gun wire tube 670.

[0051] The welding wire encoder 668 is located at the wire exit point behind the wire drawing roller group 667. It rotates with the movement of the welding wire 620 and is used to monitor the movement of the welding wire in real time to obtain the welding wire movement status information. The welding wire movement status information is transmitted to the central controller 651 of the wire feeding control device 650. The welding wire movement status information includes the welding wire movement speed and displacement.

[0052] It is understandable that the welding wire encoder 668 can be replaced with other devices for monitoring the motion status of the welding wire, such as differential output encoders, magneto-electric encoders, Hall sensors, etc., without any restrictions.

[0053] In one embodiment, the wire feeding control device 650 is used to calculate the torque change of the front wire drawing machine and the received welding wire motion status information using a preset algorithm, and output control commands to perform real-time closed-loop feedback compensation control on the back wire pusher 630 and the front wire drawing machine 660, thereby controlling the back wire pusher 630 and the front wire drawing machine 660 to rotate in coordination.

[0054] Specifically, the central controller 651 of the wire feeding control device 650 calculates the torque change of the front wire drawing machine and the welding wire movement status information based on a preset algorithm, and outputs control commands to the rear motor driver 653 and the front motor driver 656 respectively. The rear motor driver 653 drives the rear wire pushing motor 633 of the rear wire pusher 630 and the front motor driver 656 drives the front wire drawing motor 666 of the front wire drawing machine 660 to rotate in coordination. This allows the front wire drawing machine 660 to adjust according to the welding wire movement status and the rear wire pusher 630 to adjust according to the torque change of the front wire drawing machine, realizing real-time closed-loop feedback compensation control to achieve precise welding wire output control.

[0055] For example, the default algorithm is the PID control algorithm. PID is an abbreviation for Proportional, Integral, and Differential. The PID control algorithm is a control algorithm that combines proportional (P), integral (I), and derivative (D) components into one. It is the most mature and widely used control algorithm in continuous systems. The PID control algorithm calculates the output based on the input deviation value according to the functional relationship between proportional (P), integral (I), and derivative (D), and the result is used to control the output.

[0056] For details, please refer to Figure 3 The central controller 651 uses a PID control algorithm as a preset algorithm to calculate the received welding wire motion state information and outputs control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing machine 660, so that the front-end wire drawing machine 660 adjusts according to the welding wire motion state. Specifically, the front-end wire drawing motor 666 of the front-end wire drawing machine 660 operates in speed mode, and the front-end wire drawing motor 666 uses the actual wire feeding speed fed back by the welding wire encoder 668 as an anchor for closed-loop control. The specific process is as follows: S3A1 sends a control command to the front-end motor driver 656 to drive the front-end wire drawing motor 666 to start running at the set target wire feeding speed to feed the welding wire.

[0057] The process includes powering on the wire feeder, initializing system parameters, including reading the user-defined target wire feeding speed.

[0058] S3A2: Obtain the actual wire feeding speed collected in real time by the wire encoder 668.

[0059] S3A3. Compare the actual wire feeding speed obtained with the set target wire feeding speed, and calculate the real-time wire feeding speed error value, wherein the wire feeding speed error value is the difference between the actual wire feeding speed and the set target wire feeding speed.

[0060] S3A4. The PID control algorithm is used to perform PID calculation on the wire feeding speed error value, and a control quantity to eliminate the wire feeding speed error is output. Specifically, the central controller 651 uses the PID control algorithm to perform PID calculation on the calculated wire feeding speed error value. The PID controller uses formula (1) to perform PID calculation on the wire feeding speed error value according to the preset control parameters (proportional system Kp, integral time Ki and derivative time Kd), and outputs a control quantity u(k) to eliminate the wire feeding speed error.

[0061] In the above formula (1): Kp is the proportional system, Ki is the integral time, Kd is the derivative time, u(k) is the control quantity output by the kth sampling, e(k) is the deviation of the kth sampling, e(k-1) is the deviation of the -1kth sampling, and T is the sampling period.

[0062] S3A5. Based on the control quantity output by the PID controller, update the control command and send it to the front-end motor driver. The front-end motor driver then adjusts the speed of the front-end wire drawing motor according to the updated control command. Specifically, the central controller 651 converts the control quantity output by the PID controller in step S3A4 into a corresponding pulse frequency signal. The updated pulse frequency signal is then sent as a control command to the front-end motor driver 656. The front-end motor driver 656 then adjusts the speed of the front-end wire drawing motor 666 according to the received updated pulse frequency signal, so that the actual wire feeding speed approaches the target wire feeding speed.

[0063] S3A6. Repeat steps S3A2 to S3A5 to form a real-time closed-loop feedback compensation control for the front-end wire drawing motor. Through continuous speed detection, error calculation, PID operation, and motor speed regulation, continuous, accurate, and stable automatic control of the welding wire feeding speed is achieved, making the actual wire feeding speed infinitely close to the target wire feeding speed.

[0064] In this embodiment, the actual wire feeding speed is compared with the set target wire feeding speed to calculate the real-time wire feeding speed error value. A PID control algorithm is used to perform PID calculation on the wire feeding speed error value, and a control quantity to eliminate the wire feeding speed error is output. Based on the control quantity output by the PID calculation, the control command is updated and sent to the front-end motor driver. The front-end motor driver dynamically adjusts the speed of the front-end wire drawing motor according to the updated control command, thereby forming a real-time closed-loop feedback compensation control for the front-end wire drawing motor. This makes the actual wire feeding speed infinitely close to the target wire feeding speed, realizing continuous, accurate and stable automatic control of the wire feeding speed.

[0065] For details, please refer to Figure 4 The central controller 651 uses a PID control algorithm as a preset algorithm to calculate the torque changes of the front-end wire drawing machine and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pusher 630, so that the rear-end wire pusher 630 adjusts according to the torque changes of the front-end wire drawing machine. The rear-end wire pusher motor 633 of the rear-end wire pusher 630 operates in torque mode, and the rear-end wire pusher motor 633 uses the actual operating torque of the front-end wire drawing motor 666 as an anchor for closed-loop control. The specific process is as follows: S3B1 sends a control command to the rear motor driver 653 to drive the rear wire pusher motor 633 to start running at the initial wire pusher torque value to feed the welding wire.

[0066] The process includes powering on the wire feeder, initializing system parameters, including reading relevant process parameters set by the user, and calculating the initial wire feeding torque value and the target torque value of the front-end wire drawing motor based on the process parameters.

[0067] S3B2 reads the actual working torque value of the front-end wire drawing motor 666 in real time as a key feedback variable.

[0068] S3B3. Compare the actual working torque value of the front-end wire drawing motor 666 with the target torque value of the front-end wire drawing motor, and calculate the real-time torque error value. The torque error value is the difference between the target torque value and the actual working torque value of the front-end wire drawing motor.

[0069] S3B4. The torque error value is calculated using a PID control algorithm, and a control quantity is output to correct the torque of the rear wire pusher motor. Specifically, the central controller 651 performs PID calculation on the calculated torque error value using a PID control algorithm. The PID controller performs PID calculation on the torque error value using formula (1) according to the preset control parameters (proportional system Kp, integral time Ki, and derivative time Kd), and outputs a control quantity to correct the torque of the rear wire pusher motor.

[0070] The specific PID calculation formula can be found in formula (1) above, and will not be repeated here.

[0071] S3B5: Based on the control quantity calculated and output by the PID controller, the torque parameters of the back-end motor driver 653 are updated in real time, so that the back-end motor driver 653 drives the back-end wire pusher motor to adjust its output working torque according to the updated torque parameters.

[0072] S3B6. Repeat steps S3B2 to S3B5 to form a real-time closed-loop feedback compensation control for the back-end wire pusher motor, realize continuous monitoring and dynamic adjustment of the actual working torque of the front-end wire drawing motor, so that the front-end wire drawing motor works near a stable target torque value, creating favorable conditions for the speed closed-loop control of the front-end wire drawing machine.

[0073] In this embodiment, the real-time torque error value is calculated by comparing the actual working torque value of the front-end wire drawing motor 666 with the target torque value of the front-end wire drawing motor. The torque error value is then calculated using a PID control algorithm, and a control quantity is output to correct the torque of the rear-end wire pusher motor. Based on the control quantity output by the PID controller, the torque parameters of the rear-end motor driver 3 are updated in real time. The rear-end motor driver then drives the rear-end wire pusher motor to adjust its output working torque according to the updated torque parameters, thereby forming a real-time closed-loop feedback compensation control for the rear-end wire pusher motor. This, together with the real-time closed-loop feedback compensation control of the front-end wire drawing motor, constitutes a dual closed-loop feedback compensation control, improving the synchronization accuracy of the rear-end wire pusher and the front-end wire drawing machine. This fundamentally solves the problems of speed mismatch, wire blockage, or wire breakage between the rear-end wire pusher motor and the front-end wire drawing motor.

[0074] This invention provides a push-pull type wire feeder 600, whose working process is as follows: The central controller 651 of the wire feeding control device 650 sends a control command to the rear motor driver 653, driving the rear wire pusher motor 633 to start running at the initial wire pusher torque value to feed the welding wire; the central controller 651 sends a control command to the front motor driver 656, driving the front wire drawer motor 666 to start running at the set target wire feeding speed to feed the welding wire.

[0075] The welding wire 620 on the welding wire spool 610 is pushed into the wire feeding tube 640 by the first wire feeding roller 6341 and the second wire feeding roller 6342 on the rear wire feeder 630. The welding wire 620 reaches the front wire drawing machine 660 through the wire feeding tube 640. The first wire drawing roller 6671 and the second wire drawing roller 6672 of the front wire drawing machine 660 pull the welding wire 620 into the welding gun wire tube 670. After passing through the welding gun wire tube 670, the welding wire 620 finally reaches the workpiece 700. Inside the front wire drawing machine 660, the welding wire encoder 668, located at the welding wire position after the wire drawing roller group 667, rotates with the movement of the welding wire 620, monitors the welding wire movement in real time to obtain welding wire movement status information (welding wire movement speed and displacement), and transmits the welding wire movement status information to the central controller 651.

[0076] The central controller 651 calculates the welding wire motion status information based on the received information using a PID control algorithm and outputs an updated control command signal to the front-end motor driver 656. This causes the front-end motor driver 656 to dynamically adjust the speed of the front-end wire drawing motor 666 based on the updated control command signal, making the actual wire feeding speed approach the target wire feeding speed. This achieves real-time closed-loop feedback compensation control of the front-end wire drawing motor 666. Simultaneously, it outputs real-time updated torque parameters to the rear-end motor driver 653, causing the rear-end motor driver 653 to adjust its output torque based on the updated torque parameters. This achieves real-time closed-loop feedback compensation control of the rear-end wire pushing motor 633. Thus, the rear-end wire pushing motor 633 and the front-end wire drawing motor 666 are controlled to rotate in tandem, achieving real-time closed-loop feedback compensation control for precise welding wire feeding control.

[0077] This invention provides a push-pull type wire feeder 600, which has the following technical advantages: 1) High wire feeding accuracy: Placing the front wire drawing machine at the welding gun eliminates deformation errors caused by the long wire tube; a wire encoder is placed at the wire feeding point of the front wire drawing machine to monitor the wire movement in real time and obtain the wire movement status information (wire movement speed and displacement), which is transmitted to the central controller. The central controller performs dual closed-loop feedback compensation control based on the optimized PID control algorithm to perform real-time closed-loop feedback compensation control on the front wire drawing motor and the rear wire pushing motor, achieving precise wire feeding control. The measured wire feeding accuracy reached ±0.1mm.

[0078] 2) Extremely high synchronization accuracy between front and rear wire feeders: The wire feeding speed is dynamically adjusted based on the actual wire feeding speed feedback from the wire encoder, and a dual closed-loop feedback compensation control is introduced, which uses an optimized PID control algorithm to provide real-time closed-loop feedback compensation control for the front wire drawing motor and the rear wire pushing motor. This improves the synchronization accuracy between the front wire drawing machine and the rear wire pushing machine, fundamentally solving the problems of speed mismatch between the rear wire pushing motor and the front wire drawing motor, as well as wire blockage or breakage.

[0079] 3) Fast dynamic response: The push-pull wire feeder uses a rear wire pusher and a front wire drawer to work together, which has high power and strong drive. Combined with a high-performance central processing controller to control the rear wire pusher and the front wire drawer to work together, the push-pull wire feeder has a fast dynamic response. It can reach the preset target wire feeding speed in milliseconds when welding starts, ensuring that the weld start is full and flat; it can quickly retract the welding wire at the end of welding to avoid the welding wire sticking; and it can make millisecond-level response and compensation for changes in wire feeding resistance and robot motion interference during welding based on an optimized PID control algorithm.

[0080] 4) Stable and reliable long-distance wire feeding: The back-end wire pusher and the front-end wire drawer work together to push and pull, and combined with the optimized PID control algorithm, a dual closed-loop feedback compensation control is realized, which significantly improves the stability of wire feeding in long wire feeding hoses.

[0081] 5) Strong adaptability: Through dual closed-loop feedback compensation control of the front wire drawing motor speed closed-loop control and the rear wire pushing motor torque closed-loop control, the push-pull wire feeder can adapt to changes in different welding wire materials, different diameters and different welding wire spool weights.

[0082] 6) High integration and durability: The push-pull wire feeder adopts a high-performance, highly integrated central controller, coupled with an optimized PID control algorithm, which greatly reduces the number of hardware and structural parts of the entire push-pull wire feeder, and correspondingly significantly reduces the failure rate of the whole machine, making it particularly suitable for high-intensity robotic automated welding.

[0083] Based on the same inventive concept, please refer to Figure 2 The present invention also provides a wire feeding control method, applied to the push-pull wire feeder 600 described in any of the above embodiments. The executing entity of the wire feeding control method is a wire feeding control device, specifically a central controller of the wire feeding control device. The wire feeding control method includes: S1, output control command to control the back end wire pusher to push the welding wire wound on the welding wire spool into the wire feeding tube, so that the welding wire reaches the front end wire drawing machine through the wire feeding tube; S2, output control command to control the front wire drawing machine to pull the welding wire into the welding gun wire tube, so that the welding wire reaches the workpiece after passing through the welding gun wire tube; S3. Using a preset algorithm, calculate the torque change of the front wire drawing machine and the received welding wire motion status information respectively, and output control commands to perform real-time closed-loop feedback compensation control on the back wire pusher and the front wire drawing machine, and control the back wire pusher and the front wire drawing machine to rotate in coordination. The welding wire motion status information is obtained by the front wire drawing machine in real time by monitoring the welding wire motion and is transmitted to the wire feeding control device.

[0084] In this embodiment, a wire feeding control method is provided, applied to a push-pull type wire feeder. By outputting control commands, the rear wire pusher pushes the welding wire wound on the welding wire spool into the wire feeding tube, allowing the welding wire to reach the front wire drawing machine via the wire feeding tube. Control commands are also output to control the front wire drawing machine to pull the welding wire into the welding gun wire tube, allowing the welding wire to reach the workpiece after passing through the welding gun wire tube. A preset algorithm is used to calculate the torque change of the front wire drawing machine and the received welding wire motion state information, respectively, and control commands are output to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire drawing machine, controlling the rear wire pusher and the front wire drawing machine to rotate collaboratively. By using a preset algorithm to calculate the torque changes of the front-end wire drawing machine and the motion status information of the welding wire, control commands are output to perform real-time closed-loop feedback compensation control on the rear-end wire pusher and the front-end wire drawing machine. This controls the coordinated rotation of the rear-end wire pusher and the front-end wire drawing machine, achieving precise wire feeding control. This enables the push-pull wire feeder to achieve high-precision closed-loop control, has extremely fast dynamic response speed, and can adapt to complex working conditions, improving the wire feeding stability and welding quality during the welding process. This solves the problems of poor speed synchronization accuracy between the pusher and drawer motors, slow dynamic response, and lack of real-time feedback-based closed-loop control in existing push-pull wire feeding systems.

[0085] In one embodiment, in step S3, a preset algorithm is used to calculate the torque change of the front wire drawing machine and the received welding wire motion status information, and control commands are output to perform real-time closed-loop feedback compensation control on the back wire pusher and the front wire drawing machine, so as to control the back wire pusher and the front wire drawing machine to rotate in coordination. The welding wire motion status information is obtained by the front wire drawing machine from real-time monitoring of the welding wire motion and transmitted to the wire feeding control device.

[0086] The default algorithm is the PID control algorithm. PID is an abbreviation for Proportional, Integral, and Differential. The PID control algorithm combines proportional (P), integral (I), and derivative (D) components into a single control algorithm. It is the most mature and widely used control algorithm in continuous systems. The PID control algorithm calculates the output based on the input deviation value according to the functional relationship between proportional (P), integral (I), and derivative (D), and the result is used to control the output.

[0087] For details, please refer to Figure 3 The central controller uses a PID control algorithm as the preset algorithm to calculate the received welding wire motion status information and outputs control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing machine. This allows the front-end wire drawing machine 660 to adjust according to the welding wire motion status. The front-end wire drawing motor operates in speed mode, and its closed-loop control is anchored to the actual wire feeding speed fed back by the welding wire encoder. The specific process is as follows: S3A1 sends a control command to the front-end motor driver to drive the front-end wire drawing motor to start running at the set target wire feeding speed to feed the welding wire.

[0088] The process includes powering on the wire feeder, initializing system parameters, including reading the user-defined target wire feeding speed.

[0089] S3A2: Obtain the actual wire feeding speed collected in real time by the wire encoder.

[0090] S3A3. Compare the actual wire feeding speed obtained with the set target wire feeding speed, and calculate the real-time wire feeding speed error value, wherein the wire feeding speed error value is the difference between the actual wire feeding speed and the set target wire feeding speed.

[0091] S3A4. The PID control algorithm is used to perform PID calculation on the wire feeding speed error value, and a control quantity to eliminate the wire feeding speed error is output. Specifically, the central controller uses the PID control algorithm to perform PID calculation on the calculated wire feeding speed error value. The PID controller uses formula (1) to perform PID calculation on the wire feeding speed error value according to the preset control parameters (proportional system Kp, integral time Ki and derivative time Kd), and outputs a control quantity to eliminate the wire feeding speed error.

[0092] S3A5. Based on the control quantity output by the PID controller, update the control command and send it to the front-end motor driver. The front-end motor driver then adjusts the speed of the front-end wire drawing motor according to the updated control command. Specifically, the central controller converts the control quantity output by the PID controller in step S3A4 into a corresponding pulse frequency signal. The updated pulse frequency signal is then sent to the front-end motor driver as a control command. This causes the front-end motor driver to dynamically adjust the speed of the front-end wire drawing motor based on the received updated pulse frequency signal, making the actual wire feeding speed approach the target wire feeding speed.

[0093] S3A6. Repeat steps S3A2 to S3A5 to form a real-time closed-loop feedback compensation control for the front-end wire drawing motor. Through continuous speed detection, error calculation, PID operation, and motor speed regulation, continuous, accurate, and stable automatic control of the welding wire feeding speed is achieved, making the actual wire feeding speed infinitely close to the target wire feeding speed.

[0094] In this embodiment, the actual wire feeding speed is compared with the set target wire feeding speed to calculate the real-time wire feeding speed error value. A PID control algorithm is used to perform PID calculation on the wire feeding speed error value, and a control quantity to eliminate the wire feeding speed error is output. Based on the control quantity output by the PID calculation, the control command is updated and sent to the front-end motor driver. The front-end motor driver dynamically adjusts the speed of the front-end wire drawing motor according to the updated control command, thereby forming a real-time closed-loop feedback compensation control for the front-end wire drawing motor. This makes the actual wire feeding speed infinitely close to the target wire feeding speed, realizing continuous, accurate and stable automatic control of the wire feeding speed.

[0095] For details, please refer to Figure 4 The central controller uses a PID control algorithm as a preset algorithm to calculate the torque changes of the front-end wire drawing machine and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pusher 630. This allows the rear-end wire pusher 630 to adjust according to the torque changes of the front-end wire drawing machine. The rear-end wire pusher motor operates in torque mode, and its closed-loop control is anchored to the actual operating torque of the front-end wire drawing motor. The specific process is as follows: S3B1 sends a control command to the rear motor driver to drive the rear wire pusher motor to start running at the initial wire pusher torque value for feeding welding wire.

[0096] The process includes powering on the wire feeder, initializing system parameters, including reading relevant process parameters set by the user, and calculating the initial wire feeding torque value and the target torque value of the front-end wire drawing motor based on the process parameters.

[0097] S3B2: Real-time reading of the actual working torque value of the front-end wire drawing motor, serving as a key feedback variable.

[0098] S3B3. Compare the actual working torque value of the front-end wire drawing motor with the target torque value of the front-end wire drawing motor, and calculate the real-time torque error value. The torque error value is the difference between the target torque value and the actual working torque value of the front-end wire drawing motor.

[0099] S3B4. The torque error value is calculated using a PID control algorithm, and a control quantity is output to correct the torque of the rear wire pusher motor. Specifically, the central controller performs PID calculation on the calculated torque error value using the PID control algorithm. The PID controller performs PID calculation on the torque error value using formula (1) based on the preset control parameters (proportional system Kp, integral time Ki, and derivative time Kd), and outputs a control quantity to correct the torque of the rear wire pusher motor. The specific PID calculation formula can be found in formula (1) above, and will not be repeated here.

[0100] S3B5 updates the torque parameters of the back-end motor driver in real time based on the control quantity calculated and output by the PID controller, so that the back-end motor driver can drive the back-end wire pusher motor to adjust its output working torque according to the updated torque parameters.

[0101] S3B6. Repeat steps S3B2 to S3B5 to form a real-time closed-loop feedback compensation control for the back-end wire pusher motor, realize continuous monitoring and dynamic adjustment of the actual working torque of the front-end wire drawing motor, so that the front-end wire drawing motor works near a stable target torque value, creating favorable conditions for the speed closed-loop control of the front-end wire drawing machine.

[0102] In this embodiment, the real-time torque error value is calculated by comparing the actual working torque value of the front-end wire drawing motor 666 with the target torque value of the front-end wire drawing motor. The torque error value is then calculated using a PID control algorithm, and a control quantity is output to correct the torque of the rear-end wire pusher motor. Based on the control quantity output by the PID controller, the torque parameters of the rear-end motor driver 3 are updated in real time. The rear-end motor driver then drives the rear-end wire pusher motor to adjust its output working torque according to the updated torque parameters, thereby forming a real-time closed-loop feedback compensation control for the rear-end wire pusher motor. This, together with the real-time closed-loop feedback compensation control of the front-end wire drawing motor, constitutes a dual closed-loop feedback compensation control, improving the synchronization accuracy of the rear-end wire pusher and the front-end wire drawing machine. This fundamentally solves the problems of speed mismatch, wire blockage, or wire breakage between the rear-end wire pusher motor and the front-end wire drawing motor.

[0103] It should be noted that the above method embodiments and the push-pull wire feeder embodiments belong to the same concept. For details of the specific implementation process, please refer to the push-pull wire feeder embodiments. Furthermore, the technical features in the push-pull wire feeder embodiments are all applicable to the method embodiments, and will not be repeated here.

[0104] Based on the same inventive concept, please refer to Figure 5 The present invention also provides a laser processing system 900, which includes the push-pull wire feeder 600 described in any of the above embodiments.

[0105] In this embodiment, the push-pull wire feeder 600 is the same as the push-pull wire feeder 600 described in any of the above embodiments. The specific structure and function can be referred to the push-pull wire feeder 600 described in any of the above embodiments, and will not be repeated here.

[0106] As an optional embodiment, the laser processing system 900 includes a robotic arm and a welding gun mounted on the processing end of the robotic arm. A front-end wire drawing machine 660 is fixedly mounted on the processing end of the robotic arm and works in conjunction with the welding gun. The front-end wire drawing machine 660 precisely feeds the welding wire to the welding area through the welding gun wire tube 670, ensuring that the welding wire is precisely aligned with the laser processing trajectory. A rear-end wire pusher 630 is mounted on the base area of ​​the robotic arm and arranged at a preset distance from the welding wire reel 610 to provide welding wire pushing power. The rear-end wire pusher 630 and the front-end wire drawing machine 660 at the processing end form a dual-drive synchronous control structure to achieve coordinated linkage of welding wire pushing and pulling actions. Through the above structural configuration, the push-pull wire feeder can effectively eliminate problems such as welding wire jamming and bending during long-distance wire feeding, significantly improving wire feeding accuracy and stability. At the same time, combined with the multi-degree-of-freedom motion characteristics of the robotic arm, it can greatly improve the flexibility of welding operations, fully meeting the needs of industries such as automobile manufacturing and engineering machinery assembly for high-precision and high-flexibility welding operations.

[0107] As another optional embodiment, the laser processing system 900 includes a handheld welding device and a handheld welding gun. A front-end wire drawing machine 660 is integrated and installed on the handheld welding gun, corresponding to the wire outlet of the handheld welding gun. The front-end wire drawing machine 660 precisely feeds the welding wire into the welding area through the welding gun wire tube 670, ensuring the stability of wire output during manual welding. The rear-end wire pusher 630 can be selectively placed at a preset position on the ground or integrated inside the body of the handheld welding device. The rear-end wire pusher 630 and the welding wire reel 610 are arranged alternately to provide continuous and stable welding wire pushing power. The rear-end wire pusher 630 and the front-end wire drawing machine 660 at the processing end form a dual-drive synchronous control structure to achieve precise matching of pushing and pulling actions. With the above-mentioned structural design, the push-pull wire feeder can not only effectively solve the jamming problem during long-distance wire feeding, but also get rid of the limitation of fixed workstations and improve the flexibility of welding operations. Operators can hold the welding equipment and move it freely on large-sized workpieces and complex structural parts to perform welding operations. It is suitable for long weld seam welding in scenarios such as large steel structure welding, shipbuilding, and engineering machinery processing, as well as manual welding needs in areas that are difficult for conventional robotic arms to reach, such as complex curved surfaces and narrow spaces.

[0108] It should be noted that the above-mentioned laser processing system embodiment and the push-pull wire feeder embodiment belong to the same concept. For details of its implementation process, please refer to the push-pull wire feeder embodiment. Furthermore, the technical features of the push-pull wire feeder embodiment are all applicable to the laser processing system embodiment, and will not be repeated here.

[0109] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0110] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0111] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) and includes several instructions to cause a terminal (which may be a mobile phone, computer, server, air conditioner, or network device, etc.) to execute the methods described in the various embodiments of the present invention.

[0112] 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 push-pull type wire feeder, characterized in that, The equipment includes a wire spool, welding wire, a rear wire pusher, a wire feeding tube, a wire feeding control device, a front wire drawing machine, and a welding gun wire tube. The wire feeding control device is electrically connected to both the rear wire pusher and the front wire drawing machine. The welding wire spool is used to wind the welding wire; The rear wire pusher is used to push the welding wire on the welding wire spool into the wire feeding tube according to the control command of the wire feeding control device. The front-end wire drawing machine is used to pull the welding wire into the welding gun wire tube according to the control command of the wire feeding control device; and to monitor the movement of the welding wire in real time to obtain the welding wire movement status information and transmit it to the wire feeding control device. The wire feeding control device is used to calculate the torque change of the front wire drawing machine and the motion state information of the welding wire using a preset algorithm, and output control commands to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire drawing machine, thereby controlling the rear wire pusher and the front wire drawing machine to rotate in coordination.

2. The push-pull wire feeder according to claim 1, characterized in that, The wire feeding control device includes a central controller, a rear-end motor driver, and a front-end motor driver; wherein: The central controller is electrically connected to the rear motor driver and the front motor driver respectively, and is used to calculate the torque change of the front wire drawing machine and the motion state information of the welding wire using a preset algorithm, and output control commands to the rear motor driver and the front motor driver respectively. The rear-end motor driver is used to drive the rear-end wire pusher, which is electrically connected to it, to operate according to the control instructions of the central controller. The front-end motor driver is used to drive the front-end wire drawing machine, which is electrically connected to it, to operate according to the control instructions of the central controller.

3. The push-pull wire feeder according to claim 2, characterized in that, The rear wire pusher includes a rear wire pusher motor and a wire pusher roller assembly, wherein: The rear wire pusher motor is electrically connected to the rear motor driver and is used to operate under the drive of the rear motor driver. The welding wire on the welding wire spool is in close contact with the wire pusher roller assembly, which is connected to the rear wire pusher motor and is used to transport the welding wire under the drive of the rear wire pusher motor, feeding the welding wire into the wire feeding tube.

4. The push-pull wire feeder according to claim 2, characterized in that, The front-end wire drawing machine includes a front-end wire drawing motor, a wire drawing roller assembly, and a welding wire encoder; wherein: The front-end wire drawing motor is electrically connected to the front-end motor driver and is used to operate under the drive of the front-end motor driver; The wire drawing roller assembly is connected to the front-end wire drawing motor and is used to operate under the drive of the front-end wire drawing motor to draw the welding wire and feed the welding wire into the welding gun wire tube. The welding wire encoder is located at the wire exit point behind the wire drawing roller assembly. It rotates with the movement of the welding wire to monitor the movement of the welding wire in real time, obtain the welding wire movement status information, and transmit the welding wire movement status information to the central controller.

5. The push-pull wire feeder according to claim 3, characterized in that, The preset algorithm is a PID control algorithm; the central controller uses the PID control algorithm to calculate the torque change of the front-end wire drawing machine and outputs control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pushing motor.

6. The push-pull wire feeder according to claim 4, characterized in that, The preset algorithm is a PID control algorithm; the central controller uses the PID control algorithm to calculate the motion state information of the welding wire and outputs control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing motor.

7. A wire feeding control method, characterized in that, include: Output control commands to control the back-end wire pusher to push the welding wire wound on the welding wire spool into the wire feeding tube; Output control commands to control the front-end wire drawing machine to pull the welding wire into the welding gun wire tube; The preset algorithm is used to calculate the torque change of the front wire drawing machine and the welding wire motion status information, and outputs control commands to perform real-time closed-loop feedback compensation control on the rear wire pusher and the front wire drawing machine, so as to control the rear wire pusher and the front wire drawing machine to rotate in coordination. The welding wire motion status information is obtained by the front wire drawing machine from real-time monitoring of the welding wire motion.

8. The wire feeding control method according to claim 7, characterized in that, The preset algorithm is a PID control algorithm; the step of using the preset algorithm to calculate the welding wire motion state information and outputting control commands to perform real-time closed-loop feedback compensation control on the front-end wire drawing machine includes: S3A1 sends a control command to the front-end motor driver to drive the front-end wire drawing motor to start running at the set target wire feeding speed to feed the welding wire. S3A2: Obtain the actual wire feeding speed collected in real time by the wire encoder; S3A3. Compare the actual wire feeding speed with the set target wire feeding speed, and calculate the real-time wire feeding speed error value, wherein the wire feeding speed error value is the difference between the actual wire feeding speed and the set target wire feeding speed. S3A4. Use a PID control algorithm to perform PID calculation on the wire feeding speed error value and output a control quantity to eliminate the wire feeding speed error. S3A5. Based on the control quantity, update the control command and send it to the front-end motor driver, so that the front-end motor driver drives the front-end wire drawing motor to adjust the speed according to the updated control command; S3A6. Repeat steps S3A2 to S3A5 to form a real-time closed-loop feedback compensation control.

9. The wire feeding control method according to claim 7, characterized in that, The preset algorithm is a PID control algorithm; the step of using the preset algorithm to calculate the torque change of the front-end wire drawing machine and outputting control commands to perform real-time closed-loop feedback compensation control on the rear-end wire pushing machine includes: S3B1 sends a control command to the rear motor driver to drive the rear wire pusher motor to start running at the initial wire pusher torque value to feed the welding wire. S3B2: Real-time reading of the actual working torque value of the front-end wire drawing motor; S3B3. Compare the actual working torque value of the front-end wire drawing motor with the target torque value of the front-end wire drawing motor, and calculate the real-time torque error value, wherein the torque error value is the difference between the target torque value of the front-end wire drawing motor and the actual working torque value of the front-end wire drawing motor. S3B4. Use a PID control algorithm to perform PID calculation on the torque error value and output a control quantity for correcting the torque of the back-end wire pusher motor. S3B5. According to the control quantity, update the torque parameters of the back-end motor driver in real time, so that the back-end motor driver drives the back-end wire pusher motor to adjust its output working torque according to the updated torque parameters. S3B6. Repeat steps S3B2 to S3B5 to form a real-time closed-loop feedback compensation control.

10. A laser processing system, characterized in that, Includes the push-pull wire feeder as described in any one of claims 1 to 6.

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