Pulse MIG welding arc length dual-mode control method, system, device and storage medium

Abstract

The application discloses a pulse MIG welding arc length double-mode control method, system, equipment and storage medium, comprising: in response to starting welding, decoupling each pulse period in the welding process into a peak value stage and a base value stage; in each pulse period, adopting a base value duration adjustment mode based on the voltage deviation between the arc voltage of the peak value stage and the preset arc voltage for the peak value stage; adopting a switching protection mode of the welding current based on the comparison between the arc voltage of the base value stage and the preset voltage threshold for the base value stage to realize the double-mode control of the arc length in each pulse period; periodically monitoring the welding gun switch signal during the welding process, and when it is detected that the welding gun switch signal is disconnected, the current pulse period is terminated, so that the welding is completed. The application solves the problem that the existing arc length control method is difficult to realize accurate and stable regulation and control of the arc length, so that the arc length accurate control of the differential control is implemented, and the dynamic stability of the arc length in the pulse MIG welding process is effectively improved.

Description

Technical Field

[0001] The embodiments of the present invention relate to the field of automated control of electric arc welding, and particularly to a dual-mode control method, system, device and storage medium for pulsed MIG welding arc length. Background Technology

[0002] Pulsed Metal Inert Gas Welding (PMIG welding) is widely used in machinery manufacturing, aerospace, and automotive manufacturing due to its advantages such as easy heat input control, aesthetically pleasing weld formation, and minimal spatter. Arc length is a core parameter in the welding process; its stability directly determines the weld formation accuracy, mechanical properties, and weld continuity. Improper arc length control can easily lead to increased spatter, weld undercut, short-circuit wire burning, and other defects, seriously affecting the quality and reliability of the welded joint. Especially in pulsed MIG welding, arc length stability is crucial in determining the smoothness of the welding process, the consistency of droplet transfer, the effectiveness of spatter control, and the quality of the weld formation.

[0003] In some technologies, existing mainstream arc length control methods mostly rely on single-dimensional feedback mechanisms, such as adjusting the wire feeding speed through a PID controller to maintain a constant average arc voltage, or adjusting pulse parameters based on the peak voltage signal to indirectly achieve arc length regulation.

[0004] However, the existing arc length control methods mentioned above mostly control the arc length by adjusting the wire feed speed or peak current to regulate the heat input. However, adjusting the wire feed speed can easily lead to current waveform disorder, and changes in the peak current can affect the droplet transition morphology and stability, making it difficult to achieve precise and stable control of the arc length. Summary of the Invention

[0005] The purpose of this invention is to provide at least one dual-mode control method, system, device, and storage medium for arc length in pulsed MIG welding. This invention addresses the technical problems of existing arc length control methods, which often rely on adjusting wire feed speed or peak current to regulate heat input. However, adjusting wire feed speed easily leads to current waveform disturbances, and changes in peak current affect the droplet transition morphology and stability, both of which hinder precise and stable arc length control. This invention decouples the base value and peak stage of each pulse cycle during welding and constructs independent control loops for different stages. Differentiated control strategies are designed for the different arc physical characteristics of the two stages, enabling precise arc length control that can identify welding stages and implement differentiated control. This solves the problem of balancing response speed and control accuracy in traditional single-control logic, ensuring the arc length remains stable throughout the welding process. This effectively improves the dynamic stability of the arc length in pulsed MIG welding and enhances welding quality.

[0006] To address the aforementioned technical problems, at least one embodiment of this application provides a dual-mode control method for the arc length of pulsed MIG welding, comprising: In response to the start of welding, each pulse cycle during the welding process is decoupled into a peak phase and a base phase; In each pulse cycle, a base value duration adjustment method is adopted for the peak phase of the current pulse cycle based on the voltage deviation between the arc voltage of the peak phase and the preset arc voltage; a welding current switching protection method is adopted for the base value phase of the current pulse cycle based on the comparison between the arc voltage of the base value phase and the preset voltage threshold, so as to realize dual-mode control of arc length in each pulse cycle. During the welding process, the welding torch switch signal is periodically monitored. When the welding torch switch signal is detected to be off, the current pulse cycle is terminated, thereby completing the welding.

[0007] At least one embodiment of this application also provides a pulsed MIG welding arc length dual-mode control system, including: a main control unit, a power output unit, and a signal acquisition unit; The main control unit is used to decouple each pulse cycle during the welding process into a peak phase and a base phase in response to the start of welding. In each pulse cycle, the peak phase of the current pulse cycle adopts a base duration adjustment method based on the voltage deviation between the arc voltage of the peak phase obtained by the signal acquisition unit and a preset arc voltage. The base phase of the current pulse cycle adopts a welding current switching protection method based on the comparison between the arc voltage of the base phase and a preset voltage threshold, so as to realize dual-mode control of the arc length in each pulse cycle. The current switching protection is realized by the power output unit. During the welding process, the welding gun switch signal is periodically monitored. When the welding gun switch signal is detected to be open, the current pulse cycle is terminated, thereby completing the welding.

[0008] At least one embodiment of this application also provides an electronic device, including: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, the instructions being executed by the at least one processor to enable the at least one processor to perform the above-described pulsed MIG welding arc length dual-mode control method.

[0009] At least one embodiment of this application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the above-described dual-mode control method for pulsed MIG welding arc length.

[0010] The pulsed MIG welding arc length dual-mode control method, system, device, and storage medium provided in the embodiments of this application, in response to welding startup, decouple each pulse cycle during the welding process into a peak phase and a base phase. Within each pulse cycle, the peak phase of the current pulse cycle employs a base duration adjustment method based on the voltage deviation between the peak phase arc voltage and a preset arc voltage. The base phase of the current pulse cycle employs a welding current switching protection method based on a comparison between the base phase arc voltage and a preset voltage threshold, thereby achieving dual-mode control of the arc length in each pulse cycle. Furthermore, the welding torch switch signal is periodically monitored during welding; when the welding torch switch signal is detected to be off, the current pulse cycle is terminated, thus completing the welding. In this way, the base value and peak value of each pulse cycle in the welding process are decoupled and independent control closed loops for different stages are constructed. Differentiated control strategies are designed for the different arc physical characteristics of the two stages, realizing precise arc length control that can identify the welding stage and implement differentiated control. This solves the problem that it is difficult to balance the response speed and control accuracy of traditional single control logic. As a result, the arc length remains stable throughout the welding process, effectively improving the dynamic stability of the arc length in pulsed MIG welding and improving the welding quality.

[0011] In some optional embodiments, the base duration adjustment method for the peak phase of the current pulse cycle based on the voltage deviation between the arc voltage of the peak phase and a preset arc voltage includes: The output is started according to the preset peak current. When the peak duration reaches the set time threshold, the difference between the arc voltage of the peak stage within the peak duration and the preset arc voltage is calculated to obtain the voltage deviation. The base duration of the current pulse period is adjusted based on the voltage deviation to obtain the adjusted base duration of the current pulse period.

[0012] In this way, by calculating the voltage deviation and adjusting the base duration, the arc length can be finely and adaptively adjusted during the peak phase.

[0013] In some optional embodiments, adjusting the base duration of the current pulse period based on the voltage deviation to obtain the adjusted base duration of the current pulse period includes: The adjustment amount for the base value duration is determined based on the voltage deviation; Based on the adjustment amount and the base duration of the current pulse period, the adjusted base duration of the current pulse period is calculated.

[0014] In this way, by calculating the voltage deviation to determine the adjustment amount of the base value duration, the base value duration can be adjusted incrementally, so that the arc length can be finely and adaptively adjusted during the peak stage, rather than directly and drastically changing the base value duration. This makes the arc length change continuous and smooth during the welding process, avoiding welding process oscillations caused by excessive adjustment.

[0015] In some optional embodiments, the method further includes: The adjusted base duration of the current pulse period is determined as the base duration of the next pulse period.

[0016] In this way, the duration of the adjusted base value is limited by both amplitude and range to prevent the base value time from being too short or too long due to abnormal deviations. Furthermore, the duration of the adjusted base value in the current pulse cycle is used as the duration of the base value in the next pulse cycle, so that the adjustment is completed at the end of each pulse cycle and takes effect immediately in the next pulse cycle, resulting in fast response and good real-time performance.

[0017] In some optional embodiments, the method of switching the welding current based on a comparison between the arc voltage of the current pulse cycle and a preset voltage threshold during the base phase includes: Based on the adjusted base value duration, the output is started according to the preset base value current; The arc voltage in the base value stage is converted into a short-circuit signal, and the arc voltage in the base value stage is compared with the preset voltage threshold to obtain a comparison result; Current switching protection is performed based on the short-circuit signal and the comparison result.

[0018] In this way, by judging based on a preset voltage threshold, short circuits can be detected in milliseconds and current switching protection can be implemented, effectively preventing the welding wire from burning out or sticking. Furthermore, it achieves synergy between millisecond-level short circuit prevention in the base phase and fine-tuning of the arc length in the peak phase. It can quickly intervene in the sudden decrease of arc length in the base phase to prevent short circuits, while simultaneously performing fine-tuning and adaptive adjustment of the arc length in the peak phase. This enables rapid, high-precision, and stable control of the arc length throughout the entire pulse cycle, improving welding quality and process stability.

[0019] In some optional embodiments, the current switching protection based on the short-circuit signal and the comparison result includes: When the comparison result indicates that the arc voltage in the base value stage is greater than the preset voltage threshold, the short-circuit signal is invalid, and welding in the base value stage is performed using the preset base value current.

[0020] In this way, welding is performed while maintaining the preset base current, thereby maintaining a stable arc state during the welding process.

[0021] In some optional embodiments, the current switching protection based on the short-circuit signal and the comparison result further includes: When the comparison result indicates that the arc voltage in the base value stage is less than or equal to the preset voltage threshold, the short-circuit signal is valid, and the current in the base value stage is switched from the preset base value current to the preset peak current. When the arc voltage of the base phase is detected to be greater than the preset voltage threshold during the base phase duration of the current pulse cycle, the current of the base phase is switched from the preset peak current to the preset base current.

[0022] In this way, the current is rapidly increased immediately upon detection of a short circuit in milliseconds to promote a smooth transition of molten droplets during welding, avoiding the large-particle spatter that is prone to occur during short circuit transition. This can prevent wire burning or arc failure due to short circuit. Furthermore, through voltage monitoring, the current is quickly switched back to the preset base value after the short circuit ends, maintaining a stable arc state and avoiding arc interruption caused by current switching lag. This effectively improves the dynamic stability of the arc length during pulsed MIG welding, reduces the probability of welding defects such as short circuits, spatter, and undercut, and results in uniform weld formation. Attached Figure Description

[0023] One or more embodiments are illustrated by way of example with reference to the accompanying drawings, and these illustrative descriptions do not constitute a limitation on the embodiments.

[0024] Figure 1 This is a flowchart illustrating a dual-mode control method for pulsed MIG welding arc length provided in one embodiment of this application; Figure 2 This is a schematic diagram of the structure of a pulsed MIG welding arc length dual-mode control device provided in one embodiment of this application; Figure 3 This is a schematic diagram of the structure of an electronic device provided in another embodiment of this application; Figure 4 This is a flowchart illustrating a dual-mode control method for pulsed MIG welding arc length provided in one embodiment of this application; Figure 5 This is a schematic diagram of the structure of a pulsed MIG welding arc length dual-mode control system provided in one embodiment of this application; Figure 6 This is a schematic diagram of the actual current waveform obtained from a resistance box load test according to another embodiment of this application; Figure 7 This is a schematic diagram of the actual welding current waveform test results provided in another embodiment of this application. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the various embodiments of this application will be described in detail below with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the various embodiments of this application to help readers better understand this application. However, the technical solutions claimed in this application can be implemented even without these technical details and various changes and modifications based on the following embodiments. The division of the various embodiments below is for the convenience of description and should not constitute any limitation on the specific implementation of this application. The various embodiments can be combined with and referenced by each other without contradiction.

[0026] To facilitate understanding of the embodiments of this application, the relevant content of the dual-mode control method for arc length in pulsed MIG welding will be introduced first.

[0027] Pulsed Metal Inert Gas Welding (PMIG welding) is widely used in machinery manufacturing, aerospace, and automotive manufacturing due to its advantages such as easy heat input control, aesthetically pleasing weld formation, and minimal spatter. Arc length is a core parameter in the welding process; its stability directly determines the weld formation accuracy, mechanical properties, and weld continuity. Improper arc length control can easily lead to increased spatter, weld undercut, short-circuit wire burning, and other defects, seriously affecting the quality and reliability of the welded joint. Especially in pulsed MIG welding, arc length stability is crucial in determining the smoothness of the welding process, the consistency of droplet transfer, the effectiveness of spatter control, and the quality of the weld formation.

[0028] In some technologies, existing mainstream arc length control methods mostly rely on single-dimensional feedback mechanisms, such as adjusting the wire feeding speed through a PID controller to maintain a constant average arc voltage, or adjusting pulse parameters based on the peak voltage signal to indirectly achieve arc length regulation.

[0029] However, such methods have fundamental limitations: the pulse welding cycle includes a base phase and a peak phase where the energy and arc physical state differ significantly. In the base phase, the current is low and the arc energy is weak, making the arc length prone to shortening and causing instantaneous short circuits. In the peak phase, the arc energy is concentrated and the arc is highly active, requiring precise control to maintain the target arc length. Traditional single control logic cannot simultaneously address the conflicting needs of these two phases. Increasing the control gain for rapid response can easily lead to arc oscillations in the peak phase; reducing the gain to ensure steady-state accuracy cannot promptly suppress the short-circuit risk in the base phase. This contradiction between dynamic response and steady-state accuracy results in insufficient arc length stability and process robustness when dealing with external interference, positional changes, or long arc extensions during the welding process.

[0030] Specifically, the existing arc length control methods mentioned above mostly control the arc length by adjusting the wire feed speed or peak current to regulate the heat input. However, adjusting the wire feed speed easily leads to current waveform disturbances, and changes in the peak current affect the droplet transfer morphology and stability, making it difficult to achieve precise and stable arc length control. At the same time, existing methods lack effective intervention for short-circuit transition in the base value stage, which easily leads to problems such as arc instability and short-circuit wire burning, disrupting welding continuity. In addition, there is no clear quantitative standard for adjusting the base value duration, resulting in low control accuracy, poor welding consistency, and inability to adapt to welding requirements with different wire feed speeds (current magnitudes).

[0031] To address the technical problem that existing arc length control methods often rely on adjusting wire feed speed or peak current to regulate heat input and control arc length, but adjusting wire feed speed can easily lead to current waveform disturbances, and changes in peak current can affect the droplet transition morphology and stability, making it difficult to achieve precise and stable arc length control, this invention proposes a dual-mode control method for pulsed MIG welding arc length. The implementation details of the dual-mode control method for pulsed MIG welding arc length in this embodiment are described below. The following content is only for ease of understanding and is not necessary for implementing this solution.

[0032] Example 1: The pulsed MIG welding arc length dual-mode control method of this embodiment can be applied to electronic devices with communication, computing, and data storage capabilities. Its specific process can be as follows: Figure 1 As shown, it includes: Step 101: In response to the start of welding, decouple each pulse cycle during the welding process into a peak phase and a base phase.

[0033] Specifically, the welding process comprises multiple pulse cycles, each decoupled into a peak phase and a base phase; that is, one pulse cycle includes both a peak phase and a base phase. Before welding begins, welding parameters are set, including: base current, peak current, base duration, initial base duration, peak duration, preset arc voltage (also known as stable arc length voltage), wire feed speed, welding speed, and shielding gas flow rate. The base current and peak current are the currents required for welding, providing stable energy input for the welding process. In some examples, the stable arc length voltage is obtained by performing trial welds under defined welding conditions, selecting a welding state with stable arc and minimal spatter, recording the average arc voltage, and defining the average arc voltage as the stable arc length voltage under those welding parameters. Furthermore, a database of the correspondence between stable arc length voltage and wire feed speed can be established for direct retrieval under different working conditions.

[0034] Step 102: In each pulse cycle, the peak phase of the current pulse cycle is adjusted by a base value duration adjustment method based on the voltage deviation between the peak phase arc voltage and the preset arc voltage; the base phase of the current pulse cycle is adjusted by a welding current switching protection method based on the comparison between the base phase arc voltage and the preset voltage threshold, so as to realize dual-mode control of arc length in each pulse cycle.

[0035] Specifically, within the current pulse cycle, differentiated control strategies are employed for the peak phase and the base phase. Specifically, after arc ignition, the current pulse cycle's peak phase begins. During this phase, the arc voltage is acquired, representing the real-time welding voltage. The voltage deviation between the peak phase arc voltage and a preset arc voltage is calculated, and an incremental parameter adjustment based on this voltage deviation is used for the peak phase. Here, the adjusted parameter is the base duration of the base phase. In other words, the voltage deviation is used to adjust the base duration of the base phase during the peak phase. After the peak phase ends, the base phase begins. During this phase, the current base phase arc voltage is acquired, representing the real-time welding voltage. The arc voltage is compared with a preset voltage threshold, and a comparison result is used for switching protection based on the preset voltage threshold during the base phase. Here, the preset voltage threshold is a set short-circuit threshold voltage, serving as the comparison threshold for short-circuit detection. In other words, during the base value stage, the voltage threshold is compared with the real-time welding voltage of the base value stage to perform short circuit detection, and then different welding currents are switched to perform base value stage welding to avoid short circuits.

[0036] In this embodiment, incremental parameter adjustment based on voltage deviation is adopted for the peak stage, and short-circuit detection and fast switching protection based on voltage threshold is adopted for the base stage. Thus, differentiated control strategies are adopted for the peak stage and the base stage respectively, so as to realize dual-mode (peak + base) closed-loop control of arc length.

[0037] Step 103: During the welding process, periodically monitor the welding torch switch signal. When the welding torch switch signal is detected to be off, terminate the current pulse cycle to complete the welding.

[0038] Specifically, when welding is completed, the welding torch switch should be in the open state. By monitoring the welding torch switch signal in real-time or at preset intervals during the welding process, when the base duration ends and the welding torch switch is detected to be in the open state (i.e., the welding torch switch signal is open), the current pulse cycle is terminated, and the arc termination phase begins. The welding control process is completed by gradually reducing the welding current and welding voltage until the output of welding current and welding voltage stops during the welding process. In some examples, when the base duration of the current pulse cycle is detected to have ended and the welding torch switch is in the closed state (i.e., the welding torch switch signal is closed), the next pulse cycle begins, repeating the dual-mode control process of the peak and base phases until the welding torch switch signal is open, completing the welding process.

[0039] In this embodiment, in response to the start of welding, each pulse cycle during the welding process is decoupled into a peak phase and a base phase. Within each pulse cycle, the peak phase of the current pulse cycle employs a base duration adjustment method based on the voltage deviation between the peak phase arc voltage and a preset arc voltage. The base phase of the current pulse cycle then employs a welding current switching protection method based on a comparison between the base phase arc voltage and a preset voltage threshold, achieving dual-mode control of the arc length in each pulse cycle. Furthermore, the welding torch switch signal is periodically monitored during welding. When the welding torch switch signal is detected to be off, the current pulse cycle is terminated, thus completing the welding. In this way, the base and peak phases of each pulse cycle during the welding process are decoupled, and independent control loops for different phases are constructed. Differentiated control strategies are designed for the different arc physical characteristics of the two phases, achieving precise arc length control that can identify the welding stage and implement differentiated control. This solves the problem of balancing response speed and control accuracy in traditional single control logic, ensuring the arc length remains stable throughout the welding process. This effectively improves the dynamic stability of the arc length during pulsed MIG welding and enhances welding quality.

[0040] In some embodiments, the peak phase of the current pulse cycle is adjusted using a base duration adjustment method based on the voltage deviation between the peak phase arc voltage and a preset arc voltage, including: The output is started according to the preset peak current. When the peak duration reaches the set time threshold, the difference between the arc voltage during the peak phase within the peak duration and the preset arc voltage is calculated to obtain the voltage deviation. The base duration of the current pulse period is adjusted based on the voltage deviation to obtain the adjusted base duration of the current pulse period.

[0041] Specifically, after arc ignition, the system first enters the peak phase of the current pulse cycle, initiating output according to the preset peak current and acquiring the arc voltage during the peak phase in real time. When the peak duration reaches a set time threshold (i.e., the peak duration ends), the voltage deviation is calculated by comparing the peak phase arc voltage with the preset arc voltage. The voltage deviation is calculated using the following formula: ΔU = Uf1 - Ugg; where ΔU is the voltage deviation, Uf1 is the peak phase arc voltage, and Ugg is the preset arc voltage. It should be noted that when calculating the voltage deviation, the peak phase arc voltage is the average value of the peak phase arc voltage. This is achieved by filtering out data from the arc voltage collected during the peak duration, such as the first six collected data points, to remove initial voltage noise. After removing invalid data, the peak phase arc voltage is continuously acquired, and the acquired peak phase arc voltage is accumulated, averaged, and filtered to obtain a stable average peak phase arc voltage. This effectively suppresses voltage spikes and random noise at the moment of arc ignition, avoiding erroneous adjustments.

[0042] In this embodiment, after obtaining the voltage deviation, the base duration of the current pulse period is adjusted based on the voltage deviation to obtain the adjusted base duration of the current pulse period. Thus, by calculating the voltage deviation and adjusting the base duration, the arc length can be finely and adaptively adjusted during the peak phase.

[0043] In some embodiments, adjusting the base duration of the current pulse period based on the voltage deviation to obtain the adjusted base duration of the current pulse period includes: The adjustment amount for the base value duration is determined based on the voltage deviation; Based on the adjustment amount and the base duration of the current pulse period, the adjusted base duration of the current pulse period is calculated.

[0044] Specifically, the adjustment amount for the base value duration is determined based on the magnitude of the voltage deviation. There is a one-to-one correspondence between the voltage deviation and the adjustment amount for the base value duration, as shown in Table 1.

[0045] Table 1. Adjustment Rules for Voltage Deviation and Base Duration

[0046] In Table 1, a negative ΔTb indicates a shortened base value duration and increased heat input, while a positive ΔTb indicates a prolonged base value duration and reduced heat input. This compensates for the difference between the wire melting rate and the feeding rate, ensuring consistent arc length.

[0047] In this embodiment, based on the adjustment amount and the base duration of the current pulse period, the relationship Tb is used. new =Tb current +ΔTb is used to calculate the adjusted base duration of the current pulse period. Where Tb... new Tb is the adjusted base duration of the current pulse period. current ΔTb represents the base duration of the current pulse cycle, and ΔTb is the adjustment amount of the base duration. Thus, by calculating the voltage deviation to determine the adjustment amount of the base duration, the base duration is incrementally adjusted. This allows for fine-tuning and adaptive fine-tuning of the arc length during the peak phase, rather than directly and drastically changing the base duration. This ensures continuous and smooth arc length changes during welding, avoiding welding process oscillations caused by excessive adjustment.

[0048] In some cases, if the current pulse period is the first pulse period, when calculating the adjusted base duration of the current pulse period, the initial value of the base duration is added to the adjustment amount to obtain the adjusted base duration of the current pulse period.

[0049] In some embodiments, the pulsed MIG welding arc length dual-mode control method further includes: The adjusted base duration of the current pulse period is determined as the base duration of the next pulse period.

[0050] Specifically, after obtaining the adjusted base duration of the current pulse period, it is necessary to apply both amplitude and range constraints to the adjusted base duration of the current pulse period before storing it as the base duration of the next pulse period. In some examples, the adjusted base duration Tb of the current pulse period... new The amplitude limit is: if Tb new >200ms, then Tb new Forced to 200ms; if Tb new If the time is less than 0.1ms, then Tb will be... new Forced to be set to 0.1ms; the adjusted base duration Tb of the current pulse period. new The range is limited to: the preset base value time variation range, with the variation range set between 0-100%, Tb newThe duration of the adjusted base value needs to vary within a preset percentage range corresponding to the initial value. This imposes dual limitations on the amplitude and range of the adjusted base value duration, preventing it from becoming too short or too long due to abnormal deviations. Furthermore, the adjusted base value duration of the current pulse cycle is used as the base value duration for the next pulse cycle, ensuring that the adjustment is completed at the end of each pulse cycle and takes effect immediately in the next pulse cycle, resulting in fast response and good real-time performance.

[0051] In some embodiments, a welding current switching protection method is adopted for the base value phase of the current pulse cycle, which compares the arc voltage of the base value phase with a preset voltage threshold, including: Based on the adjusted base value duration, the output is started according to the preset base value current; The arc voltage in the base phase is converted into a short-circuit signal, and the arc voltage in the base phase is compared with a preset voltage threshold to obtain the comparison result; Current switching protection is performed based on the short-circuit signal and the comparison result.

[0052] Specifically, the preset voltage threshold is a short-circuit threshold voltage, which serves as the comparison threshold for short-circuit detection. In this embodiment, after the peak phase ends, a base value phase begins, and a preset base value current is output according to the adjusted base value duration. During this time, the preset base value current is used as the welding current required for welding. Subsequently, the welding voltage (i.e., the arc voltage of the base value phase) acquired in the base value phase is converted into a short-circuit signal, and the arc voltage of the base value phase is compared with the preset voltage threshold. That is, the preset voltage threshold is compared with the real-time welding voltage of the base value phase to obtain a comparison result. Then, the short-circuit signal and the comparison result are combined for short-circuit detection to determine whether a short circuit has occurred, and current switching protection is performed to avoid short circuits. In this way, by judging based on a preset voltage threshold, short circuits can be detected in milliseconds and current switching protection can be implemented, effectively preventing the welding wire from burning out or sticking. Furthermore, it achieves synergy between millisecond-level short circuit prevention in the base phase and fine-tuning of the arc length in the peak phase. It can quickly intervene in the sudden decrease of arc length in the base phase to prevent short circuits, while simultaneously performing fine-tuning and adaptive adjustment of the arc length in the peak phase. This enables rapid, high-precision, and stable control of the arc length throughout the entire pulse cycle, improving welding quality and process stability.

[0053] In some embodiments, current switching protection based on a short-circuit signal and a comparison result includes: When the comparison result shows that the arc voltage in the base value stage is greater than the preset voltage threshold, the short circuit signal is invalid, and welding in the base value stage is performed with the preset base value current.

[0054] Specifically, after comparing the arc voltage in the base phase with a preset voltage threshold, if the comparison result shows that the arc voltage in the base phase is greater than the preset voltage threshold, the short-circuit signal is invalid. Since the arc voltage in the base phase is greater than the preset voltage threshold, it can be determined that no short circuit has occurred during the current welding process, and the preset base current can be maintained to perform welding in the base phase. In other words, energy is output using the preset base current to perform welding in the current base phase. Thus, by maintaining the preset base current during welding, a stable arc state is maintained during the welding process.

[0055] In some embodiments, the current switching protection based on the short-circuit signal and the comparison result further includes; When the comparison result shows that the arc voltage in the base phase is less than or equal to the preset voltage threshold, the short-circuit signal is valid, and the current in the base phase is switched from the preset base current to the preset peak current. When the arc voltage in the base phase is detected to be greater than the preset voltage threshold during the base phase duration of the current pulse cycle, the current in the base phase is switched from the preset peak current to the preset base current.

[0056] Specifically, after comparing the arc voltage in the base phase with a preset voltage threshold, if the comparison result shows that the arc voltage in the base phase is less than or equal to the preset voltage threshold, the short-circuit signal is considered valid, indicating a short-circuit transition. The current in the base phase is then immediately switched from the preset base current to the preset peak current. This allows for a rapid increase in current upon detecting a short circuit within milliseconds, promoting a smooth droplet transition during welding and preventing large-particle spatter that is common with short-circuit transitions. This also helps avoid wire burnout or arc maintenance failure due to short circuits.

[0057] In this embodiment, after switching to peak current, the arc voltage during the base value phase is continuously monitored until the base value duration ends. When the arc voltage during the base value phase is detected to be greater than a preset voltage threshold, the short-circuit transition process is determined to have ended, and the current setting is immediately switched back to the preset base value current, restoring the normal arc-maintaining state. Thus, through voltage monitoring, the preset base value current is quickly switched back after the short circuit ends, maintaining a stable arc state and avoiding arc interruption caused by current switching lag. This effectively improves the dynamic stability of the arc length during pulsed MIG welding, reduces the probability of welding defects such as short circuits, spatter, and undercut, and results in uniform weld formation.

[0058] Example 2: like Figure 5 As shown, the pulsed MIG welding arc length dual-mode control system of this embodiment includes: a main control unit, a power output unit, and a signal acquisition unit; The main control unit is used to respond to the start of welding by decoupling each pulse cycle during the welding process into a peak phase and a base phase. In each pulse cycle, the peak phase of the current pulse cycle adopts a base duration adjustment method based on the voltage deviation between the arc voltage of the peak phase obtained by the signal acquisition unit and the preset arc voltage. The base phase of the current pulse cycle adopts a welding current switching protection method based on the comparison between the arc voltage of the base phase and the preset voltage threshold, so as to realize dual-mode control of the arc length in each pulse cycle. The current switching protection is realized through the power output unit. During the welding process, the welding torch switch signal is periodically monitored. When the welding torch switch signal is detected to be open, the current pulse cycle is terminated, thereby completing the welding.

[0059] In this embodiment, each pulse cycle is decoupled into a peak phase and a base phase. Differentiated control strategies are employed for the peak phase and the base phase within the current pulse cycle. Specifically, after arc ignition, the current pulse cycle's peak phase begins. During the peak phase, the arc voltage is collected, i.e., the real-time welding voltage of the peak phase is collected. Based on the arc voltage of the peak phase and a preset arc voltage, the voltage deviation between the two is obtained. An incremental parameter adjustment method based on the voltage deviation is used for the peak phase. Here, the adjusted parameter is the base duration of the base phase. That is, the voltage deviation is used to adjust the base duration of the base phase during the peak phase. After the peak phase ends, the base phase begins. During the base phase, the current base phase arc voltage is collected, i.e., the real-time welding voltage of the base phase is collected. Based on a comparison between the arc voltage of the base phase and a preset voltage threshold, a comparison result is obtained. A switching protection method based on the preset voltage threshold is used for the base phase based on the comparison result. Here, the preset voltage threshold is a set short-circuit threshold voltage, serving as the comparison threshold for short-circuit judgment. In other words, during the base value stage, the voltage threshold is compared with the real-time welding voltage of the base value stage to perform short circuit detection, and then different welding currents are switched to perform base value stage welding to avoid short circuits.

[0060] In this embodiment, when welding is completed, the welding torch switch should be in the off state. By monitoring the welding torch switch signal in real-time or at preset intervals during the welding process, when the base value duration ends and the welding torch switch is detected to be in the off state (i.e., the welding torch switch signal is off), the current pulse cycle is terminated, and the arc termination phase begins. The welding control process is completed by gradually reducing the welding current and welding voltage until the output of welding current and welding voltage during the welding process stops, thus completing the welding. In some examples, when the base value duration of the current pulse cycle is detected to have ended and the welding torch switch is in the closed state (i.e., the welding torch switch signal is closed), the next pulse cycle begins, repeating the dual-mode control process of the peak phase and the base value phase until the welding torch switch signal is off, completing the welding.

[0061] In this embodiment, the pulsed MIG welding arc length dual-mode control system further includes: a wire feeding system, a parameter storage unit, and a human-machine interface unit. The main control unit, based on a high-speed digital signal processor, is used to achieve overall control of the entire welding process. The power output unit includes an inverter main circuit and a driver, used to generate the base current and peak current required for welding, providing stable energy input for the welding process. The wire feeding system consists of a wire feeder control box and a wire feeding mechanism, used to meet the electrode and filler metal delivery requirements of welding, adapting to different welding parameter conditions. The signal acquisition unit consists of a high-precision sensor and an analog-to-digital converter circuit, realizing real-time, high-speed acquisition of welding voltage and welding current, providing accurate signal input for the arc length control algorithm. The parameter storage unit stores a process parameter database, containing key parameters such as stable arc length voltage under different welding specifications, preset welding parameters, and preset voltage thresholds (short-circuit threshold voltages), facilitating rapid retrieval and updates during the welding process. The human-machine interface unit uses a touch screen as the host computer to set welding parameters and wire feeding speed parameters. At the same time, it can display key welding status parameters such as welding current and voltage in real time, which is convenient for operators to monitor and adjust.

[0062] In some cases, the main control unit preferably uses the high-performance STM32G474 chip, a high-performance mixed-signal MCU from STMicroelectronics' STM32G4 series, designed for real-time control and digital power applications. Welding parameters include preset base current, preset peak current, base duration, and peak duration. The wire feeding system can provide a maximum wire feed speed of 10 m / min; the human-machine interface unit interacts with the main control unit via RS485 MODBUS communication protocol.

[0063] In this embodiment, the main control unit is electrically connected to the power output unit, the wire feeding system, the signal acquisition unit, the parameter storage unit, and the human-machine interaction unit, respectively; it is used to send welding parameters, wire feeding parameters, and other parameters and related instructions, and to receive parameters such as actual arc voltage, actual welding current, and actual wire feeding speed; and to collect and process the electrical signal information of the signal acquisition unit, and output control instructions based on the processing results.

[0064] In this embodiment, in response to the start of welding, each pulse cycle during the welding process is decoupled into a peak phase and a base phase. Within each pulse cycle, the peak phase of the current pulse cycle employs a base duration adjustment method based on the voltage deviation between the arc voltage of the peak phase acquired by the signal acquisition unit and a preset arc voltage. The base phase of the current pulse cycle then employs a welding current switching protection method based on a comparison between the arc voltage of the base phase and a preset voltage threshold, thereby achieving dual-mode control of the arc length in each pulse cycle. The current switching protection is implemented through a power output unit. Furthermore, the welding torch switch signal is periodically monitored during welding. When the welding torch switch signal is detected to be off, the current pulse cycle is terminated, thus completing the welding process. In this way, the base value and peak value of each pulse cycle in the welding process are decoupled and independent control closed loops for different stages are constructed. Differentiated control strategies are designed for the different arc physical characteristics of the two stages, realizing precise arc length control that can identify the welding stage and implement differentiated control. This solves the problem that it is difficult to balance the response speed and control accuracy of traditional single control logic. As a result, the arc length remains stable throughout the welding process, effectively improving the dynamic stability of the arc length in pulsed MIG welding and improving the welding quality.

[0065] Example 3: like Figure 4 and Figure 5 As shown, this embodiment provides exemplary content for Embodiment 1 and Embodiment 2, namely, an exemplary process for a dual-mode control method and system for pulsed MIG welding arc length, specifically including: In this embodiment, the dual-mode control system for the arc length of pulsed MIG welding is implemented by a digital welding power supply system, including a main control unit, a power output unit, a wire feeding system, a signal acquisition unit, a parameter storage unit, and a human-machine interaction unit. The main control unit, with a high-speed digital signal processor as its core, is used to execute all control algorithms and achieve overall control of the entire welding process; The power output unit, including the inverter main circuit and driver, is used to generate the base current and peak current required for welding, providing a stable energy input for the welding process; The wire feeding system, consisting of a wire feeder control box and a wire feeding mechanism, is used to meet the electrode and filler metal feeding requirements for welding and is adaptable to different welding parameters. The signal acquisition unit, consisting of a high-precision sensor and an analog-to-digital converter circuit, enables real-time, high-speed acquisition of welding voltage Uf and welding current If, providing accurate signal input for the arc length control algorithm. The parameter storage unit is used to store the process parameter database, which includes key parameters such as stable arc length voltage Ugg, preset pulse parameters and preset voltage threshold U1 under different welding specifications, so as to facilitate quick retrieval and updating during the welding process. The human-machine interface unit uses a touch screen as the host computer to set welding parameters and wire feeding speed parameters. At the same time, it can display key welding status parameters such as welding current and voltage in real time, which is convenient for operators to monitor and adjust.

[0066] Based on the aforementioned dual-mode control system for pulsed MIG welding arc length, the main control unit preferably uses the high-performance STM32G474 chip. This chip is a high-performance mixed-signal MCU from STMicroelectronics' STM32G4 series, designed specifically for real-time control and digital power supply applications. Welding parameters include preset base current Ib, preset peak current Ip, base duration Tb, and peak duration Tp. The wire feeding system can provide a maximum wire feeding speed of 10 m / min. The human-machine interface unit interacts with the main control unit via the RS485 MODBUS communication protocol.

[0067] According to the dual-mode control system for pulsed MIG welding arc length described above, the main control unit is electrically connected to the power output unit, wire feeding system, signal acquisition unit, parameter storage unit, and human-machine interaction unit, respectively. It is used to send welding parameters, wire feeding parameters, and other parameters and related instructions, and to receive parameters such as actual arc voltage, actual welding current, and actual wire feeding speed. It also collects and processes the electrical signal information from the signal acquisition unit and outputs control instructions based on the processing results.

[0068] The dual-mode control method for the arc length of pulsed MIG welding in this embodiment utilizes the dual-mode control system for the arc length of pulsed MIG welding described above to achieve control, including the following steps: (1) Initialize the welding parameters through the human-machine interaction unit, store them in the parameter storage unit, and start the welding process; (2) During the welding process, the signal acquisition unit collects the welding voltage Uf and welding current If in real time and feeds them back to the main control unit. The wire feeding system feeds the wire according to the preset parameters, the power output unit outputs the base current and peak current, and the main control unit displays the key parameters of the welding process in real time; (3) The main control unit decouples a single pulse cycle into two stages: the base value and the peak value. For the peak value stage, incremental parameter adjustment based on voltage deviation is adopted, and for the base value stage, fast switching protection based on voltage threshold is adopted to achieve dual-mode closed-loop control and stabilize the arc length in real time; (4) During the welding process, the welding gun switch signal is continuously monitored. If the welding gun switch is detected to be disconnected, the current pulse cycle is immediately terminated and the arc termination stage is entered. The system gradually reduces the welding current and voltage until the output stops, thus completing the welding control process.

[0069] In this embodiment, the dual-mode control method for the arc length of pulsed MIG welding includes the following welding parameters in step (1): pulse base current Ib, base duration Tb, initial base duration cmdTb0, pulse peak current Ip, peak duration Tp, preset arc voltage Ugg, wire feed speed WFS, welding speed WS, and shielding gas flow rate Q. The stable arc length voltage Ugg is obtained by performing a trial weld under determined welding conditions, selecting the welding state with stable arc and minimal spatter, recording its average arc voltage, and defining it as Ugg under these parameters; a database corresponding to Ugg and wire feed speed can be established for easy direct calling under different working conditions.

[0070] In this embodiment, the dual-mode control method for the arc length of pulsed MIG welding, specifically the incremental parameter adjustment process based on deviation during the peak phase, is as follows: (1) After the arc is started, the pulse peak stage is entered first. The power output unit starts to output according to the preset peak current Ip, and the signal acquisition unit starts to acquire the arc voltage Uf of the peak stage in real time. Tp ; (2) Remove the arc voltage data collected in the first 6 times, filter out the voltage noise in the initial stage, remove invalid data, and then continuously collect the arc voltage Uf in the peak stage. Tp and the collected Uf Tp The cumulative average filtering process is performed to obtain a stable peak stage arc voltage average value Uf1. (3) When the peak duration reaches the set value Tp, calculate the voltage deviation ΔU=Uf1-Ugg, and determine the adjustment amount ΔTb of the base value time of the next pulse cycle based on the magnitude of ΔU; (4) Based on the adjustment amount ΔTb, combined with the current base value time Tb current Through the formula Tb new = Tb current + ΔTb calculates the base time Tb of the next pulse cycle. new and for Tb new After applying both amplitude and range constraints, the data is stored in the parameter storage unit as the base time Tb for the next pulse cycle. current .

[0071] The dual-mode control method for the arc length of pulsed MIG welding in this embodiment has the following adjustment rules for ΔU and ΔTb: Table 1.

[0072] Table 1. Adjustment Rules for Voltage Deviation and Base Duration

[0073] In Table 1, a negative ΔTb indicates a shortened base value duration and increased heat input, while a positive ΔTb indicates a prolonged base value duration and reduced heat input. This compensates for the difference between the wire melting rate and the feeding rate, ensuring consistent arc length.

[0074] The dual-mode control method for pulsed MIG welding arc length in this embodiment, for Tb new The amplitude limit is: if Tb new >200ms, then Tb new Forced to 200ms; if Tb new If the time is less than 0.1ms, then Tb will be... new Forced to 0.1ms; for Tb new The range is limited to: the preset base value time variation range, with the variation range set between 0-100%, Tb new It needs to vary within the corresponding preset percentage range of the initial value cmdTb0 of the base value duration.

[0075] like Figure 6 As shown, the dual-mode control method for pulsed MIG welding arc length in this embodiment, specifically the fast switching protection process based on voltage threshold in the base value stage, is as follows: (1) After the peak phase ends, the base phase begins, and the power output unit operates according to the adjusted base time Tb. new Output base current Ib; (2) Set the short-circuit threshold voltage U1=3.75V, and the signal acquisition unit collects the arc voltage Uf in real time during the base value stage. Tb The main control unit converts it into a short-circuit signal SC1 to determine whether a short circuit has occurred. (3) When the arc voltage Uf is detected Tb When the voltage is greater than 3.75V, the SC1 signal is invalid, no short circuit occurs, and the preset base current is maintained to perform base value stage welding. (4) When the arc voltage Uf is detected Tb When the voltage is ≤3.75V, the SC1 signal is valid. If a short circuit transition is detected, the current setting value of the base stage (i.e., the preset base current) will be immediately switched to the current setting value of the peak stage (the preset peak current) to avoid short circuit burnout or arc failure. (5) After switching to the preset peak current, continuously monitor the arc voltage Uf during the base value phase before the base value time ends. Tb When Uf is detected Tb When the voltage is greater than 3.75V, the short-circuit transition process is determined to be over, and the current setting value is immediately switched back to the preset base current value to restore the normal arc-maintaining state. (6) When the base value duration ends and the welding gun switch is in the closed state, the next pulse cycle begins, and the dual-mode control process of peak and base value stages is repeated.

[0076] In this embodiment, millisecond-level rapid intervention can be performed on the sudden decrease in arc length during the base phase to prevent short circuits. Simultaneously, fine-tuning and adaptive adjustment of the arc length are performed during the peak phase, thereby achieving rapid, high-precision, and stable control of the arc length throughout the entire pulse cycle, improving welding quality and process stability. Specifically, through a dual-mode control closed-loop architecture, the base and peak phases of the pulse cycle are decoupled and independent control loops are constructed. Differentiated control strategies are designed for the different physical characteristics of the arc in the two phases. Furthermore, an experimentally calibrated stable arc length voltage Ugg is introduced as a unified physical reference to achieve parameterized control logic. This invention uses arc voltage and current as feedback quantities and base time and welding current as control quantities. By identifying the welding stage in real time and executing dedicated control logic, it achieves the synergy of millisecond-level short-circuit prevention in the base stage and fine-tuning of arc length in the peak stage. It solves the problem that traditional single control logic cannot balance response speed and control accuracy. It effectively improves the dynamic stability of arc length in pulsed MIG welding, reduces the probability of welding defects such as short circuits, spatter, and undercut, and produces uniform weld formation. The welding process is continuous and reliable. Moreover, the control algorithm is parameterized and has clear rules, making it easy to implement and promote in engineering.

[0077] The following are specific examples: A dual-mode control system for pulsed MIG welding arc length, such as Figure 5 As shown, it includes a main control unit 1, a power output unit 2, a wire feeding system 3, a signal acquisition unit 4, a parameter storage unit 5, and a human-machine interaction unit 6.

[0078] The main control unit 1 is an STM32G474 chip, which is electrically connected to the power output unit 2, wire feeding system 3, signal acquisition unit 4, parameter storage unit 5 and human-machine interaction unit 6 respectively. It is used to execute all control algorithms, send various welding parameters and instructions, receive actual electrical signal parameters, collect and process electrical signal information from signal acquisition unit 4, and realize the overall control of the entire welding process.

[0079] The power output unit 2 includes a front-stage inverter main circuit and a rear-stage pulse output circuit. It is electrically connected to the main control unit 1, receives instructions from the main control unit 1, generates and outputs the base current and peak current required for welding, and provides stable energy input for the welding process.

[0080] The wire feeding system 3 consists of a wire feeder control box and a wire feeding mechanism. It is electrically connected to the main control unit 1, receives wire feeding parameters and instructions from the main control unit 1, and can provide a maximum wire feeding speed of 10m / min to meet the electrode and filler metal conveying requirements for welding.

[0081] The signal acquisition unit 4 consists of high-precision current and voltage sensors and analog-to-digital conversion circuits. It is electrically connected to the main control unit 1 to realize real-time and high-speed acquisition of arc voltage Uf and welding current If, providing accurate signal input for the arc length control algorithm and ensuring control accuracy.

[0082] The parameter storage unit 5 is electrically connected to the main control unit 1 and is used to store the process parameter database, which includes key parameters such as stable arc length voltage Ugg under different welding specifications, welding parameters (preset base current Ib, preset peak current Ip, base duration Tb, peak duration Tp) and control threshold U1, so as to facilitate quick retrieval and updating during the welding process.

[0083] The human-machine interaction unit 6 is a touch screen host computer that interacts with the main control unit 1 via RS485 MODBUS communication protocol to set welding parameters and wire feeding speed parameters. At the same time, it can display key welding status parameters such as welding current and voltage in real time, which is convenient for operators to monitor and adjust.

[0084] A dual-mode control method for the arc length of pulsed MIG welding is proposed. This method utilizes the aforementioned dual-mode control system for the arc length of pulsed MIG welding to achieve dual-mode closed-loop control of the arc length during pulsed MIG welding. The specific steps are as follows: Welding parameters are initialized and set via the touchscreen human-machine interface unit 6. The welding plate is Q235 steel plate, and the welding wire is ER321 welding wire. The base current Ib = 60A, the initial base time cmdTb0 = 10ms, the peak current Ip = 400A, and the peak time Tp = 3ms. The arc voltage is given as Ugg = 30V (this parameter has been calibrated through testing and is suitable for a wire feeding speed of 6m / min to ensure arc stability and minimal spatter). The wire feeding speed WFS = 6m / min, and the welding speed WS = 400mm / min. The base time variation range is set to 100%, and the short-circuit threshold voltage U1 = 3.75V. The shielding gas flow rate is set to meet the welding requirements of Q235 steel plate. All parameters are stored in the parameter storage unit 5.

[0085] The welding process signal acquisition and feedback starts the welding process. After the arc is ignited, the signal acquisition unit 4 collects the arc voltage Uf and welding current If in real time and feeds them back to the main control unit 1. The wire feeding system 3 feeds the wire at a wire feeding speed of 6m / min. The power output unit 2 alternately outputs a base current of 60A and a peak current of 400A. The main control unit 1 displays key parameters such as welding current and voltage in real time. The operator can monitor the welding status in real time through the touch screen.

[0086] The dual-mode closed-loop control execution main control unit 1 decouples a single pulse cycle into two stages: base value and peak value, and executes differentiated dual-mode control: Incremental parameter adjustment during peak phase: After arc ignition, the system first enters the peak phase, with power output unit 2 outputting a 400A peak current. Signal acquisition unit 4 acquires the arc voltage Uf, discards the first 6 invalid data, and then performs cumulative averaging filtering to obtain the filtered voltage Uf. Tp =29.8V; After the peak time of 3ms, the voltage deviation ΔU = 29.8 - 30 = -0.2V is calculated, which is within the dead zone range of -0.5 < ΔU < +0.5, so ΔTb = 0ms is determined; The new base time Tb is calculated. new= 10 + 0 = 10 ms. This value satisfies the amplitude limit of 0.1 ms < 10 ms < 200 ms, and is within the range limit of ±100% of the initial value. Determine Tb accordingly. new =10ms to store in parameter storage unit 5.

[0087] Base value phase fast switching protection: After the peak phase ends, the system enters the base value phase, with power output unit 2 outputting a 60A base value current for 10ms; signal acquisition unit 4 acquires the arc voltage Uf during the base value phase in real time. Tb Uf was detected Tb The voltage remained consistently between 8V and 10V, never falling below the 3.75V short-circuit threshold, indicating no short circuit had occurred. The arc was then maintained at a base current of 60A.

[0088] Cyclic loop: After the 10ms base value time ends, the welding torch switch remains closed and enters the next pulse cycle, repeating the control process of the peak and base value stages to achieve cyclical and stable control of the arc length.

[0089] Arc termination control: After the Q235 steel plate welding is completed, the welding gun switch is turned off. After the main control unit 1 detects the switch signal, it immediately terminates the current pulse cycle and enters the arc termination stage. The power output unit 2 gradually reduces the welding current and voltage until it stops outputting. The wire feeding system 3 stops feeding wire, and the entire welding process ends.

[0090] Welding results: such as Figure 7 As shown, the arc length fluctuation was controlled within ±0.5mm during the welding process, and no short-circuit transition, arc maintenance failure, or excessive spatter occurred. The weld formation was uniform, without undercut, porosity, or spatter. The entire welding process was continuous and stable, with rapid control response, verifying the practicality and superiority of this method.

[0091] Example 4: Another embodiment of this application relates to a dual-mode control device for pulsed MIG welding arc length. The implementation details of this embodiment's dual-mode control device for pulsed MIG welding arc length are described below. The following details are provided for ease of understanding and are not essential for implementing this solution. A schematic diagram of this embodiment's dual-mode control device for pulsed MIG welding arc length can be seen as follows: Figure 2As shown, it includes: Decoupling module 201 is used to decouple each pulse cycle during the welding process into a peak phase and a base phase in response to the start of welding. The control module 202 is used to adjust the duration of the arc length in each pulse cycle by adjusting the voltage deviation between the peak stage arc voltage and the preset arc voltage in the peak stage of the current pulse cycle; and to switch the welding current in the base stage arc cycle by comparing the arc voltage in the base stage arc voltage with the preset voltage threshold, so as to realize dual-mode control of the arc length in each pulse cycle. The monitoring module 203 is used to periodically monitor the welding torch switch signal during the welding process. When the welding torch switch signal is detected to be off, the current pulse cycle is terminated, thereby completing the welding.

[0092] In some embodiments, the control module 202 includes: The calculation unit is used to start the output according to the preset peak current. When the peak duration reaches the set time threshold, it calculates the difference between the arc voltage during the peak stage within the peak duration and the preset arc voltage to obtain the voltage deviation. The adjustment unit is used to adjust the base duration of the current pulse period based on the voltage deviation, so as to obtain the adjusted base duration of the current pulse period.

[0093] In some embodiments, the adjustment unit is used to determine the adjustment amount of the base value duration based on the voltage deviation; and to calculate the adjusted base value duration of the current pulse period based on the adjustment amount and the base value duration of the current pulse period.

[0094] In some embodiments, the pulsed MIG welding arc length dual-mode control device is further configured to determine the adjusted base duration of the current pulse cycle as the base duration of the next pulse cycle.

[0095] In some embodiments, the control module 202 further includes: The start-up unit is used to start the output according to the preset base value current based on the adjusted base value duration; The comparison unit is used to convert the arc voltage in the base value stage into a short-circuit signal and compare the arc voltage in the base value stage with a preset voltage threshold to obtain the comparison result. The switching unit is used to switch the current for protection based on the short-circuit signal and the comparison result.

[0096] In some embodiments, the switching unit includes: The first comparison subunit is used to invalidate the short-circuit signal and perform welding in the base value stage with the preset base value current when the comparison result is that the arc voltage in the base value stage is greater than the preset voltage threshold.

[0097] In some embodiments, the switching unit further includes: The second comparison subunit is used to switch the current in the base value stage from the preset base value current to the preset peak current when the comparison result is that the arc voltage in the base value stage is less than or equal to the preset voltage threshold. The switching subunit is used to switch the current in the base phase from the preset peak current to the preset base current when the arc voltage in the base phase is detected to be greater than the preset voltage threshold during the base phase duration of the current pulse cycle.

[0098] It is worth mentioning that all modules involved in this embodiment are logical modules. In practical applications, a logical unit can be a physical unit, a part of a physical unit, or a combination of multiple physical units. Furthermore, to highlight the innovative aspects of this application, this embodiment does not introduce units that are not closely related to solving the technical problems proposed in this application; however, this does not mean that other units are absent in this embodiment.

[0099] Example 5: Another embodiment of this application relates to an electronic device, such as... Figure 3 As shown, it includes: at least one processor 901; and a memory 902 communicatively connected to the at least one processor 901; wherein the memory 902 stores instructions executable by the at least one processor 901, the instructions being executed by the at least one processor 901 to enable the at least one processor 901 to execute the pulse MIG welding arc length dual-mode control method in the above embodiments.

[0100] The memory and processor are connected via a bus, which can include any number of interconnecting buses and bridges, connecting various circuits of one or more processors and memories. The bus can also connect various other circuits, such as peripheral devices, voltage regulators, and power management circuits, which are well known in the art and will not be described further herein. The bus interface provides an interface between the bus and the transceiver. The transceiver can be a single element or multiple elements, such as multiple receivers and transmitters, providing a unit for communicating with various other devices over a transmission medium. Data processed by the processor is transmitted over the wireless medium via an antenna, which further receives data and transmits it to the processor.

[0101] The processor manages the bus and general processing, and also provides various functions, including timing, peripheral interfaces, voltage regulation, power management, and other control functions. Memory is used to store data used by the processor during operation.

[0102] Example 6: Another embodiment of this application relates to a computer-readable storage medium storing a computer program. When executed by a processor, the computer program implements the method embodiments described above.

[0103] That is, those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware. This program is stored in a storage medium and includes several instructions to cause a device (which may be a microcontroller, chip, etc.) or processor to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0104] Those skilled in the art will understand that the above embodiments are specific embodiments for implementing this application, and in practical applications, various changes can be made to them in form and detail without departing from the spirit and scope of this application.

Claims

1. A dual-mode control method for arc length in pulsed MIG welding, characterized in that, include: In response to the start of welding, each pulse cycle during the welding process is decoupled into a peak phase and a base phase; In each pulse cycle, the peak phase of the current pulse cycle is adjusted using a base value duration adjustment method based on the voltage deviation between the arc voltage at the peak phase and the preset arc voltage. A welding current switching protection method is adopted for the base value stage of the current pulse cycle, which compares the arc voltage of the base value stage with a preset voltage threshold to achieve dual-mode control of the arc length in each pulse cycle. During the welding process, the welding torch switch signal is periodically monitored. When the welding torch switch signal is detected to be off, the current pulse cycle is terminated, thereby completing the welding.

2. The dual-mode control method for arc length in pulsed MIG welding according to claim 1, characterized in that, The method of adjusting the peak phase of the current pulse cycle using a base value duration adjustment based on the voltage deviation between the arc voltage at the peak phase and a preset arc voltage includes: The output is started according to the preset peak current. When the peak duration reaches the set time threshold, the difference between the arc voltage of the peak stage within the peak duration and the preset arc voltage is calculated to obtain the voltage deviation. The base duration of the current pulse period is adjusted based on the voltage deviation to obtain the adjusted base duration of the current pulse period.

3. The dual-mode control method for arc length in pulsed MIG welding according to claim 2, characterized in that, The step of adjusting the base duration of the current pulse period based on the voltage deviation to obtain the adjusted base duration of the current pulse period includes: The adjustment amount for the base value duration is determined based on the voltage deviation; Based on the adjustment amount and the base duration of the current pulse period, the adjusted base duration of the current pulse period is calculated.

4. The dual-mode control method for arc length in pulsed MIG welding according to any one of claims 1-3, characterized in that, The method further includes: The adjusted base duration of the current pulse period is determined as the base duration of the next pulse period.

5. The dual-mode control method for arc length in pulsed MIG welding according to claim 2, characterized in that, The method of switching welding current based on a comparison between the arc voltage of the current pulse cycle and a preset voltage threshold during the base phase includes: Based on the adjusted base value duration, the output is started according to the preset base value current; The arc voltage in the base value stage is converted into a short-circuit signal, and the arc voltage in the base value stage is compared with the preset voltage threshold to obtain a comparison result; Current switching protection is performed based on the short-circuit signal and the comparison result.

6. The dual-mode control method for arc length in pulsed MIG welding according to claim 5, characterized in that, The current switching protection based on the short-circuit signal and the comparison result includes: When the comparison result indicates that the arc voltage in the base value stage is greater than the preset voltage threshold, the short-circuit signal is invalid, and welding in the base value stage is performed using the preset base value current.

7. The dual-mode control method for arc length in pulsed MIG welding according to claim 6, characterized in that, The current switching protection based on the short-circuit signal and the comparison result further includes; When the comparison result indicates that the arc voltage in the base value stage is less than or equal to the preset voltage threshold, the short-circuit signal is valid, and the current in the base value stage is switched from the preset base value current to the preset peak current. When the arc voltage of the base phase is detected to be greater than the preset voltage threshold during the base phase duration of the current pulse cycle, the current of the base phase is switched from the preset peak current to the preset base current.

8. A dual-mode control system for pulsed MIG welding arc length, characterized in that, include: Main control unit, power output unit, signal acquisition unit; The main control unit is used to decouple each pulse cycle during the welding process into a peak phase and a base phase in response to the start of welding. In each pulse cycle, the peak phase of the current pulse cycle adopts a base duration adjustment method based on the voltage deviation between the arc voltage of the peak phase obtained by the signal acquisition unit and a preset arc voltage. The base phase of the current pulse cycle adopts a welding current switching protection method based on the comparison between the arc voltage of the base phase and a preset voltage threshold, so as to realize dual-mode control of the arc length in each pulse cycle. The current switching protection is realized by the power output unit. During the welding process, the welding gun switch signal is periodically monitored. When the welding gun switch signal is detected to be open, the current pulse cycle is terminated, thereby completing the welding.

9. An electronic device, characterized in that, include: At least one processor; as well as, A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor to enable the at least one processor to perform the pulsed MIG welding arc length dual-mode control method as described in any one of claims 1 to 7.

10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the pulse MIG welding arc length dual-mode control method as described in any one of claims 1 to 7.

Images