A double-wire feeding device for laser build-up welding of inner holes and a control method thereof

Abstract

The application discloses a kind of inner hole laser surfacing double wire feeding device and control method, it is related to laser welding technical field.Device includes double wire feeder, wire feeding nozzle seat and wire feeding detection device in the side of wire feeding nozzle seat close to both sides, for real-time detection wire I and wire II actual wire feeding speed.Control method constructs closed-loop control link with measured speed as feedback, adopts double-loop PID hierarchical regulation mechanism, first respectively to each wire is carried out single wire deviation independent closed-loop correction, then to double wire synchronous deviation is carried out secondary closed-loop compensation, makes double wire feeding speed under dynamic disturbance tend to be consistent;While introducing overage delay determination mechanism, realize the automatic identification and shutdown protection of abnormal carding fault.The application realizes the accurate synchronous wire feeding of inner hole double wire laser surfacing by wire feeding detection and double-loop PID cooperative regulation, effectively improves the quality consistency of surfacing layer and reduces defect maintenance cost.

Description

Technical Field

[0001] This application relates to the field of laser welding technology, specifically to a dual-wire feeding device and control method for laser overlay welding of internal holes. Background Technology

[0002] Hydraulic supports are core support equipment in fully mechanized coal mining operations. Due to the complex and harsh mine environment, hydraulic supports operate under heavy loads underground for extended periods, making them prone to corrosion, wear, and seal failure. This not only poses safety hazards but also shortens the equipment's lifespan. In the field of hydraulic support manufacturing and remanufacturing, the repair and corrosion protection of the hydraulic cylinder's inner bore is a core processing step with a large workload and high necessity.

[0003] Currently, common processes for preparing coatings for the inner bore of hydraulic cylinders include traditional electroplating, arc welding, laser powder cladding, and laser wire welding. However, each process has significant technical shortcomings: traditional electroplating is highly polluting and has limited anti-corrosion performance, and has been gradually phased out by the industry; arc welding suffers from low production efficiency, high dilution rate of the weld layer, and large workpiece deformation; laser powder cladding faces problems such as low powder utilization and the fact that fumes and spatter during the cladding process can reduce the stability of the laser head; laser wire welding, due to its high material utilization, low weld layer dilution rate, high production efficiency, and environmentally friendly processing, has become the preferred technology for strengthening and repairing the inner bore of hydraulic cylinders.

[0004] Existing laser wire cladding mainly uses two methods: single-wire feeding and dual-wire feeding. Single-wire laser cladding suffers from limited wire filling capacity and low cladding efficiency. While dual-wire laser cladding can improve efficiency, the wire feeding nozzle is located deep within the workpiece when the laser head operates inside the hydraulic cylinder, making real-time monitoring of the wire feeding status difficult. The wire feeding system typically uses open-loop control, resulting in insufficient precision and stability. It struggles to effectively suppress external disturbances such as fluctuations in wire feeding resistance, leading to asynchronous wire feeding speeds, wire jamming, uneven feeding, and consequently, uneven weld layer thickness, unstable dilution rate, and even defects like porosity and incomplete fusion. Therefore, there is an urgent need for a dual-wire feeding device and control method for internal hole laser cladding that can achieve synchronous, precise, and stable dual-wire feeding with real-time monitoring of the wire feeding status. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a dual-wire feeding device and control method for internal hole laser welding. By combining wire feeding detection with dual-loop PID coordinated adjustment, precise synchronous wire feeding for internal hole dual-wire laser welding is achieved, effectively improving the consistency of weld layer quality and reducing defect repair costs.

[0006] In a first aspect, the technical solution of the present invention provides a dual-wire feeding device for laser welding of internal holes, comprising: The feed nozzle holder is fixed to the inner hole laser head; Double feed nozzles, installed on the feed nozzle holder; A dual wire feeder is used to drive the feeding of welding wire I and welding wire II; and The wire feeding detection device is installed on the inner hole laser head, located between the dual wire feeder and the wire feeding nozzle seat, and is positioned closer to the wire feeding nozzle seat. The wire feeding detection device is used to detect the actual wire feeding speed of welding wire I and welding wire II.

[0007] In an optional embodiment, the wire feeding detection device includes: a wire feeding detection module I and a wire feeding detection module II, wherein the wire feeding detection module I is used to detect the actual wire feeding speed of welding wire I in real time, and the wire feeding detection module II is used to detect the actual wire feeding speed of welding wire II in real time; The wire feeding detection module I and the wire feeding detection module II have the same structure and are installed symmetrically. Both the wire feeding detection module I and the wire feeding detection module II include: a base, an encoder, and an encoder wheel; the encoder is fixed on the base, the encoder wheel is fixed on the encoder's rotating shaft, and welding wire I and welding wire II are respectively attached to the corresponding encoder wheel to drive the corresponding encoder wheel to rotate through friction.

[0008] In an optional embodiment, both the wire feeding detection module I and the wire feeding detection module II further include: V-shaped wheel bearing I, V-shaped wheel bearing II, bearing slide I, bearing slide II, compression spring I, compression spring II, and adjusting pressure plate; Bearing slide I and bearing slide II are respectively installed in the base and can slide up and down. A compression spring I is provided between bearing slide I and the base, and a compression spring II is provided between bearing slide II and the base. The adjusting plate is installed on the base. Adjusting screw I and adjusting screw II are installed on the adjusting plate. Adjusting screw I abuts against the bottom of bearing slide I, and adjusting screw II abuts against the bottom of bearing slide II. V-type bearing I is mounted on bearing slide I via locking pad I, and V-type bearing II is mounted on bearing slide II via locking pad II; V-type wheel bearing I and V-type wheel bearing II press against the surface of welding wire I or welding wire II respectively, so that the welding wire always adheres to the encoder wheel.

[0009] In one optional embodiment, adjusting screw I is provided with locking nut I, and adjusting screw II is provided with locking nut II, for locking the positions of adjusting screw I and adjusting screw II after adjustment.

[0010] In an optional embodiment, the wire feeding detection device further includes: a wire infeed fixing seat and a wire outlet fixing seat, which are respectively installed at both ends of the wire feeding detection module I and the wire feeding detection module II along the wire feeding direction.

[0011] Secondly, the technical solution of the present invention provides a method for controlling the dual-wire feeding of laser welding in internal holes, applicable to the dual-wire feeding device for laser welding in internal holes according to any of the above claims, comprising the following steps: S1, Set theoretical wire feeding speed Single filament deviation threshold Synchronization Deviation Threshold Excessive delay judgment time and out-of-tolerance delay alarm time ; S2, the dual wire feeder drives welding wire I and welding wire II according to... Silk feeding; S3. The actual speed of welding wire I is collected in real time by wire feeding detection module I and wire feeding detection module II respectively. and the actual speed of welding wire II ; S4. Calculate the theoretical wire feed speed Actual speed of welding wire I monofilament deviation value And calculate the theoretical wire feeding speed Actual speed of welding wire II monofilament deviation value ; S5. Control the single filament deviation based on the single filament deviation value: like and If the current wire feeding parameters remain unchanged, proceed to step S6. like or Then the timer T will begin to accumulate; like If the current wire feeding parameters remain unchanged, proceed to step S6. like According to and The speed compensation amounts of welding wire I and welding wire II are calculated using a PID algorithm and output to step S2 for adjustment. like If the fault alarm is triggered, the machine will stop and the timer T will be cleared. S6. Calculate the actual speed of welding wire I. and the actual speed of welding wire II Synchronization deviation between ; S7. Perform synchronization deviation control based on synchronization deviation: like If the current wire feeding parameters remain unchanged, proceed to step S8. like Start accumulating time ; like If the current wire feeding parameters remain unchanged, proceed to step S8. like According to The speed compensation amount of welding wire I or welding wire II is calculated using a PID algorithm and output to step S2 for adjustment; like If the fault occurs, a fault alarm will be issued and the machine will stop, clearing the timer. ; S8. Repeat steps S2 to S7 until a processing completion signal is received.

[0012] In an optional implementation, in step S7, if If the value is positive, then the speed compensation amount of welding wire I is corrected; if If the value is negative, then the speed compensation amount of welding wire II is corrected.

[0013] In one optional implementation, according to and The speed compensation amounts for welding wire I and welding wire II are calculated using a PID algorithm, specifically by calculating the speed compensation amounts using the following formula:

[0014]

[0015] in, This is the sampling time sequence number. The sampling period is , These are the speed compensation amounts for welding wire I and welding wire II, respectively. These are the proportional coefficient, integral coefficient, and differential coefficient of the closed-loop welding wire speed I, respectively. These are the proportional coefficient, integral coefficient, and differential coefficient of the welding wire II speed closed loop, respectively.

[0016] In one optional implementation, according to The speed compensation amount for welding wire I or welding wire II is calculated using a PID algorithm, specifically by calculating the speed compensation amount using the following formula:

[0017] in, This is the sampling time sequence number. The sampling period is This is the speed compensation amount for welding wire I or welding wire II. These are the proportional coefficient, integral coefficient, and derivative coefficient for the synchronous deviation control of welding wire I and welding wire II, respectively.

[0018] In an optional implementation, step S3 specifically includes: During the wire feeding process, welding wire I and welding wire II are respectively in contact with the encoder wheel of wire feeding detection module I and the encoder wheel of wire feeding detection module II. The corresponding encoder wheel is driven to rotate by friction, and the encoder wheel drives the encoder's rotating shaft to rotate synchronously. The encoder outputs pulse signals as the rotating shaft rotates. The control system calculates the speed of the encoder wheel based on the number of pulses collected per unit time, and calculates the actual speed of welding wire I based on the outer circumference of the encoder wheel. and the actual speed of welding wire II .

[0019] As can be seen from the above technical solution, this application has the following advantages: A wire feeding detection device is set between the dual wire feeder and the wire feeding nozzle seat, and closer to the wire feeding nozzle seat. During laser processing, the actual wire feeding speeds of welding wire I and welding wire II at the wire feeding nozzle are acquired in real time, and the measured speed is introduced into the control system as feedback, constructing a closed-loop control link of measurement-comparison-correction. Based on this, a dual-loop PID graded adjustment mechanism is adopted. First, the deviation between the actual speed and the theoretical speed of each welding wire is independently corrected in a closed loop. Then, the synchronization deviation between the two welding wires is compensated in a secondary closed loop. The two-stage adjustment works synergistically to ensure that the dual-path wire feeding speed always tends to be consistent under dynamic disturbances. Simultaneously, by introducing an over-tolerance delay judgment into the control strategy, instantaneous disturbances and continuous abnormalities are distinguished, achieving automatic identification and shutdown protection of abnormal wire jamming faults while ensuring system stability. This application solves the technical problems of asynchronous wire feeding speeds, insufficient wire feeding accuracy and stability caused by the inability to monitor the wire feeding status in a closed environment. It can achieve precise and coordinated control of the wire feeding speed of the two wires, thereby effectively improving the consistency of the weld overlay thickness and composition. At the same time, through automatic fault identification and protection, it avoids the generation of large-area weld overlay quality defects caused by abnormal wire feeding, reduces the repair cost of defective workpieces, and provides a reliable technical guarantee for efficient and high-quality laser welding repair of the inner bore of hydraulic support cylinders. Attached Figure Description

[0020] To more clearly illustrate the technical solution of this application, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a three-dimensional schematic diagram of a dual-wire feeding device for laser welding of internal holes provided in an embodiment of the present invention.

[0022] Figure 2 yes Figure 1A magnified view of part A.

[0023] Figure 3 This is a three-dimensional schematic diagram of the wire feeding detection device of the present invention.

[0024] Figure 4 This is a three-dimensional schematic diagram of the wire feeding detection module I and the wire feeding detection module II of the present invention.

[0025] Figure 5 This is a three-dimensional schematic diagram showing a partial cross-section of the wire feeding detection module I and the wire feeding detection module II of the present invention.

[0026] Figure 6 This is a schematic diagram illustrating the principle of a dual-wire feeding control method for laser overlay welding of internal holes provided in an embodiment of the present invention.

[0027] Figure 7 This is a schematic diagram of a dual-wire feeding control method for laser overlay welding of internal holes provided in an embodiment of the present invention.

[0028] In the diagram, 1. Welding wire I; 2. Welding wire II; 3. Wire feed tube I; 4. Wire feed tube II; 5. Dual wire feeder; 5001. Welding wire drive device I; 5002. Welding wire drive device II; 6. Internal laser head; 6001. Laser beam; 7. Wire feeding detection device; 7100, Wire feed fixing seat; 7200. Wire feeding detection module I; 7201. Base; 7202. Encoder wheel; 7203. V-wheel bearing I; 7204. Locking pad I; 7205. Adjusting pressure plate; 7206. Locking nut I; 7207. Adjusting screw I; 7208. Locking nut II; 7209. Adjusting screw II; 7210. V-wheel bearing II; 7211. Locking pad II; 7212. Encoder; 7213. Bearing slide I; 7214. Compression spring I; 7215. Bearing slide II; 7216. Compression spring II; 7300, wire ejection fixing seat; 7400, Wire Feeding Detection Module II; 8. Mounting bracket; 9. Thread feeder seat; 10. Double thread feeder. Detailed Implementation

[0029] To make the purpose, features, and advantages of this application more apparent and understandable, specific embodiments and accompanying drawings will be used to clearly and completely describe the technical solution protected by this application. Obviously, the embodiments described below are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0030] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The various terms used in this specification are merely for describing specific embodiments and do not constitute a limitation thereof.

[0031] In the description of this application, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0032] like Figure 1 and Figure 2 As shown, the internal hole laser welding dual wire feeding device provided in this embodiment includes: welding wire I1, welding wire II2, wire feeding tube I3, wire feeding tube II4, dual wire feeder 5, internal hole laser head 6, wire feeding detection device 7, mounting frame 8, wire feeding nozzle seat 9, and dual wire feeding nozzle 10.

[0033] The internal laser head 6 is used to extend into the inner bore of the hydraulic cylinder to perform surfacing welding. The wire feed nozzle seat 9 is fixedly installed on the outside of the internal laser head 6 by the mounting bracket 8. The double wire feed nozzles 10 are installed on the wire feed nozzle seat 9 and are used to guide the welding wires I1 and II2 to the position of the laser beam 6001 emitted by the internal laser head 6, so that the welding wires melt under the action of the laser to form a surfacing layer.

[0034] The dual wire feeder 5 is located outside the inner-hole laser head 6 and serves as the active wire feeding power source. The dual wire feeder 5 includes a wire drive device I 5001 and a wire drive device II 5002, which respectively drive the welding wire I1 and welding wire II2 forward. One end of the wire feeding tube I 3 is connected to the wire drive device I 5001, and the other end extends to the wire inlet side of the wire feeding detection device 7, and then extends through the wire outlet side of the wire feeding detection device 7 to the wire feeding nozzle seat 9, allowing the welding wire I1 to travel along the wire feeding tube I 3 from the dual wire feeder 5, sequentially passing through the wire feeding detection device 7 and the wire feeding nozzle seat 9 to reach the dual wire feeding nozzle 10. Similarly, one end of the wire feeding tube II 4 is connected to the wire drive device II 5002, and the other end extends through the wire feeding detection device 7 to the wire feeding nozzle seat 9, allowing the welding wire II2 to pass through.

[0035] The wire feeding detection device 7 is integrally mounted on the inner hole laser head 6 and located on the wire feeding path between the dual wire feeder 5 and the wire feed nozzle seat 9. It is used to detect the actual wire feeding speed of welding wire I1 and welding wire II2. In particular, the wire feeding detection device 7 is spatially positioned close to the wire feed nozzle seat 9, that is, its detection point is as close as possible to the entrance of the dual wire feed nozzle 10. This shortens the length of the wire feeding tube between the wire feeding detection device 7 and the dual wire feed nozzle 10, reduces the speed change of the welding wire caused by resistance fluctuations in this section of the wire feeding tube, and thus ensures that the welding wire speed measured by the wire feeding detection device 7 can truly reflect the actual wire feeding speed before the welding wire enters the molten pool.

[0036] like Figure 3 As shown, the wire feeding detection device 7 includes a wire inlet fixing seat 7100, a wire outlet fixing seat 7300, a wire feeding detection module I 7200, and a wire feeding detection module II 7400. The wire inlet fixing seat 7100 and the wire outlet fixing seat 7300 are respectively disposed at both ends of the wire feeding detection module I 7200 and the wire feeding detection module II 7400 along the wire feeding direction, and are used to connect the external wire feeding tube with the welding wire channel inside the detection module, and to guide and fix the welding wire when it enters and leaves the detection module.

[0037] Wire feeding detection module I 7200 and wire feeding detection module II 7400 have the same structure and are installed symmetrically with respect to the central plane of wire feeding detection device 7. Wire feeding detection module I 7200 is used to detect the actual wire feeding speed of welding wire I1, and wire feeding detection module II 7400 is used to detect the actual wire feeding speed of welding wire II2.

[0038] The following is combined with Figure 4 and Figure 5 The internal structure of the wire feeding detection module I 7200 will be described as an example. The wire feeding detection module I 7200 includes a base 7201, an encoder 7212, an encoder wheel 7202, a V-shaped wheel bearing I 7203, a V-shaped wheel bearing II 7210, a bearing slide I 7213, a bearing slide II 7215, a compression spring I 7214, a compression spring II 7216, and an adjusting pressure plate 7205.

[0039] The base 7201 serves as the supporting foundation for the wire feeding detection device 7, and is used to install the aforementioned components. The encoder 7212 is fixedly mounted on one side of the base 7201, and the encoder wheel 7202 is coaxially fixed on the rotating shaft of the encoder 7212. The encoder wheel 7202 can rotate synchronously with the rotating shaft of the encoder 7212. The outer circumferential surface of the encoder wheel 7202 is used to contact the welding wire, and is driven to rotate by the frictional force generated when the welding wire advances. Specifically, welding wire I1 and welding wire II2 are respectively fitted with their corresponding encoder wheels 7202 to drive the corresponding encoder wheels 7202 to rotate through friction.

[0040] Bearing slide I 7213 and bearing slide II 7215 are respectively installed in the base 7201 and can slide up and down along the guide structure of the base 7201 to accommodate the height adjustment requirements of welding wires of different diameters. A compression spring I 7214 is provided between bearing slide I 7213 and the base 7201, and a compression spring II 7216 is provided between bearing slide II 7215 and the base 7201. The two compression springs apply elastic thrust to their respective bearing slides, so that the V-shaped wheel bearings installed on the bearing slides always maintain a tendency to press towards the welding wire.

[0041] V-gear bearing I 7203 is mounted on bearing slide I 7213 via locking pad I 7204, and V-gear bearing II 7210 is mounted on bearing slide II 7215 via locking pad II 7211. The two V-gear bearings are distributed on both sides of encoder wheel 7202, forming a clamping structure for the welding wire together with encoder wheel 7202.

[0042] Adjusting plate 7205 is fixedly mounted on base 7201. Adjusting screw I 7207 and adjusting screw II 7209 are mounted on adjusting plate 7205. The lower end of adjusting screw I 7207 abuts against the lower part of bearing slide I 7213, and the lower end of adjusting screw II 7209 abuts against the lower part of bearing slide II 7215. When the operator rotates the adjusting screws, the corresponding bearing slide can be moved up or down, thereby adjusting the clamping clearance between the V-shaped wheel bearing and the encoder wheel 7202. Locking nuts I 7206 and II 7208 are respectively mounted on adjusting screw I 7207 and adjusting screw II 7209, used to lock the position of the adjusting screws after adjustment to prevent the adjustment position from loosening due to vibration during use.

[0043] V-type bearing I 7203 and V-type bearing II 7210 press against the surface of welding wire I1 or welding wire II2 respectively, so that the welding wire is always in contact with the encoder wheel 7202. Specifically, under the combined action of the spring thrust and the adjusting screw, V-type bearing I 7203 and V-type bearing II 7210 press the welding wire against the outer circumference of the encoder wheel 7202 from both sides, so that the welding wire is always in close contact with the encoder wheel 7202, ensuring sufficient and stable friction between the welding wire and the encoder wheel 7202, and avoiding speed detection distortion due to slippage.

[0044] The wire travel path is as follows: Welding wire I1 enters the wire feeding detection module I7200 from the wire inlet fixing seat 7100, passes between the V-type wheel bearing I7203 and the encoder wheel 7202 in sequence, and between the V-type wheel bearing II7210 and the encoder wheel 7202, and then exits from the wire outlet fixing seat 7300 and continues to move along the wire feeding tube I3 towards the wire feeding nozzle seat 9.

[0045] When the welding wire is driven forward by the dual wire feeder 5, the friction between the welding wire and the encoder wheel 7202 drives the encoder wheel 7202 to rotate, and the rotating shaft of the encoder 7212 rotates accordingly. The encoder 7212 outputs a pulse signal corresponding to the rotation speed to the control system, and the control system calculates the real-time wire feeding speed of the welding wire.

[0046] The structure and working principle of wire feeding detection module II 7400 are exactly the same as those of wire feeding detection module I 7200, the only difference being that the object it detects is welding wire II 2. Wire feeding detection module I 7200 and wire feeding detection module II 7400 work independently, transmitting the actual speed signals of welding wire I 1 and welding wire II 2 to the control system respectively.

[0047] The following example illustrates the usage of this device.

[0048] ①According to the diameter of the welding wire, adjust the V-type wheel bearings I7203 and II7210 to a suitable height by adjusting screws I7207 and II7209 respectively, and tighten the welding wire so that the welding wire is always in contact with the encoder wheel 7202. Tighten the adjusting screws I7207 and II7209 by locking nuts I7206 and II7208 respectively. ②According to the system control signal, the welding wire drive device I 5001 and welding wire drive device II 5002 on the double wire feeder 5 drive the welding wire I1 and welding wire II2 forward respectively; ③ Welding wire I1 and welding wire II2 drive the encoder wheel 7202 on the wire feeding detection module I 7200 and the wire feeding detection module II 7400 to rotate through friction, thereby driving the rotating shaft of encoder 7212 to rotate; ④ The encoders 7212 on the wire feeding detection module I 7200 and the wire feeding detection module II 7400 respectively transmit the collected speed signals to the control system; ⑤ The control system transmits the wire feeding speed correction signal to the dual wire feeder 5; ⑥ Welding wire I1 and welding wire II2 pass through the double wire feeder 5, wire feeding detection device 7, wire feeding nozzle seat 9, and double wire feeding nozzle 10 in sequence, and intersect with the laser beam 6001 emitted by the inner hole laser head 6, and melt to form a molten pool.

[0049] ⑦ Repeat steps ②-⑥ until the welding operation is complete.

[0050] The above text provides a detailed description of an embodiment of a dual-wire feeding device for laser welding of internal holes. Based on the dual-wire feeding device for laser welding of internal holes described in the above embodiment, this invention also provides a corresponding dual-wire feeding control method for laser welding of internal holes.

[0051] See Figure 6The control system is electrically connected to the encoder 7212 of the wire feeding detection module I 7200, the encoder 7212 of the wire feeding detection module II 7400, and the wire drive devices I 5001 and II 5002 of the dual wire feeder 5. The speed signal acquired in real time by the encoder 7212 is transmitted to the control system via a signal line. After internal calculation, the control system outputs a speed correction signal to the dual wire feeder 5, thus forming a closed-loop control circuit. As a preferred embodiment, the encoder 7212 communicates with the control system via an RS485 bus to ensure the stability of signal transmission and anti-interference capability.

[0052] See Figure 7 The overall flow of the control method provided in this embodiment of the invention is as follows: After system initialization, the analog signal of the wire feeding speed is output to drive the dual wire feeder to feed the wire. The encoder collects the actual rotation speed and calculates the actual wire feeding speed. The single wire deviation and synchronization deviation are judged successively. According to the deviation, PID adjustment or fault alarm shutdown is executed respectively. The above process continues to cycle until the processing completion signal is received, at which point wire feeding stops and the laser is turned off. Specifically, it includes the following steps.

[0053] S1, Set theoretical wire feeding speed Single filament deviation threshold Synchronization Deviation Threshold Excessive delay judgment time and out-of-tolerance delay alarm time .

[0054] S2, the double wire feeder 5 drives welding wire I1 and welding wire II2 according to... Send silk.

[0055] This step initiates the wire feeding process, and the control system will display the theoretical wire feeding speed. The analog speed signals are output to the wire drive devices I 5001 and II 5002 of the dual wire feeder 5, respectively. Wire drive devices I 5001 and II 5002 drive wires I1 and II 2 forward at the theoretical feeding speed, respectively. The two drives are independent of each other, each receiving a speed command signal from the control system.

[0056] S3. The actual speed of welding wire I1 is collected in real time by wire feeding detection module I 7200 and wire feeding detection module II 7400 respectively. and the actual speed of welding wire II2 .

[0057] During the wire feeding process, welding wire I1 and welding wire II2 are respectively attached to the encoder wheel 7202 of the wire feeding detection module I 7200 and the encoder wheel 7202 of the wire feeding detection module II 7400. The corresponding encoder wheel 7202 is driven to rotate by friction, and the encoder wheel 7202 drives the rotating shaft of the encoder 7212 to rotate synchronously.

[0058] The encoder 7212 outputs pulse signals as the rotating shaft rotates. The control system collects the number of pulses output by the encoder 7212 in each sampling cycle, calculates the rotational speed of the encoder wheel 7202 based on the number of pulses collected per unit time, and calculates the actual speed of the welding wire I1 based on the outer circumference of the encoder wheel 7202. and the actual speed of welding wire II2 .

[0059] S4. Calculate the theoretical wire feed speed Actual speed of welding wire I1 monofilament deviation value And calculate the theoretical wire feeding speed Actual speed of welding wire II2 monofilament deviation value .

[0060] This step involves calculating the single-filament deviation. If... A positive value indicates that the actual wire feeding speed of welding wire I1 is lower than the theoretical set value; if A negative value indicates that the actual wire feeding speed is higher than the theoretical set value. The meaning is the same.

[0061] S5. Control the single filament deviation based on the single filament deviation value.

[0062] 1) If and If the current wire feeding parameters remain unchanged, proceed to step S6.

[0063] If this condition is met, it indicates that the actual wire feeding speed of both welding wires is within the allowable deviation range. The control system keeps the current wire feeding parameters unchanged and jumps directly to step S6.

[0064] 2) If or Then the timer T will begin to accumulate.

[0065] This condition indicates that the actual speed of at least one welding wire deviates from the theoretical speed beyond the allowable range, and the control system starts accumulating time T, with the timing starting from zero.

[0066] 3) If If the current wire feeding parameters remain unchanged, proceed to step S6.

[0067] During the timing process, first determine whether... If so, it indicates that the detected deviation is a short-term instantaneous disturbance, such as oil stains or uneven roughness on the surface of the welding wire causing a sudden increase in friction between the wire and the inner wall of the wire feeding tube, or an occasional jump in the encoder signal. The system does not need to adjust immediately, but keeps the current wire feeding parameters unchanged and jumps to step S6 to avoid frequent adjustments to the control system due to small and short-term disturbances, thereby ensuring the stability of system operation.

[0068] 4) If According to and The speed compensation amounts of welding wire I1 and welding wire II2 are calculated using a PID algorithm and output to step S2 for adjustment.

[0069] When timer T reaches Then, further judgment is needed on whether If so, it indicates that the deviation is not an instantaneous disturbance, but a persistent speed deviation, triggering PID control. Specifically, the system adjusts according to... and The values ​​are used to calculate the speed compensation amount of welding wire I1. Speed ​​compensation amount of welding wire II2 .when and When speed compensation is applied only to welding wire II2, welding wire I1 retains its current parameters; when and When both welding wires are out of tolerance, speed compensation is performed only for welding wire I1; when both welding wires are out of tolerance, their respective compensation amounts are calculated independently. The speed compensation amount is output to step S2 in the form of an analog signal and superimposed on the original speed command to correct the wire feeding speed of the corresponding welding wire.

[0070] 5) If If the fault occurs, a fault alarm will be issued and the machine will stop, and the timer T will be cleared.

[0071] If time T exceeds If the deviation cannot be eliminated under PID control, it indicates that the wire feeding system may have experienced a serious, unrecoverable malfunction, such as the welding wire getting stuck in the wire feeding tube or severe slippage of the wire feeding wheel. The control system immediately issues an audible and visual alarm signal and cuts off the drive power to the dual wire feeder 5, safely stopping the equipment and resetting the timer T to zero.

[0072] S6. Calculate the actual speed of welding wire I1 and the actual speed of welding wire II2 Synchronization deviation between .

[0073] This step involves calculating the synchronization deviation. If... A positive value indicates that the speed of welding wire I1 is greater than that of welding wire II2; if A negative value indicates that the speed of welding wire I1 is less than that of welding wire II2.

[0074] S7. Perform synchronization deviation control based on synchronization deviation.

[0075] 1) If If the current wire feeding parameters remain unchanged, proceed to step S8.

[0076] First, determine if... If so, it indicates that the actual wire feeding speeds of the two welding wires maintain good synchronization. The control system keeps the current wire feeding parameters unchanged and jumps to step S8.

[0077] 2) If Start accumulating time .

[0078] like This indicates that there is a synchronization deviation between the two welding wires that exceeds the allowable range, and the control system begins to accumulate timing. . The timer is independent of T in step S5, and the two do not interfere with each other.

[0079] 3) If If the current wire feeding parameters remain unchanged, proceed to step S8.

[0080] like This indicates that the synchronization deviation is an instantaneous deviation. Keep the current wire feeding parameters unchanged and proceed to step S8.

[0081] 4) If According to The speed compensation amount of welding wire I1 or welding wire II2 is calculated using a PID algorithm and output to step S2 for adjustment.

[0082] Specifically, according to Calculate the synchronization speed deviation compensation amount .when That is, when the speed of welding wire I is greater than the speed of welding wire II, negative speed compensation is performed on welding wire I1; when When the speed of welding wire I is less than the speed of welding wire II, negative speed compensation is applied to welding wire II2. This means that only the faster welding wire is decelerated, simplifying the control logic and avoiding coupling oscillations that may be caused by simultaneous adjustment of two paths. The compensation amount is output to step S2 via an analog signal.

[0083] 5) If If the fault occurs, a fault alarm will be issued and the machine will stop, clearing the timer. .

[0084] like This indicates that the synchronization deviation cannot be eliminated. The control system issues an audible and visual alarm signal and stops the machine, while simultaneously setting the timer. Reset to zero.

[0085] S8. Repeat steps S2 to S7 until a processing completion signal is received.

[0086] Repeat steps S2 to S7 to continuously perform closed-loop control and deviation detection of wire feeding speed throughout the entire process of laser cladding of the inner hole until the control system receives the processing completion signal, stops wire feeding, turns off the laser, and ends the entire cladding process.

[0087] In the above control method, the specific calculation formula of the PID algorithm used in step S5 is as follows:

[0088]

[0089] in, This is the sampling time sequence number. The sampling period is , These are the speed compensation amounts for welding wire I1 and welding wire II2, respectively. These are the proportional coefficient, integral coefficient, and differential coefficient of the closed-loop speed control for welding wire I1, respectively. These are the proportional coefficient, integral coefficient, and differential coefficient of the welding wire II2 speed closed loop, respectively.

[0090] The specific calculation formula for the synchronous PID algorithm used in step S7 is as follows:

[0091] in, This is the sampling time sequence number. The sampling period is This is the speed compensation amount for welding wire I1 or welding wire II2. These are the proportional coefficient, integral coefficient, and derivative coefficient for the synchronous deviation control of welding wire I1 and welding wire II2, respectively.

[0092] The PID coefficients are predetermined and stored in the control system based on actual working conditions such as welding wire material, welding wire diameter, wire feed tube length and bending degree through engineering tuning methods.

[0093] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A dual-wire feeding device for laser welding of internal holes, characterized in that, include: The feed nozzle seat (9) is fixed on the inner hole laser head (6); Double feed nozzles (10) are installed on feed nozzle seat (9); A dual wire feeder (5) is used to drive the feeding of welding wire I (1) and welding wire II (2); as well as The wire feeding detection device (7) is installed on the inner hole laser head (6), and is located between the double wire feeder (5) and the wire feeding nozzle seat (9), and is located on the side close to the wire feeding nozzle seat (9); The wire feeding detection device (7) is used to detect the actual wire feeding speed of welding wire I (1) and welding wire II (2).

2. The dual-wire feeding device for laser welding of internal holes according to claim 1, characterized in that, The wire feeding detection device (7) includes: wire feeding detection module I (7200) and wire feeding detection module II (7400). The wire feeding detection module I (7200) is used to detect the actual wire feeding speed of welding wire I (1) in real time, and the wire feeding detection module II (7400) is used to detect the actual wire feeding speed of welding wire II (2) in real time. The wire feeding detection module I (7200) and the wire feeding detection module II (7400) have the same structure and are installed symmetrically; Both the wire feeding detection module I (7200) and the wire feeding detection module II (7400) include: a base (7201), an encoder (7212), and an encoder wheel (7202); the encoder (7212) is fixed on the base (7201), the encoder wheel (7202) is fixed on the rotating shaft of the encoder (7212), and the welding wire I (1) and welding wire II (2) are respectively attached to the corresponding encoder wheel (7202) to drive the corresponding encoder wheel (7202) to rotate by friction.

3. The dual-wire feeding device for laser welding of internal holes according to claim 2, characterized in that, Both the wire feeding detection module I (7200) and the wire feeding detection module II (7400) further include: V-shaped wheel bearing I (7203), V-shaped wheel bearing II (7210), bearing slide I (7213), bearing slide II (7215), compression spring I (7214), compression spring II (7216), and adjusting pressure plate (7205); Bearing slide I (7213) and bearing slide II (7215) are respectively installed in the base (7201) and can slide up and down. A compression spring I (7214) is provided between bearing slide I (7213) and the base (7201), and a compression spring II (7216) is provided between bearing slide II (7215) and the base (7201). An adjusting plate (7205) is installed on a base (7201). An adjusting screw I (7207) and an adjusting screw II (7209) are installed on the adjusting plate (7205). The adjusting screw I (7207) abuts against the underside of the bearing slide I (7213), and the adjusting screw II (7209) abuts against the underside of the bearing slide II (7215). V-type wheel bearing I (7203) is mounted on bearing slide I (7213) via locking pad I (7204), and V-type wheel bearing II (7210) is mounted on bearing slide II (7215) via locking pad II (7211); V-type wheel bearing I (7203) and V-type wheel bearing II (7210) press against the surface of welding wire I (1) or welding wire II (2) respectively, so that the welding wire always adheres to the encoder wheel (7202).

4. The dual-wire feeding device for laser welding of internal holes according to claim 3, characterized in that, The adjusting screw I (7207) is provided with a locking nut I (7206), and the adjusting screw II (7209) is provided with a locking nut II (7208), which are used to lock the positions of the adjusting screw I (7207) and adjusting screw II (7209) after adjustment.

5. The dual-wire feeding device for laser welding of internal holes according to any one of claims 2 to 4, characterized in that, The wire feeding detection device (7) also includes: a wire infeed fixing seat (7100) and a wire outlet fixing seat (7300), which are respectively installed at both ends of the wire feeding detection module I (7200) and the wire feeding detection module II (7400) along the wire feeding direction.

6. A method for controlling dual wire feeding in laser welding of internal holes, applied to the dual wire feeding device for laser welding of internal holes as described in any one of claims 1 to 4, characterized in that, Includes the following steps: S1, Set theoretical wire feeding speed Single filament deviation threshold Synchronization Deviation Threshold Excessive delay judgment time and out-of-tolerance delay alarm time ; S2, the double wire feeder (5) drives welding wire I (1) and welding wire II (2) according to Silk feeding; S3. The actual speed of welding wire I (1) is collected in real time by wire feeding detection module I (7200) and wire feeding detection module II (7400). and the actual speed of welding wire II (2) ; S4. Calculate the theoretical wire feed speed Actual speed of welding wire I (1) monofilament deviation value And calculate the theoretical wire feeding speed Actual speed of welding wire II (2) monofilament deviation value ; S5. Control the single filament deviation based on the single filament deviation value: like and If the current wire feeding parameters remain unchanged, proceed to step S6. like or Then the timer T will begin to accumulate; like If the current wire feeding parameters remain unchanged, proceed to step S6. like According to and The speed compensation amount of welding wire I (1) and welding wire II (2) is calculated by using the PID algorithm and output to step S2 for adjustment; like If the fault alarm is triggered, the machine will stop and the timer T will be cleared. S6. Calculate the actual speed of welding wire I (1) and the actual speed of welding wire II (2) Synchronization deviation between ; S7. Perform synchronization deviation control based on synchronization deviation: like If the current wire feeding parameters remain unchanged, proceed to step S8. like Start accumulating time ; like If the current wire feeding parameters remain unchanged, proceed to step S8. like According to The speed compensation amount of welding wire I (1) or welding wire II (2) is calculated using a PID algorithm and output to step S2 for adjustment; like If the fault occurs, a fault alarm will be issued and the machine will stop, clearing the timer. ; S8. Repeat steps S2 to S7 until a processing completion signal is received.

7. The dual-wire feeding control method for laser welding of internal holes according to claim 6, characterized in that, In step S7, if If the value is positive, then the speed compensation amount of welding wire I (1) is corrected; if If the value is negative, then the speed compensation amount of welding wire II (2) is corrected.

8. The dual-wire feeding control method for laser welding of internal holes according to claim 6, characterized in that, according to and The speed compensation amount of welding wire I (1) and welding wire II (2) is calculated using the PID algorithm, specifically by calculating the speed compensation amount using the following formula: in, This is the sampling time sequence number. The sampling period is , The speed compensation amounts for welding wire I (1) and welding wire II (2) are respectively. These are the proportional coefficient, integral coefficient, and differential coefficient of the closed-loop speed of welding wire I (1), respectively. These are the proportional coefficient, integral coefficient, and differential coefficient of the speed closed loop of welding wire II (2), respectively.

9. The dual-wire feeding control method for laser welding of internal holes according to claim 6, characterized in that, according to The speed compensation amount of welding wire I (1) or welding wire II (2) is calculated using a PID algorithm, specifically by calculating the speed compensation amount using the following formula: in, This is the sampling time sequence number. The sampling period is For the speed compensation amount of welding wire I (1) or welding wire II (2), These are the proportional coefficient, integral coefficient, and differential coefficient for the synchronous deviation control of welding wire I (1) and welding wire II (2), respectively.

10. The dual-wire feeding control method for laser welding of internal holes according to claim 6, characterized in that, Step S3 specifically includes: During the wire feeding process, welding wire I (1) and welding wire II (2) are respectively attached to the encoder wheel (7202) of the wire feeding detection module I (7200) and the encoder wheel (7202) of the wire feeding detection module II (7400), and the corresponding encoder wheel (7202) is driven to rotate by friction. The encoder wheel (7202) drives the rotating shaft of the encoder (7212) to rotate synchronously. The encoder (7212) outputs pulse signals as the rotating shaft rotates. The control system calculates the rotational speed of the encoder wheel (7202) based on the number of pulses collected per unit time, and calculates the actual speed of welding wire I (1) based on the outer circumference of the encoder wheel (7202). and the actual speed of welding wire II (2) .

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