A control method and device for MAG welding of large-gap ultra-thin carbon steel plates and a storage medium
Patent Information
- Application Number
- CN202611139347.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-29
- Publication Date
- 2026-09-25
AI Technical Summary
但是，在自动焊领域，多道焊引发的焊接节拍较慢、示教位置偏移难以确定和程序调用逻辑复杂等原因一直以来未能妥善解决
[0022]有益效果：本发明提供一种用于MAG焊接大间隙超薄碳钢板的控制方法、装置及存储介质，首先根据预设焊接电流下调比例控制焊接过程中燃弧阶段的电流下降幅度，也会相应降低实际电压，从而实现在同设定电流下，大幅降低热输入的效果，实现焊接控制，另外，根据摆动频率和摆动半径控制驱动焊枪螺旋摆动前进，实现轨迹控制，螺旋摆动过程中，前半圆可起到打底的作用，后半圆则在打底的基础上进行堆高。设置左右半径即为调整焊缝的焊宽，保证充分填充间隙并连接两侧母材。设置摆动频率则可以控制焊枪运动的线速度以保证熔池稳定和热输入精准控制，最后，推拉送丝在焊接过程中起到促进熔滴顺利过渡和减少飞溅的作用。综上，本发明通过结合焊接控制和轨迹控制，能够在单道焊的前提下，满足低热输入、高熔敷率和大熔敷宽度的焊接需求，在应对存在0~4mm间隙的1~2mm的超薄碳钢板焊接难题时，能够保证焊缝成型一致美观。
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Figure CN122807235A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a control method, device, and storage medium for MAG welding of large-gap ultrathin carbon steel plates, belonging to the field of thin-plate MAG welding control technology. Background Technology
[0002] In MAG (Metal Electrode Gas) welding of thin plates, gaps often appear at the weld joint due to poor material cutting accuracy, poor tooling accuracy, poor assembly accuracy, and welding thermal deformation. This poses a significant challenge to the heat resistance of the base material. The adaptability of MAG weld gaps is generally considered to be less than 1 times the plate thickness or 1.2 times the welding wire diameter.
[0003] For ultra-thin plates with a thickness of less than 2mm, low-current, multi-pass welding is often used to address the challenge of welding large gaps, ensuring low heat input and sufficient deposition. However, in the field of automated welding, issues such as slow welding cycle time, difficulty in determining teaching position offset, and complex program calling logic caused by multi-pass welding have remained unresolved. Summary of the Invention
[0004] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a control method, device and storage medium for MAG welding of large gap ultrathin carbon steel plates, which can accurately control heat input and deposition amount under the premise of single-pass welding and stably realize large gap MAG welding.
[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:
[0006] In a first aspect, the present invention discloses a control method for large-gap ultrathin carbon steel plates used in MAG welding, comprising the following steps:
[0007] Obtain the gap between the carbon steel plates to be welded and the preset welding current reduction ratio;
[0008] Welding control parameters and trajectory control parameters are determined based on the size of the gap. The welding control parameters include the set current and welding speed, while the trajectory control parameters include the oscillation frequency and oscillation radius.
[0009] Based on the push-pull wire feeding welding method, the welding torch is controlled according to the set current and welding speed, and the current drop during the arc stage of welding is controlled according to the preset welding current reduction ratio to achieve welding control. The welding torch is driven to swing forward in a spiral motion according to the oscillation frequency and oscillation radius to achieve trajectory control.
[0010] The thickness of the carbon steel plates to be welded is 1~2mm, and the gap is no more than 4mm.
[0011] When the gap is greater than 0 mm and less than or equal to 1 mm, the current is set to 90~120A, the welding speed to 0.2~0.35 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 1.5~2.5 mm; when the gap is greater than 1 mm and less than or equal to 2 mm, the current is set to 105~130A, the welding speed to 0.15~0.3 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 1.5~3 mm; when the gap is greater than 2 mm and less than or equal to 3 mm, the current is set to 115~140A, the welding speed to 0.1~0.25 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 2.5~3.5 mm; when the gap is greater than 3 mm and less than or equal to 4 mm, the current is set to 120~145A, the welding speed to 0.08~0.2 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 2.5~4 mm.
[0012] The preset arc current reduction ratio is 60% to 80%.
[0013] The preset arc current reduction ratio is 70%.
[0014] The welding wire used in the welding torch has a diameter of 0.8~1.0mm.
[0015] The welding wire material includes Er50-6.
[0016] The frequency of push-pull wire feeding is 100~150Hz.
[0017] In a second aspect, the present invention discloses a control device for MAG welding of large-gap ultra-thin carbon steel plates, comprising:
[0018] The welding data acquisition module is used to acquire the gap between the carbon steel plates to be welded and the preset welding current reduction ratio;
[0019] The control parameter confirmation module is used to determine the welding control parameters and trajectory control parameters according to the size of the gap. The welding control parameters include the set current and welding speed, and the trajectory control parameters include the oscillation frequency and oscillation radius.
[0020] The welding torch control module is used for welding based on push-pull wire feeding. It controls the operation of the welding torch according to the set current and welding speed, and controls the current reduction during the arcing stage of the welding process according to the preset welding current reduction ratio to achieve welding control. It also controls the spiral oscillation of the welding torch according to the oscillation frequency and oscillation radius to achieve trajectory control.
[0021] Thirdly, the present invention discloses a computer-readable storage medium storing a computer program / instruction thereon, which, when executed by a processor, implements the steps of the control method for MAG welding of large-gap ultrathin carbon steel plates.
[0022] Beneficial Effects: This invention provides a control method, device, and storage medium for MAG welding of large-gap ultrathin carbon steel plates. Firstly, it controls the current reduction during the arc-ignition phase of welding based on a preset welding current reduction ratio, which also correspondingly reduces the actual voltage. This achieves a significant reduction in heat input under the same set current, thus realizing welding control. Secondly, it controls the spiral oscillation of the welding torch based on the oscillation frequency and radius, achieving trajectory control. During the spiral oscillation, the first semicircle serves as a base coat, while the second semicircle builds up the weld height based on the base coat. Setting the left and right radii adjusts the weld width, ensuring sufficient gap filling and connection of the base materials on both sides. Setting the oscillation frequency controls the linear speed of the welding torch movement to ensure a stable molten pool and precise heat input control. Finally, the push-pull wire feeding promotes smooth droplet transfer and reduces spatter during welding. In summary, this invention, by combining welding control and trajectory control, can meet the welding requirements of low heat input, high deposition rate, and large deposition width under single-pass welding conditions. When dealing with the challenge of welding 1-2mm ultrathin carbon steel plates with gaps of 0-4mm, it ensures consistent and aesthetically pleasing weld formation. Attached Figure Description
[0023] Figure 1 This is a diagram showing the spiral oscillation trajectory of the welding torch when using trajectory control in this invention.
[0024] Figure 2 This is a schematic diagram comparing the conventional waveform with the welding waveform when using welding control according to the present invention;
[0025] Figure 3 This is an example of a lap weld with a plate thickness of 1~2mm and a gap of 2~3mm. The welding and trajectory control were used to complete the welding effect photos after welding. Among them, a is the macro view after welding, b is the micro view after welding, c is the gap measurement view before welding, and d is the back forming view after welding. Detailed Implementation
[0026] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to illustrate the technical solution of the present invention more clearly, and should not be used to limit the scope of protection of the present invention.
[0027] Example 1
[0028] This invention discloses a control method for large-gap ultrathin carbon steel plates used in MAG welding, comprising the following steps:
[0029] Step 1: Obtain the gap between the carbon steel plates to be welded and the preset welding current reduction ratio. The thickness of the carbon steel plates to be welded is 1-2 mm, and the gap is no more than 4 mm. The preset arc current reduction ratio is set to 60% to 80%, and in this embodiment, it is preferably 70%.
[0030] Step 2: Determine the welding control parameters and trajectory control parameters based on the gap size. The welding control parameters include the set current and welding speed, while the trajectory control parameters include the oscillation frequency and oscillation radius. When the gap is greater than 0 mm and less than or equal to 1 mm, the current is set to 90~120 A, the welding speed to 0.2~0.35 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 1.5~2.5 mm; when the gap is greater than 1 mm and less than or equal to 2 mm, the current is set to 105~130 A, the welding speed to 0.15~0.3 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 1.5~3 mm; when the gap is greater than 2 mm and less than or equal to 3 mm, the current is set to 115~140 A, the welding speed to 0.1~0.25 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 2.5~3.5 mm; when the gap is greater than 3 mm and less than or equal to 4 mm, the current is set to 120~145 A, the welding speed to 0.08~0.2 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 2.5~4 mm. In this embodiment, the welding parameters are shown in Table 2. The welding wire used in the welding torch has a diameter of 0.8~1.0mm, and in this embodiment, it is preferably 1.0mm, and the material is Er50-6.
[0031] Step three involves a high-frequency (100-150Hz) push-pull wire feeding welding method. The welding torch operation is controlled according to the set current and welding speed, and the current reduction during the arc-ignition phase is controlled according to a preset welding current reduction ratio to achieve welding control. Welding control primarily utilizes high-frequency wire pulling and a special welding waveform, which can be compared with conventional welding waveforms. Figure 2 The dashed lines in the figure represent the actual current and voltage before the descent. As can be seen from the figure, the special welding waveform designed in this invention mainly reduces the actual current and voltage during the arc-ignition stage, thereby significantly reducing heat input. Table 1 shows a comparison of heat input examples under the same deposition rate. As can be seen from the table, after using welding control in this invention, the actual current decreased from 200A to 120A, the actual voltage decreased from 16V to 11V, and the heat input decreased from 6.4kJ / cm to 2.64kJ / cm. Furthermore, the high-frequency wire drawing in this invention promotes smooth droplet transfer and reduces spatter during the welding process.
[0032] Simultaneously, the welding torch is driven to swing forward in a spiral motion based on the oscillation frequency and oscillation radius to achieve trajectory control. The trajectory of the spiral oscillation is as follows: Figure 1 As shown, the welding torch is driven to swing forward in a spiral motion. The swing frequency and lateral radius are adjusted for different gap sizes, increasing the weld width to cover the gap while ensuring stability of the molten pool and welding process. This invention allows adjustment of the spiral swing trajectory by setting the lateral radius and swing frequency of the arc. During the spiral swing, the first semicircle acts as a base layer, while the second semicircle builds up the weld on top of this base layer. Setting the lateral radius adjusts the weld width, ensuring sufficient filling of the gap and connection of the base materials on both sides. Setting the swing frequency controls the linear speed of the welding torch movement to ensure molten pool stability and precise heat input control.
[0033] Table 1. Comparison of heat input with and without welding control under the same deposition amount
[0034]
[0035] Table 2 Relevant Welding Parameter Settings
[0036]
[0037] This invention combines the above welding control and trajectory control methods, resulting in a weld formation effect as follows: Figure 3 As shown in the figure, the weld formation of the present invention is aesthetically pleasing and it stably achieves large-gap MAG welding.
[0038] Example 2
[0039] This embodiment discloses a control device for MAG welding of large-gap ultra-thin carbon steel plates, used to implement the control method for MAG welding of large-gap ultra-thin carbon steel plates in Embodiment 1. The control device includes:
[0040] The welding data acquisition module is used to acquire the gap between the carbon steel plates to be welded and the preset welding current reduction ratio;
[0041] The control parameter confirmation module is used to determine the welding control parameters and trajectory control parameters according to the size of the gap. The welding control parameters include the set current and welding speed, and the trajectory control parameters include the oscillation frequency and oscillation radius.
[0042] The welding torch control module is used for welding based on push-pull wire feeding. It controls the operation of the welding torch according to the set current and welding speed, and controls the current reduction during the arcing stage of the welding process according to the preset welding current reduction ratio to achieve welding control. It also controls the spiral oscillation of the welding torch according to the oscillation frequency and oscillation radius to achieve trajectory control.
[0043] Example 3
[0044] This embodiment discloses a computer-readable storage medium storing a computer program / instruction thereon. When the computer program / instruction is executed by a processor, it implements the steps of the control method for MAG welding of large-gap ultra-thin carbon steel plates in Embodiment 1.
[0045] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.
[0046] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.
[0047] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.
[0048] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.
[0049] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A control method for large-gap ultrathin carbon steel plates used in MAG welding, characterized in that: Includes the following steps: Obtain the gap between the carbon steel plates to be welded and the preset welding current reduction ratio; Welding control parameters and trajectory control parameters are determined based on the size of the gap. The welding control parameters include the set current and welding speed, while the trajectory control parameters include the oscillation frequency and oscillation radius. Based on the push-pull wire feeding welding method, the welding torch is controlled according to the set current and welding speed, and the current drop during the arc stage of welding is controlled according to the preset welding current reduction ratio to achieve welding control. The welding torch is driven to swing forward in a spiral motion according to the oscillation frequency and oscillation radius to achieve trajectory control.
2. The control method for large-gap ultrathin carbon steel plates for MAG welding according to claim 1, characterized in that: The thickness of the carbon steel plates to be welded is 1~2mm, and the gap is no more than 4mm.
3. The control method for large-gap ultrathin carbon steel plates for MAG welding according to claim 2, characterized in that: When the gap is greater than 0 mm and less than or equal to 1 mm, the current is set to 90~120A, the welding speed to 0.2~0.35 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 1.5~2.5 mm; when the gap is greater than 1 mm and less than or equal to 2 mm, the current is set to 105~130A, the welding speed to 0.15~0.3 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 1.5~3 mm; when the gap is greater than 2 mm and less than or equal to 3 mm, the current is set to 115~140A, the welding speed to 0.1~0.25 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 2.5~3.5 mm; when the gap is greater than 3 mm and less than or equal to 4 mm, the current is set to 120~145A, the welding speed to 0.08~0.2 m / min, the oscillation frequency to 1~3 Hz, and the oscillation radius to 2.5~4 mm.
4. The control method for large-gap ultra-thin carbon steel plates for MAG welding according to claim 1, characterized in that: The preset arc current reduction ratio is 60% to 80%.
5. The control method for large-gap ultrathin carbon steel plates for MAG welding according to claim 4, characterized in that: The preset arc current reduction ratio is 70%.
6. The control method for large-gap ultrathin carbon steel plates for MAG welding according to claim 1, characterized in that: The welding wire used in the welding torch has a diameter of 0.8~1.0mm.
7. The control method for large-gap ultrathin carbon steel plates for MAG welding according to claim 6, characterized in that: The welding wire material includes Er50-6.
8. The control method for large-gap ultrathin carbon steel plates for MAG welding according to claim 1, characterized in that: The frequency of push-pull wire feeding is 100~150Hz.
9. A control device for MAG welding of large-gap ultra-thin carbon steel plates, characterized in that: include; The welding data acquisition module is used to acquire the gap between the carbon steel plates to be welded and the preset welding current reduction ratio; The control parameter confirmation module is used to determine the welding control parameters and trajectory control parameters according to the size of the gap. The welding control parameters include the set current and welding speed, and the trajectory control parameters include the oscillation frequency and oscillation radius. The welding torch control module is used for welding based on push-pull wire feeding. It controls the operation of the welding torch according to the set current and welding speed, and controls the current reduction during the arcing stage of the welding process according to the preset welding current reduction ratio to achieve welding control. It also controls the spiral oscillation of the welding torch according to the oscillation frequency and oscillation radius to achieve trajectory control.
10. A computer-readable storage medium having a computer program / instructions stored thereon, characterized in that: When the computer program / instructions are executed by the processor, they implement the steps of the control method for MAG welding of large-gap ultrathin carbon steel plates as described in any one of claims 1-8.