A welding control method and controller

Abstract

The application relates to the technical field of automatic welding, in particular to a welding control method and a controller, which solve the technical problem that the welding quality is reduced due to the change of the arc voltage caused by the change of the electrode feeding speed, the welding defects and the like in the prior art. The welding control method provided by the application first acquires the real-time arc voltage in the current calculation period in the welding process, and when the real-time arc voltage is within a preset range, the initial feeding speed is calculated according to the real-time arc voltage and a reference arc voltage, and the initial feeding speed corresponding to the current calculation period is corrected by using the target feeding speed corresponding to the last calculation period, so that the rising edge and the falling edge of the speed change curve of the driving motor are smoothly transitioned, the pure lagging influence caused by the mechanical system and the signal acquisition delay is reduced, the feeding speed of the electrode is real-timely regulated in the whole welding process, and the electrode process under different electrodes and different processes can be stably carried out.

Description

Technical Field

[0001] This application relates to the field of automated welding technology, and more specifically, to a welding control method and a controller. Background Technology

[0002] Arc welding utilizes the ionization of air to generate an electric arc. The heat generated by the arc melts the welding electrode and the workpiece together, and the weld joint is formed after solidification. Compared with other welding methods, arc welding has advantages such as adaptability to complex operation scenarios in the field and on-site, moderate cost of welding electrodes and welding machines, and no need for complex auxiliary equipment. However, traditional manual shielded metal arc welding methods can hardly meet the requirements of modern production for welding quality stability, production efficiency, and operational safety, especially in field emergency repair tasks.

[0003] Current automated welding electrode systems use a motor-driven electrode guide rail to feed the electrode at a certain speed. However, the feeding speed fluctuates during the feeding process, causing changes in the electrode extension length, which in turn leads to variations in arc voltage. Unstable arc voltage can result in defects such as localized burn-through, weld beads, and undercut, thereby reducing welding quality. Summary of the Invention

[0004] The purpose of this application is to provide a welding control method and controller, which solves the technical problem in the prior art where changes in electrode feed speed lead to changes in arc voltage, resulting in welding defects and reduced welding quality.

[0005] As a first aspect of this application, this application provides a welding control method, comprising: Obtain the real-time arc voltage corresponding to the current calculation cycle during the welding process; When the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage, the speed adjustment amount is calculated based on the real-time arc voltage and the target arc voltage. Calculate the initial feed speed based on the speed adjustment amount and the reference feed speed; Based on the target feed rate corresponding to the previous calculation cycle, the initial feed rate is corrected to obtain the target feed rate corresponding to the current calculation cycle; The drive motor is controlled according to the target feed speed to control the electrode guide rail to feed the electrode at the target feed speed.

[0006] In one embodiment of this application, the theoretical feed rate is calculated based on a first-order discrete smoothing filter equation, according to the target feed rate corresponding to the previous calculation cycle, the speed adjustment amount, and the reference feed rate; wherein, the first-order discrete smoothing filter equation is: ;in, , This represents the theoretical feed rate corresponding to the current calculation cycle. It is a first-order smoothing factor. The target feed rate corresponding to the previous calculation cycle. This represents the initial feed rate corresponding to the current calculation cycle. For reference feed speed, For speed adjustment; When the theoretical feeding speed is greater than the preset lower limit of feeding speed and less than the preset upper limit of feeding speed, the theoretical feeding speed is determined as the target feeding speed. In one embodiment of this application, the step of correcting the initial feed rate based on the target feed rate corresponding to the previous calculation cycle further includes: When the theoretical feed rate is less than or equal to the preset feed rate lower limit, the preset feed rate lower limit is determined to be the target feed rate; or When the theoretical feed rate is greater than or equal to the preset feed rate upper limit, the preset feed rate upper limit is determined to be the target feed rate.

[0007] In one embodiment of this application, the first-order smoothing factor is 0.4.

[0008] In one embodiment of this application, the step of calculating the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than a first preset arc voltage and less than a second preset arc voltage includes: When the real-time arc voltage is greater than the third preset arc voltage and less than the fourth preset arc voltage, the voltage change is calculated based on the real-time arc voltage and the target arc voltage, wherein the third preset arc voltage is greater than the first preset arc voltage and the fourth preset arc voltage is less than the second preset arc voltage. When the absolute value of the voltage change is greater than the first change threshold and less than the second change threshold, the speed adjustment is calculated based on the proportional-integral control algorithm according to the arc column voltage gradient coefficient of the welding arc and the voltage change.

[0009] In one embodiment of this application, the step of calculating the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than a first preset arc voltage and less than a second preset arc voltage further includes: When the absolute value of the voltage change is less than the first change threshold, the speed adjustment amount is determined to be a preset change value.

[0010] In one embodiment of this application, the step of calculating the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than a first preset arc voltage and less than a second preset arc voltage further includes: When the real-time arc voltage is greater than the first preset arc voltage and less than or equal to the third preset arc voltage; or when the real-time arc voltage is greater than or equal to the fourth preset arc voltage and less than the second preset arc voltage, the voltage change is calculated based on the real-time arc voltage and the target arc voltage. The speed adjustment is calculated based on the arc column voltage gradient coefficient of the welding electrode arc and the voltage change, wherein the speed adjustment is equal to twice the product of the arc column voltage gradient coefficient of the welding electrode arc and the voltage change.

[0011] In one embodiment of this application, the welding control method further includes: When the real-time arc voltage is less than or equal to the first preset arc voltage, the target feed speed of the welding electrode is determined to be 0; or When the real-time arc voltage is greater than or equal to the second preset arc voltage, the target feed speed of the welding electrode is determined to be 0.

[0012] In one embodiment of this application, the welding control method further includes: The reference feed speed for feeding the welding electrode is calculated based on the electrode's melting coefficient and the preset welding current. As a second aspect of this application, this application also provides a welding controller, comprising: The data acquisition module is used to acquire the real-time arc voltage corresponding to the current calculation cycle during the welding process; The first calculation module is used to calculate the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage. The second calculation module is used to calculate the initial feed speed based on the speed adjustment amount and the reference feed speed; The correction module is used to correct the initial feed rate according to the target feed rate corresponding to the previous calculation cycle, so as to obtain the target feed rate corresponding to the current calculation cycle. The control module is used to control the drive motor according to the target feed speed, so as to control the electrode guide rail to feed the electrode at the target feed speed.

[0013] The welding control method provided in this application first obtains the real-time arc voltage of the current calculation cycle during the welding process. When the real-time arc voltage is within a preset range (i.e., greater than the first preset arc voltage and less than the second preset arc voltage), the speed adjustment amount is calculated based on the actual arc voltage and the reference arc voltage. The initial feed speed is calculated based on the speed adjustment amount and the reference feed speed. The initial feed speed corresponding to the current calculation cycle is corrected using the target feed speed corresponding to the previous calculation cycle. This allows for a smooth transition between the rising and falling edges of the speed change curve of the drive motor, reducing the pure hysteresis effect caused by the delay in the mechanical system and signal acquisition. At the same time, it enhances the anti-vibration capability of the closed-loop system. The electrode feed speed is adjusted in real time throughout the welding process, enabling stable electrode processes under different electrodes and different processes. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0015] Figure 1 The diagram shown is a schematic flowchart of a welding control method provided in an embodiment of this application.

[0016] Figure 2 The diagram shown is a flowchart of a welding control method provided in another embodiment of this application.

[0017] Figure 3 The diagram shown is a flowchart of a welding control method provided in another embodiment of this application.

[0018] Figure 4 The diagram shown is a working block diagram of a welding controller provided in an embodiment of this application.

[0019] Figure 5 The diagram shown is a block diagram of an electronic device provided in an embodiment of this application. Detailed Implementation

[0020] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] In the description of this application, it should be noted that the terms "upper", "lower", "front", "horizontal", 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.

[0022] In the description of this application, it should be noted that, unless otherwise explicitly specified and limited, the term "installation" should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral connection; it can refer to a mechanical connection or an electrical connection; it can refer to a direct connection or an indirect connection through an intermediate medium; and it can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0023] The present application will now be described in further detail with reference to specific embodiments and accompanying drawings.

[0024] Exemplary methods As a first aspect of this application, this application provides a welding control method applicable to an arc welding system, wherein the arc welding system includes a welding machine, a drive motor, a welding electrode guide rail, and a welding robot. The drive motor is poweredly connected to the welding electrode guide rail, the welding electrode guide rail clamps the welding electrode, the drive motor drives the welding electrode guide rail to move and feed the welding electrode at a certain welding electrode feeding speed, and the welding robot clamps the welding electrode to perform welding operations.

[0025] Figure 1 The diagram shown is a schematic flowchart of a welding control method provided in an embodiment of this application. Figure 1 As shown, an embodiment of this application provides a welding control method, including the following steps S100-S800: S100: Obtain the real-time arc voltage U corresponding to the current calculation cycle during the welding process. a ; It should be noted that the welding parameters for the target workpiece are preset during welding. S100 refers to the real-time arc voltage corresponding to the calculation cycle obtained during the actual welding process of the target workpiece. A welding preparation stage is also included before the actual welding of the target workpiece.

[0026] Specifically, welding parameters include: arc initiation current, anti-sticking time, welding current, welding voltage, welding speed, oscillation mode, oscillation width, oscillation frequency, left and right oscillation dwell time, single-pass overlap length, and multi-pass offset distance. Welding parameters can be determined based on the welding electrode. For example, a welding database stores electrode types and their corresponding welding parameters. Therefore, once the electrode type is determined, the corresponding welding parameters can be queried from the welding database. For example, if the electrode is J507 (E5015) type, Φ4.0 mm, the corresponding welding parameters are: arc initiation current 185 A, anti-sticking time 0.5 s, welding current 140 A, welding voltage 27.5 V. To achieve a welding effect comparable to manual welding, the welding speed is set to 4.1 mm / s, the oscillation mode is Z-shaped oscillation, the left and right oscillation width is 6 mm, the oscillation frequency is 2.5 Hz, the left and right oscillation dwell time is 100 ms, the single-pass overlap length is 4 mm, and the multi-pass offset distance is 8 mm.

[0027] Welding preparation stage: (1) Place the dried welding rod (e.g., 4.0 mm CHE507RH) in the welding rod box; simply grind and clean the surface of the base metal of the target workpiece to ensure welding quality; connect the welding power supply to the welding rod guide rail, base metal, etc., and reset the communication signal module of the welding robot, welding machine and welding rod box; locate and adjust the welding rod clamping point and welding rod discarding point during the welding robot's movement process, clamp a welding rod to teach the welding path and welding posture adjustment. Among them, the specific teaching method of welding posture adjustment is: clamp a welding rod, according to the preset welding trajectory, use the two straight lines (straight line start point and straight line end point) trajectory position of the welding rod tip contacting the workpiece surface, raise the radial height of each point by 3 mm, and adjust the four-axis joint and six-axis joint of the robot so that the welding rod posture is tilted 5°-10° with the welding forward tangent direction at the start point and end point positions. (2) The drive motor rotates, driving the electrode guide rail to move to the lower limit position to remove the electrode from the electrode box. Then, the drive motor drives the electrode guide rail to move to the upper limit position so that the electrode is at the welding start position of the target workpiece, preparing for welding. At the same time, the welding robot moves and adjusts its posture to the target position.

[0028] Welding Stage: Upon startup and receiving the arc ignition command signal, the welding machine's high-frequency oscillation system applies a continuous high-frequency voltage electric field between the electrode tip and the base metal. Subsequently, the drive motor drives the electrode guide rail at a speed of 0.8 mm / s, allowing the electrode to slowly approach the base metal at a speed of 0.8 mm / s. The gap between the electrode and the base metal decreases from 3 mm to 0~0.5 mm. At this gap, the high-frequency high voltage breaks down the air between the electrode and the base metal, generating an arc, connecting the welding circuit to form the welding current. Simultaneously, the high-frequency arc ignition relay is disconnected, separating the high-frequency oscillation system from the main welding circuit. The arc melts the arc-ignition section at the electrode tip and forms a molten pool on the base metal.

[0029] After the arc is ignited, the detector monitors the real-time arc voltage and adjusts the electrode feed speed in real time according to the real-time arc voltage to maintain the stability of the welding process.

[0030] Specifically, arc voltage refers to the voltage drop applied across the two ends of an electric arc when the arc is burning.

[0031] Specifically, the calculation period refers to the sampling period of the arc voltage detector during the welding process. The current calculation period refers to the current sampling time. Optionally, the calculation period, i.e., the sampling period T, can be 0.2s.

[0032] S200: Determine the real-time arc voltage U a Is it greater than the first preset arc voltage? Specifically, the first preset arc voltage can be 10V.

[0033] When the judgment result of S200 is negative, that is, the real-time arc voltage U a If the arc voltage is less than or equal to the first preset arc voltage, it means that the tip of the welding electrode is in contact with the molten pool and the arc is about to be extinguished, resulting in wire sticking. At this time, the electrode feeding needs to be stopped, that is, the feeding speed is controlled to 0, i.e., S800 is executed, and an arc extinguishing command is issued at the same time to stop the welding process and prevent the guide rail from overshooting.

[0034] When the judgment result of S200 is yes, that is, the real-time arc voltage U a If the arc voltage is greater than the first preset arc voltage, then the real-time arc voltage U is further determined. a If the voltage is less than the second preset arc voltage, then execute S300.

[0035] S300: Determine the real-time arc voltage U a Is it less than the second preset arc voltage? Specifically, the second preset arc voltage can be 40V.

[0036] When the judgment result of S300 is yes, that is, the real-time arc voltage U a If the voltage is less than the second preset arc voltage, then execute S400.

[0037] When the judgment result of S300 is negative, that is, the real-time arc voltage U a If the arc voltage is greater than or equal to the second preset arc voltage, it is determined that the welding electrode has been accidentally extinguished. At this time, the electrode feeding is stopped, that is, the feeding speed is controlled to 0, i.e., S800 is executed. At the same time, an arc extinguishing command is issued to stop the welding process and stop the electrode feeding movement to prevent guide rail overshoot.

[0038] S400: Based on real-time arc voltage U a and the target arc voltage U g Calculate the speed adjustment amount ΔV r ; Specifically, the target arc voltage U g The set voltage value. Based on the real-time arc voltage U a and the target arc voltage U g Calculate the speed adjustment amount ΔV r .

[0039] First, based on the real-time arc voltage U a and the target arc voltage U g Calculate the voltage change ΔU, and then calculate the speed adjustment ΔV based on the voltage change ΔU. r Speed ​​adjustment amount ΔV r It is negatively correlated with the voltage change ΔU.

[0040] S500: Adjustment based on speed ΔV r and reference feed rate V b Calculate the initial feed rate ; Optionally, the reference feed rate of the welding electrode can be calculated based on the electrode's melting coefficient and the preset welding current. The formula for calculating the reference feed rate of the welding electrode is as follows:

[0041] In the formula, V b Here, I is the reference feed rate of the welding electrode, S is the welding current, and ρ is the core material density. Taking a 3.2mm diameter Atlantic CHE507RH welding electrode as an example, the welding parameters can be found in the welding database according to the electrode type, and the corresponding welding current can then be determined. Therefore, the corresponding reference feed rate is: Where I is the welding current, if the welding current I is 106A, the corresponding V b The value is 4.1 mm / s. If the welding current I is 120 A, the corresponding value is... V b The value is 4.64 mm / s.

[0042] When the speed adjustment amount ΔV is calculated r and reference feed rate V b The initial feed rate can then be calculated. .

[0043] The formula for calculating the initial feed rate is as follows:

[0044] in, For reference feed speed, For speed adjustment amount, This represents the initial feed rate corresponding to the current calculation cycle.

[0045] S600: Based on the target feed rate corresponding to the previous calculation cycle, adjust the initial feed rate. Make corrections to obtain the target feed rate corresponding to the current calculation cycle. ; S700: Controls the drive motor according to the target feed speed to control the electrode guide rail to feed the electrode at the target feed speed.

[0046] Once the target feed speed is determined, the rotation of the drive motor can be controlled according to the target feed speed, so that the welding electrode guide rail can feed the welding electrode at the target feed speed. By using the target feed speed corresponding to the previous calculation cycle to correct the initial feed speed corresponding to the current calculation cycle, the rising and falling edges of the speed change curve of the drive motor can be smoothly transitioned, thereby reducing the pure hysteresis effect caused by the mechanical system and signal acquisition delay, and enhancing the anti-vibration capability of the closed-loop system.

[0047] S800: Set the target feed rate of the welding electrode to 0.

[0048] When the real-time arc voltage U a When the electrode feed rate is less than or equal to the first preset arc voltage, or greater than or equal to the second preset arc voltage, the electrode feeding is stopped, i.e., the target electrode feeding speed is set to 0 to prevent mechanical overshoot of the electrode feeding motor.

[0049] The welding control method provided in this application first obtains the real-time arc voltage of the current calculation cycle during the welding process. When the real-time arc voltage is within a preset range (i.e., greater than the first preset arc voltage and less than the second preset arc voltage), the speed adjustment amount is calculated based on the actual arc voltage and the reference arc voltage. The initial feed speed is then calculated based on the speed adjustment amount and the reference feed speed. The initial feed speed corresponding to the current calculation cycle is corrected using the target feed speed corresponding to the previous calculation cycle. This allows for a smooth transition between the rising and falling edges of the speed change curve of the drive motor, reducing the pure hysteresis effect caused by the delay in the mechanical system and signal acquisition. At the same time, it enhances the anti-vibration capability of the closed-loop system. The electrode feed speed is adjusted in real time throughout the welding process, so that it fluctuates within the set arc voltage range, enabling stable electrode processes under different electrodes and different processes.

[0050] In one embodiment of this application, as Figure 2 As shown, S600 (correcting the initial feed rate based on the target feed rate corresponding to the previous calculation cycle) specifically includes the following steps S610-S650: S610: Based on the first-order discrete smoothing filter equation, the theoretical feed rate is calculated according to the target feed rate, the speed adjustment amount and the reference feed rate corresponding to the previous calculation cycle. The first-order discrete smoothing filter equation is as follows: ; in, , This represents the theoretical feed rate corresponding to the current calculation cycle. It is a first-order smoothing factor. The target feed rate corresponding to the previous calculation cycle. This represents the initial feed rate corresponding to the current calculation cycle. For reference feed speed, For speed adjustment; Optionally, the first-order smoothing factor is 0.4.

[0051] S620: Determine whether the theoretical feed speed is greater than the preset feed speed lower limit and less than the preset feed speed upper limit; Specifically, both the preset lower and upper limits of the feed speed are determined based on the electrode diameter and welding current. For example, as shown in the table below:

[0052] When the judgment result of S620 is yes, the theoretical feeding speed is between the preset lower limit of the feeding speed and the preset upper limit of the feeding speed. Therefore, the theoretical feeding speed can be directly determined as the target feeding speed, i.e., S630 is executed.

[0053] If the result of S620 is negative, then S640 and S650 are executed.

[0054] S630: Determine the theoretical feed rate as the target feed rate.

[0055] S640: When the theoretical feed rate is less than or equal to the preset feed rate lower limit, the preset feed rate lower limit is determined to be the target feed rate; When the theoretical feed speed is less than or equal to the preset feed speed lower limit, the preset feed speed lower limit is set as the target feed speed to prevent mechanical overshoot in the electrode feeding motor.

[0056] S650: When the theoretical feed speed is greater than or equal to the preset feed speed upper limit, the preset feed speed upper limit is determined to be the target feed speed.

[0057] When the theoretical feed speed is greater than or equal to the preset feed speed upper limit, the preset feed speed upper limit is set as the target feed speed to prevent mechanical overshoot in the electrode feeding motor.

[0058] In one embodiment of this application, as Figure 3 As shown, S400 (when the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage, the speed adjustment amount is calculated based on the real-time arc voltage and the target arc voltage) specifically includes the following steps S410-S480: S410: Determine whether the real-time arc voltage is greater than the third preset arc voltage; Specifically, the third preset arc voltage is greater than the first preset arc voltage. For example, the first preset arc voltage is 10V and the third preset arc voltage is 20V.

[0059] If the judgment result of S410 is yes, then it is further determined whether the real-time arc voltage is less than the fourth preset arc voltage, that is, S420-S460 are executed.

[0060] When the judgment result of S410 is negative, that is, the real-time arc voltage U a Less than or equal to the third preset arc voltage, for example, 10 < real-time arc voltage U a If the voltage is ≤20V, it indicates that the system determines the arc is in an unstable state with a low or high arc length. In this case, a strong proportional control algorithm is used to calculate the speed adjustment ΔV. r That is, execute S470-S480.

[0061] S420: Determine whether the real-time arc voltage is less than the fourth preset arc voltage; Specifically, the fourth preset arc voltage is less than the second preset arc voltage. For example, the fourth preset arc voltage is 30V and the second preset arc voltage is 40V.

[0062] When the judgment result of S420 is yes, that is, the real-time arc voltage U a When the arc voltage is less than the fourth preset arc voltage, the real-time arc voltage U is... a Greater than the third preset arc voltage and less than the fourth preset arc voltage, for example, 20V < real-time arc voltage U a If the voltage is <30V, it indicates that the arc is in the linear fluctuation range. Therefore, the speed adjustment ΔV is further calculated based on the voltage change between the real-time arc voltage and the target arc voltage. r That is, execute S430-S460.

[0063] When the judgment result of S420 is negative, that is, the real-time arc voltage U a When the real-time arc voltage U is greater than or equal to the fourth preset arc voltage, the real-time arc voltage U is... a Greater than or equal to the fourth preset arc voltage and less than the second preset arc voltage, for example, 30V ≤ real-time arc voltage U a If the voltage is less than 40V, it indicates that the system determines the arc is in an unstable state with a low or high arc length. In this case, a strong proportional control algorithm is activated to calculate the speed adjustment ΔV. r That is, execute S470-S480.

[0064] S430: Calculate the voltage change based on the real-time arc voltage and the target arc voltage; Voltage change ΔU=U g -U a , among which, U g For the target arc voltage, U a This is the real-time arc voltage.

[0065] S440: Determine whether the absolute value of the voltage change is greater than the first change threshold; Specifically, the first change threshold can be 1V.

[0066] When the judgment result of S440 is negative, that is, the absolute value of the voltage change is less than or equal to the first change threshold, for example, |ΔU|≤1V, it indicates that the arc is in an ideal and stable state. At this time, the speed adjustment amount is directly determined to be the preset change value, that is, S460 is executed. For example, if the preset change value is 0, it means that there is no need to adjust the feed speed, that is, the speed adjustment amount is determined to be 0.

[0067] When the judgment result of S440 is negative, that is, when the absolute value of the voltage change is greater than the first change threshold, for example, |ΔU|>1V, it is considered that the arc has fluctuated. At this time, the proportional-integral control algorithm (i.e., PID control algorithm) is activated to calculate the speed adjustment ΔV. r That is, execute S450.

[0068] S450: When the change threshold is less than the second change threshold, the speed adjustment is calculated based on the proportional-integral control algorithm, according to the arc column voltage gradient coefficient of the welding arc and the voltage change.

[0069] Specifically, the second change threshold is 10V, meaning that when the absolute value of the voltage change is greater than the first change threshold but less than the second change threshold, for example, 1V < |ΔU| < 10V, then the speed adjustment ΔV is calculated based on the proportional-integral control algorithm. r The calculation formula is as follows:

[0070] Where ΔU is the voltage change, and ΔV r K1 is the arc voltage gradient coefficient of the electrode arc, calculated from the static equation of arc voltage and arc length under constant current power supply. I1 K1 is a weak integral coefficient used to compensate for the drift caused by the heating of the welding electrode over time; K2 is a differential coefficient that can overcome the delay in the reaction time of the mechanism and prevent overshoot.

[0071] Optional, K1 = 1.82 mm / (s·V), K I1 =0.11 mm / (mm2·V), K2=0.79 mm / V.

[0072] S460: Set the speed adjustment amount to the preset change value.

[0073] Specifically, the preset change value is 0, meaning that when the absolute value of the voltage change is less than or equal to the first change threshold, for example, |ΔU|≤1, there is no need to adjust the feed speed.

[0074] S470: Calculate the voltage change based on the real-time arc voltage and the target arc voltage; When the real-time arc voltage U a The arc voltage is greater than the first preset arc voltage and less than or equal to the third preset arc voltage, for example, 10 < real-time arc voltage U. a ≤20V, or real-time arc voltage U a The arc voltage is greater than or equal to the third preset arc voltage and less than the fourth preset arc voltage, for example, 30V ≤ real-time arc voltage U. a If the voltage is less than 40V, it indicates that the system determines the arc is in an unstable state with a low or high arc length. In this case, the voltage change is calculated first, and then the strong proportional control algorithm is used to calculate the speed adjustment ΔV. r That is, execute S480.

[0075] S480: Calculate the speed adjustment amount based on the arc column voltage gradient coefficient and voltage change of the electrode arc.

[0076] Specifically, the speed adjustment is equal to twice the product of the arc voltage gradient coefficient and the voltage change of the electrode arc, calculated using the following formula:

[0077] Where, ΔV r ΔU is the speed adjustment amount, ΔU is the voltage change amount, and K1 is the arc column voltage gradient coefficient of the welding arc, which is calculated from the static equation of arc voltage and arc length under constant current power supply.

[0078] In one embodiment of this application, when the length of the welding rod is shortened to a certain length, the welding rod guide rail is controlled to move to the lower limit position, the limit switch is triggered, an arc extinguishing command is issued, the welding current is reduced and the welding rod feeding is stopped to extinguish the arc, and the welding robot moves to the designated position to discard the welding rod.

[0079] Exemplary controller As a second aspect of this application, a welding controller is also provided. Figure 4 The diagram shown is a working block diagram of a welding controller according to an embodiment of this application. Figure 4 As shown, the welding controller 10 provided in this application includes: Data acquisition module 101 is used to acquire the real-time arc voltage corresponding to the current calculation cycle during the welding process; The first calculation module 102 is used to calculate the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage. The second calculation module 103 is used to calculate the initial feed speed based on the speed adjustment amount and the reference feed speed. The correction module 104 is used to correct the initial feed rate according to the target feed rate corresponding to the previous calculation cycle, so as to obtain the target feed rate corresponding to the current calculation cycle. The control module 105 is used to control the drive motor according to the target feed speed, so as to control the electrode guide rail to feed the electrode at the target feed speed.

[0080] The welding controller provided in this application first acquires the real-time arc voltage of the current calculation cycle during the welding process. When the real-time arc voltage is within a preset range (i.e., greater than the first preset arc voltage and less than the second preset arc voltage), it calculates the speed adjustment amount based on the actual arc voltage and the reference arc voltage. Then, it calculates the initial feed speed based on the speed adjustment amount and the reference feed speed. Finally, it corrects the initial feed speed corresponding to the current calculation cycle using the target feed speed corresponding to the previous calculation cycle. This allows for a smooth transition between the rising and falling edges of the speed change curve of the drive motor, thereby reducing the pure hysteresis effect caused by the delay in the mechanical system and signal acquisition. At the same time, it enhances the anti-vibration capability of the closed-loop system. The feeding speed of the welding electrode is controlled in real time throughout the welding process, enabling stable welding processes under different welding electrodes and different processes.

[0081] Exemplary electronic devices As a fourth aspect of this application, this application also provides an electronic device, such as... Figure 5 As shown, it includes a processor and a memory. The memory stores a computer program. When the processor executes the computer program, it performs the welding control method described above.

[0082] Specifically, the electronic device includes a processor, memory, network interface, and input device connected via a device bus. The processor provides computing and control capabilities. The memory includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores operating devices and computer programs. The internal memory provides an environment for the operation of the operating devices and computer programs in the non-volatile storage medium. The network interface is used for communication with external terminals via a network connection. When the computer program is executed by the processor, it follows the steps of a welding control method according to various embodiments of this specification as described in the above embodiments.

[0083] The processor may include the main processor, as well as baseband chips, modems, etc.

[0084] The memory stores a program for executing the technical solution of this application, and may also store operating devices and other key business functions. Specifically, the program may include program code, which includes computer operation instructions. More specifically, the memory may include read-only memory (ROM), other types of static storage devices capable of storing static information and instructions, random access memory (RAM), other types of dynamic storage devices capable of storing information and instructions, disk storage, flash memory, etc.

[0085] The processor can be a general-purpose processor, such as a general-purpose central processing unit (CPU), a microprocessor, etc., or an application-specific integrated circuit (ASIC), or one or more integrated circuits used to control the execution of the program of the present application. It can also be a digital signal processor (DSP), an application-specific integrated circuit (ASIC), an off-the-shelf programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components.

[0086] Input devices may include devices that receive data and information input by the user, such as keyboards, mice, cameras, scanners, light pens, voice input devices, touch screens, pedometers, or gravity sensors.

[0087] Output devices may include devices that allow information to be output to the user, such as displays, printers, speakers, etc.

[0088] The communication interface may include any transceiver-like device for communicating with other devices or communication networks, such as Ethernet, Radio Access Network (RAN), Wireless Local Area Network (WLAN), etc.

[0089] The processor executes the program stored in the memory and calls other devices, which can be used to implement any of the steps of the welding control method provided in the above embodiments of this specification.

[0090] The electronic device may also include a display component and a voice component. The display component may be a liquid crystal display or an e-ink display. The input device of the controller may be a touch layer covering the display component, or a button, trackball, or touchpad set on the controller housing, or an external keyboard, touchpad, or mouse, etc.

[0091] Those skilled in the art will understand that Figure 5 The structures shown are merely block diagrams of a portion of the structure related to the scheme described in this specification, and do not constitute a limitation on the electronic devices to which the scheme described in this specification is applied. Specific electronic devices may include more or fewer components than those shown in the figures, or may combine certain components, or may have different component arrangements.

[0092] Exemplary computer program products and storage media In addition to the methods and devices described above, a welding control method provided in the embodiments of this specification can also be a computer program product, which includes computer program instructions that, when executed by a processor, cause the processor to perform the steps in a welding control method according to various embodiments of this specification as described in the "Exemplary Methods" section above.

[0093] The aforementioned computer program product can be implemented through hardware, software, or a combination thereof. In one optional embodiment, the computer program product is specifically embodied in a computer storage medium; in another optional embodiment, the computer program product is specifically embodied in a software product, such as a software development kit (SDK), etc.

[0094] The computer program product can be written in any combination of one or more programming languages ​​to perform the operations of the embodiments of this specification. The programming languages ​​include object-oriented programming languages ​​such as Java and C++, as well as conventional procedural programming languages ​​such as the "C" language or similar programming languages.

[0095] Furthermore, embodiments of this specification also provide a computer-readable storage medium having a computer program stored thereon, the computer program being executed by a processor of the steps in a welding control method according to various embodiments of this specification as described in the "Exemplary Methods" section above.

[0096] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this specification can include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in a variety of forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), RAMbus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0097] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0098] The embodiments described above are merely illustrative of several implementation methods outlined in this specification. While the descriptions are specific and detailed, they should not be construed as limiting the scope of the solutions provided in this specification. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this specification, and these all fall within the scope of protection of this specification. Therefore, the scope of protection for this patent should be determined by the appended claims.

Claims

1. A welding control method, characterized in that, include: Obtain the real-time arc voltage corresponding to the current calculation cycle during the welding process; When the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage, the speed adjustment amount is calculated based on the real-time arc voltage and the target arc voltage. Calculate the initial feed speed based on the speed adjustment amount and the reference feed speed; Based on the target feed rate corresponding to the previous calculation cycle, the initial feed rate is corrected to obtain the target feed rate corresponding to the current calculation cycle; The drive motor is controlled according to the target feed speed to control the electrode guide rail to feed the electrode at the target feed speed.

2. The welding control method according to claim 1, characterized in that, The step of correcting the initial feed rate based on the target feed rate corresponding to the previous calculation cycle includes: Based on the first-order discrete smoothing filter equation, the theoretical feed rate is calculated according to the target feed rate corresponding to the previous calculation cycle, the speed adjustment amount, and the reference feed rate; wherein, the first-order discrete smoothing filter equation is: ;in, , This represents the theoretical feed rate corresponding to the current calculation cycle. It is a first-order smoothing factor. The target feed rate corresponding to the previous calculation cycle. This represents the initial feed rate corresponding to the current calculation cycle. For reference feed speed, For speed adjustment; When the theoretical feeding speed is greater than the preset lower limit of feeding speed and less than the preset upper limit of feeding speed, the theoretical feeding speed is determined as the target feeding speed.

3. The welding control method according to claim 2, characterized in that, The step of correcting the initial feed rate based on the target feed rate corresponding to the previous calculation cycle further includes: When the theoretical feed rate is less than or equal to the preset feed rate lower limit, the preset feed rate lower limit is determined to be the target feed rate; or When the theoretical feed rate is greater than or equal to the preset feed rate upper limit, the preset feed rate upper limit is determined to be the target feed rate.

4. The welding control method according to claim 2, characterized in that, The first-order smoothing factor is 0.

4.

5. The welding control method according to claim 1, characterized in that, When the real-time arc voltage is greater than a first preset arc voltage and less than a second preset arc voltage, the speed adjustment amount is calculated based on the real-time arc voltage and the target arc voltage, including: When the real-time arc voltage is greater than the third preset arc voltage and less than the fourth preset arc voltage, the voltage change is calculated based on the real-time arc voltage and the target arc voltage, wherein the third preset arc voltage is greater than the first preset arc voltage and the fourth preset arc voltage is less than the second preset arc voltage. When the absolute value of the voltage change is greater than the first change threshold and less than the second change threshold, the speed adjustment is calculated based on the proportional-integral control algorithm according to the arc column voltage gradient coefficient of the welding arc and the voltage change.

6. The welding control method according to claim 5, characterized in that, The step of calculating the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage further includes: When the absolute value of the voltage change is less than the first change threshold, the speed adjustment amount is determined to be a preset change value.

7. The welding control method according to claim 5, characterized in that, The step of calculating the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage further includes: When the real-time arc voltage is greater than the first preset arc voltage and less than or equal to the third preset arc voltage; or when the real-time arc voltage is greater than or equal to the fourth preset arc voltage and less than the second preset arc voltage, the voltage change is calculated based on the real-time arc voltage and the target arc voltage. The speed adjustment is calculated based on the arc column voltage gradient coefficient of the welding electrode arc and the voltage change, wherein the speed adjustment is equal to twice the product of the arc column voltage gradient coefficient of the welding electrode arc and the voltage change.

8. The welding control method according to claim 1, characterized in that, The welding control method further includes: When the real-time arc voltage is less than or equal to the first preset arc voltage, the target feed speed of the welding electrode is determined to be 0; or When the real-time arc voltage is greater than or equal to the second preset arc voltage, the target feed speed of the welding electrode is determined to be 0.

9. The welding control method according to claim 1, characterized in that, The welding control method further includes: The reference feed speed for feeding the welding electrode is calculated based on the electrode's melting coefficient and the preset welding current.

10. A welding controller, characterized in that, include: The data acquisition module is used to acquire the real-time arc voltage corresponding to the current calculation cycle during the welding process; The first calculation module is used to calculate the speed adjustment amount based on the real-time arc voltage and the target arc voltage when the real-time arc voltage is greater than the first preset arc voltage and less than the second preset arc voltage. The second calculation module is used to calculate the initial feed speed based on the speed adjustment amount and the reference feed speed; The correction module is used to correct the initial feed rate according to the target feed rate corresponding to the previous calculation cycle, so as to obtain the target feed rate corresponding to the current calculation cycle. The control module is used to control the drive motor according to the target feed speed, so as to control the electrode guide rail to feed the electrode at the target feed speed.

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