Flux consumption calculation device and submerged arc welding system

Abstract

The present invention provides a flux consumption calculation device that enables estimation of flux consumption for each weld, and a submerged arc welding system equipped with the flux consumption calculation device. [Solution] The flux consumption calculation unit 12 includes a current acquisition unit 121 that acquires a current value indicating the welding current, a voltage acquisition unit 122 that acquires a voltage value indicating the welding voltage, and a calculation unit 125 that calculates the flux consumption per unit time based on the current value and the voltage value. The welding system A1 also includes the flux consumption calculation unit 12.

Description

Technical Field

[0006] , , , ,

[0001] The present invention relates to a flux consumption amount calculation device and a submerged arc welding system including the flux consumption amount calculation device.

Background Art

[0002] Conventionally, submerged arc welding is known. Submerged arc welding involves spraying granular flux onto the workpiece, feeding a welding wire into the flux, and generating an arc between the tip of the welding wire and the workpiece to perform welding. In submerged arc welding, thick plates can be welded with high efficiency by passing a large current through a thick welding wire.

[0003] The flux shields the periphery of the arc and stabilizes the arc. Also, a part of the flux melts by the arc heat to become slag, protects the molten metal from the atmosphere, and shapes the bead when the molten metal solidifies.

[0004] The unmelted flux is recovered and reused. Patent Document 1 discloses a flux supply device for submerged arc welding. The flux supply device supplies the granular flux in the flux spraying hopper to the workpiece and recovers the excess welding flux from the welding track by a flux recovery nozzle.

[0005] On the other hand, the flux that has once melted and become slag cannot be reused and is discarded. Therefore, the flux is a consumable that needs to be replenished as appropriate. In order to correctly calculate the welding cost, it is necessary to grasp the consumption amount of the flux.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

[0007] Flux consumption varies depending on various conditions such as welding conditions and welding time, and also differs significantly depending on the type of flux. One method for accurately determining flux consumption is to measure the weight change of flux before and after welding, but this is very time-consuming and impractical. Therefore, generally, flux consumption is not tracked in detail, and is limited to a rough estimate based on the annual purchase volume and purchase cost, without considering the flux consumption for each weld. In the submerged arc welding flux supply device disclosed in Patent Document 1, flux is supplied from the flux supply hopper to the flux dispensing hopper when the flux level inside the flux dispensing hopper reaches the lower limit level. Therefore, it is not possible to determine the flux consumption for each weld. For example, reducing the welding voltage reduces flux consumption, but it is usually difficult to grasp the cost reduction effect resulting from this.

[0008] The present invention was conceived under the circumstances described above, and aims to provide a flux consumption calculation device that can estimate the amount of flux consumed for each weld, and a submerged arc welding system equipped with the flux consumption calculation device. [Means for solving the problem]

[0009] A flux consumption calculation device provided by a first aspect of the present invention comprises a current acquisition unit that acquires a current value indicating the welding current, a voltage acquisition unit that acquires a voltage value indicating the welding voltage, and a calculation unit that calculates the flux consumption per unit time based on the current value and the voltage value.

[0010] "Welding current" is the current that flows through the electrodes during welding. "Current value indicating welding current" may be the set value (current command value) of the welding current, the actual measured value of the welding current, or any other current value related to welding current. "Welding voltage" is the voltage applied between the workpiece and the tip of the electrode during welding. "Voltage value indicating welding voltage" may be the set value (voltage command value) of the welding voltage, the actual measured value of the welding voltage, or any other voltage value related to welding voltage.

[0011] In a preferred embodiment of the present invention, a time acquisition unit is further provided to acquire welding time, and the calculation unit further calculates flux consumption based on the welding time.

[0012] In a preferred embodiment of the present invention, the current acquisition unit acquires a current command value as the current value, the voltage acquisition unit acquires a voltage command value as the voltage value, and the calculation unit calculates the flux consumption C based on the following equation (1), where I is the current command value, V is the voltage command value, T is the welding time, and K is a coefficient that varies depending on the type of flux. C=K·I·V·T ··· (1)

[0013] In a preferred embodiment of the present invention, the current acquisition unit acquires a current command value as the current value, the voltage acquisition unit acquires a voltage command value as the voltage value, and the calculation unit calculates the flux consumption C based on the following equation (2), using coefficients α, β, γ, and δ which differ depending on the type of flux, when the current command value is I, the voltage command value is V, and the welding time is T. C=α·I+β·V+γ·T+δ (2)

[0014] A submerged arc welding system provided by a second aspect of the present invention comprises a welding power supply device for supplying power, a control device for controlling the welding power supply device, and a flux consumption calculation device provided by a first aspect of the present invention, wherein the flux consumption calculation device is included in the control device. [Effects of the Invention]

[0015] According to the present invention, the flux consumption calculation device calculates the flux consumption per unit time based on a current value indicating the welding current and a voltage value indicating the welding voltage. Therefore, the flux consumption calculation device can estimate the flux consumption for each weld. [Brief explanation of the drawing]

[0016] [Figure 1] This diagram illustrates a welding system according to the first embodiment, where (a) is a block diagram showing the overall configuration of the welding system, and (b) is a block diagram showing the internal configuration of the welding power supply and control device. [Figure 2] This is an example flowchart illustrating the flux consumption calculation process performed by the flux consumption calculation unit of the welding system according to the first modified example of the first embodiment. [Figure 3] (a) is a block diagram showing the internal configuration of the control device for a welding system according to a third modified example of the first embodiment, and (b) is a block diagram showing the internal configuration of the control device for a welding system according to a fourth modified example of the first embodiment. [Figure 4] This diagram illustrates a welding system according to a second embodiment, where (a) is a block diagram showing the overall configuration of the welding system, and (b) is a block diagram showing the internal configuration of the welding power supply and control device. [Figure 5] This block diagram shows the internal configuration of the welding power supply unit and control unit of the welding system according to the third embodiment. [Figure 6]FIG. 0 is a diagram for explaining a welding system according to the fourth embodiment, where (a) is a block diagram showing the overall configuration of the welding system, and (b) is a block diagram showing the internal configurations of the welding power source device, the control device, and the management device.

Embodiments for Carrying Out the Invention

[0017] Hereinafter, preferred embodiments of the present invention will be specifically described with reference to the accompanying drawings.

[0018] 〔First Embodiment〕 FIG. 1 is a diagram for explaining a welding system A1 according to the first embodiment. FIG. 1(a) is a block diagram showing the overall configuration of the welding system A1. FIG. 1(b) is a block diagram showing the internal configurations of the welding power source device 2 and the control device 1.

[0019] The welding system A1 is a welding system for performing submerged arc welding. As shown in FIG. 1(a), the welding system A1 includes a control device 1, a welding power source device 2, a carriage 4, a wire feeding device 5, a wire reel 6, a spraying device 71, a recovery device 72, and an electrode 8. The welding system A1 moves the carriage 4 along the welding line of the workpiece W to be welded, sprays the granular flux 79 from the spraying device 71, and feeds the welding wire into the flux 79 by the wire feeding device 5. The welding wire is supplied from the wire reel 6. The welding power source device 2 converts the AC power supplied from the commercial power source P into power suitable for welding and outputs it, and generates an arc between the electrode 8, which is the tip portion of the welding wire, and the workpiece W to be welded inside the flux 79. Welding is performed by the heat of the arc. Thereby, welding is performed along the welding line of the workpiece W to be welded. A part of the sprayed flux 79 melts by the arc heat to become slag, protecting the molten metal from the atmosphere. The unmolten flux 79 is recovered by the recovery device 72 and reused. Instead of using the carriage 4, the workpiece W to be welded may be moved or rotated.

[0020] The control device 1 performs various controls on the welding system A1. The control device 1 may be a general-purpose computer installed with a program for performing various controls on the welding system A1, or may be a dedicated device for controlling the welding system A1. The control device 1 moves the carriage 4 at a predetermined moving speed. The moving speed is set according to the material and thickness of the workpiece W, etc. The control device 1 instructs the wire feeding device 5 to start, stop, and control the feeding speed of the welding wire. The feeding speed is set according to the set welding current, etc. The control device 1 instructs the welding power source device 2 to output power.

[0021] In addition, the control device 1 instructs the spraying device 71 to start and end the spraying of the flux 79. Note that the operator may instruct the start and end of the spraying of the flux 79. Also, the operator may manually spray the flux 79 before the start of welding. In this case, the welding system A1 may not include the spraying device 71. The recovery device 72 may be instructed by the control device 1 to start and end the recovery of the flux 79, or may start and end the recovery according to the start and end of the spraying of the spraying device 71. Also, the operator may manually recover the flux 79 after the end of welding. In the present embodiment, the control device 1 has a function of calculating the flux consumption and displaying it on the display unit 13. Note that the control device 1 may notify the calculated flux consumption by other methods. Details of the method by which the control device 1 calculates the flux consumption will be described later.

[0022] The welding power source device 2 converts the AC power supplied from the commercial power source P into AC power of a desired frequency and outputs it. As shown in Fig. 1(b), the welding power source device 2 includes a rectifying and smoothing circuit 21, an inverter circuit 22, a transformer 23, a rectifying and smoothing circuit 24, an inverter circuit 25, a current sensor 26, a voltage sensor 27, and a control circuit 28.

[0023] The rectifier and smoothing circuit 21 converts the AC power input from the commercial power supply P into DC power and outputs it. The inverter circuit 22 converts the DC power input from the rectifier and smoothing circuit 21 into high-frequency power and outputs it by switching a switching element according to the output control drive signal input from the control circuit 28. The transformer 23 transforms the high-frequency voltage output by the inverter circuit 22 and outputs it to the rectifier and smoothing circuit 24.

[0024] The rectifier and smoothing circuit 24 converts the high-frequency power input from the transformer 23 into DC power and outputs it. The inverter circuit 25 converts the DC power input from the rectifier and smoothing circuit 24 into AC power and outputs it by switching a switching element in response to a switching drive signal input from the control circuit 28. The inverter circuit 25 switches between positive polarity, where the potential of output terminal a (connected to the workpiece W) is higher than the potential of output terminal b (connected to the welding wire), and reverse polarity, where the potential of output terminal a is lower than the potential of output terminal b.

[0025] The current sensor 26 detects the output current of the welding power supply unit 2, and in this embodiment, it is located on the connecting wire that connects one output terminal of the inverter circuit 25 to output terminal a. The output current of the welding power supply unit 2 detected by the current sensor 26 is approximately equal to the current flowing through the electrode 8. The current sensor 26 outputs a current value signal corresponding to the detected instantaneous current value to the control circuit 28 and the control device 1. The voltage sensor 27 detects the output voltage of the welding power supply unit 2, and in this embodiment, it detects the terminal voltage between output terminal a and output terminal b. This voltage is approximately equal to the voltage applied between the workpiece W and the tip of the electrode 8. The voltage sensor 27 outputs a voltage value signal corresponding to the detected instantaneous voltage value to the control circuit 28 and the control device 1.

[0026] The control circuit 28 is a circuit for controlling the welding power supply unit 2 and is implemented by, for example, a microcomputer. The control circuit 28 receives a current value signal from the current sensor 26, a voltage value signal from the voltage sensor 27, and various command signals and various setting values ​​from the control device 1. The control circuit 28 then outputs drive signals to the inverter circuit 22 and the inverter circuit 25, respectively.

[0027] When the control circuit 28 receives a command signal from the control device 1 instructing it to start power output, it starts outputting drive signals to the inverter circuit 22 and inverter circuit 25, respectively, thereby starting power output. Conversely, when the control circuit 28 receives a command signal from the control device 1 instructing it to stop power output, it stops outputting drive signals, thereby stopping power output.

[0028] Furthermore, the control circuit 28 calculates the effective current value from the current value signal input from the current sensor 26. Then, based on the effective current value and the current command value (set value of the welding current) input from the control device 1, the control circuit 28 generates an output control drive signal to control the switching elements of the inverter circuit 22 and outputs it to the inverter circuit 22. In other words, the control circuit 28 performs feedback control (constant current control) so that the effective current value matches the current command value. Alternatively, the control circuit 28 can also generate an output control drive signal based on the voltage value signal input from the voltage sensor 27 and the voltage command value (set value of the welding voltage), and perform feedback control (constant voltage control) so that the effective voltage value matches the voltage command value.

[0029] Furthermore, the control circuit 28 generates a switching drive signal to control the switching elements of the inverter circuit 25 based on the current value signal input from the current sensor 26 and a waveform command signal generated internally, and outputs it to the inverter circuit 25. In other words, the control circuit 28 performs feedback control so that the waveform of the output current matches the waveform commanded by the waveform command signal. In this embodiment, the waveform command signal is a square wave (trapezoidal wave) signal. The waveform command signal may be other waveform signals such as a sine wave signal. By generating a switching drive signal based on the waveform command signal and outputting it to the inverter circuit 25, the inverter circuit 25 outputs a sinusoidal AC current corresponding to the waveform command signal. The control circuit 28 may also generate the switching drive signal based only on the waveform command signal without using the instantaneous value of the output current.

[0030] Furthermore, when the control circuit 28 receives a DC output command signal from the control device 1, it outputs a switching drive signal to the inverter circuit 25 that fixes a predetermined switching element in the ON state and the other switching elements in the OFF state. For example, when the state of each switching element is fixed such that the positive output terminal of the rectifier and smoothing circuit 24 is connected to output terminal a, and the negative output terminal of the rectifier and smoothing circuit 24 remains connected to output terminal b, the welding power supply unit 2 outputs DC power with output terminal a as the positive terminal and output terminal b as the negative terminal. In other words, welding system A1 is a dual AC / DC welding system that can output not only AC power but also DC power. In addition, welding power supply unit 2 can control the output current based on the current command value input from the control device 1. Therefore, welding system A1 can appropriately control the output current. Note that the configuration of welding power supply unit 2 is not limited.

[0031] Next, we will explain in detail the method used by the control device 1 to calculate flux consumption.

[0032] Flux 79 is sprayed onto the workpiece W, some of which melts into slag due to arc heat, and the unmelted portion is recovered and reused. The amount of flux 79 that melts into slag and is not recovered is the flux consumption. Therefore, flux consumption increases as the amount of energy applied during welding increases. Flux consumption has a positive correlation with welding current, welding voltage, and welding time, respectively. In this embodiment, the control device 1 calculates an estimated value of flux consumption based on the current command value, voltage command value, and welding time during welding.

[0033] The control device 1, as shown in Figure 1(b), includes a setting unit 11, a flux consumption calculation unit 12, and a display unit 13 for calculating and displaying flux consumption. The control device 1 also includes other components, but these are not shown or described.

[0034] The setting unit 11 is configured for setting each welding condition. The setting unit 11 sets values ​​input by the operator through the operation of an operation unit (not shown). The setting unit 11 sets various setting values ​​such as welding current, welding voltage, welding speed (movement speed of the trolley 4), overhang length, torch angle, joint shape, groove angle, wire feeding speed, wire material, wire diameter, material of the workpiece W, thickness of the workpiece W, and flux type indicating the type of flux 79. The setting unit 11 may also set values ​​calculated from the setting values ​​of the welding conditions as other setting values. The control device 1 instructs the wire feeding device 5 to use the wire feeding speed set by the setting unit 11 and moves the trolley 4 according to the welding speed (movement speed of the trolley 4). In this embodiment, the setting unit 11 also outputs the setting value of the welding current (current command value) and the setting value of the welding voltage (voltage command value) to the flux consumption calculation unit 12 and the control circuit 28 of the welding power supply device 2. Furthermore, the setting unit 11 outputs the flux type to the flux consumption calculation unit 12.

[0035] The flux consumption calculation unit 12 is configured to calculate an estimated value of flux consumption. As shown in Figure 1(b), the flux consumption calculation unit 12 includes a current acquisition unit 121, a voltage acquisition unit 122, a time acquisition unit 123, a coefficient acquisition unit 124, and a calculation unit 125.

[0036] The current acquisition unit 121 acquires the set value (current command value) of the welding current set in the setting unit 11. The voltage acquisition unit 122 acquires the set value (voltage command value) of the welding voltage set in the setting unit 11.

[0037] The time acquisition unit 123 acquires the welding time, which is the time spent welding by the welding power supply unit 2 outputting welding current and welding voltage. The control device 1 instructs the welding power supply unit 2 to start and stop power output. The time acquisition unit 123 acquires the welding time measured from the time the control device 1 instructs the welding power supply unit 2 to start power output until the time the control device 1 instructs it to stop output. The time acquisition unit 123 may acquire the welding time measured by the control device 1, or it may measure the welding time itself.

[0038] The coefficient acquisition unit 124 acquires a coefficient K corresponding to the flux type set in the setting unit 11. The coefficient K is stored in a memory (not shown) for each flux type, and is read from the memory and set according to the flux type set in the setting unit 11. Note that if the type of flux 79 used is fixed, the flux consumption calculation unit 12 does not need to have a coefficient acquisition unit 124, and a fixed value coefficient K can be used.

[0039] The calculation unit 125 calculates the flux consumption based on the current command value acquired by the current acquisition unit 121, the voltage command value acquired by the voltage acquisition unit 122, the welding time acquired by the time acquisition unit 123, and the coefficient K acquired by the coefficient acquisition unit 124. Specifically, the calculation unit 125 calculates the flux consumption C based on the following equation (3) according to the current command value I, the voltage command value V, the welding time T, and the coefficient K. The calculation unit 125 outputs the calculated flux consumption C to the display unit 13. C = K·I·V·T ··· (3)

[0040] The coefficient K is calculated based on equation (4) below, according to the flux consumption per unit time C' (kg / min) at a certain current I' and voltage V', and is stored in memory. The flux consumption per unit time C' may be the manufacturer's published value or may be measured. K = C' / (I'·V') ··· (4)

[0041] The flux consumption calculation unit 12 may use the average value of the measured welding current detected by the current sensor 26 instead of the current command value. Similarly, it may use the average value of the measured welding voltage detected by the voltage sensor 27 instead of the voltage command value.

[0042] The display unit 13 is configured to display various information and is equipped with a display device. The display device may be, for example, a liquid crystal display or a simple display device such as a 7-segment display. The display unit 13 displays the flux consumption amount C, which is input from the flux consumption amount calculation unit 12, on the display device. After welding is completed, the operator can check the display on the display device to understand the flux consumption amount for each weld.

[0043] In this embodiment, the flux consumption calculation unit 12 can be said to be the flux consumption calculation device according to the present invention. Alternatively, the control device 1, which includes the flux consumption calculation unit 12, can also be said to be the flux consumption calculation device according to the present invention.

[0044] Next, the operation and effects of the flux consumption calculation unit 12 and the welding system A1 according to this embodiment will be described.

[0045] According to this embodiment, the flux consumption calculation unit 12 calculates the flux consumption based on the current command value, voltage command value, and welding time. Therefore, the flux consumption calculation unit 12 can estimate the flux consumption for each weld.

[0046] Furthermore, according to this embodiment, the flux consumption calculation unit 12 obtains a coefficient K corresponding to the flux type and calculates the flux consumption based on equation (3) above. Therefore, the flux consumption calculation unit 12 can easily estimate the flux consumption.

[0047] [First variation] Figure 2 is a diagram illustrating a first modified example of the welding system A1 according to the first embodiment. Figure 2 is an example of a flowchart illustrating the flux consumption calculation process performed by the flux consumption calculation unit 12 of the welding system A11 according to the first modified example. Note that the overall configuration of the welding system A11, as well as the block diagram showing the internal configuration of the welding power supply unit 2 and the control device 1, are the same as in Figure 1, so their description and explanation are omitted. In submerged arc welding, the current command value or voltage command value may be changed during welding. The flux consumption calculation unit 12 of the welding system A11 according to the first modified example is configured to handle cases where the current command value or voltage command value is changed during welding.

[0048] Figure 2 is an example of a flowchart illustrating the consumption calculation process for the first modified example. This consumption calculation process is initiated when the welding start instruction is given.

[0049] First, a coefficient K corresponding to the flux type is obtained (S1). Specifically, the coefficient acquisition unit 124 acquires the coefficient K corresponding to the flux type set in the setting unit 11. Next, the current command value is obtained (S2). Specifically, the current acquisition unit 121 acquires the set value (current command value) of the welding current set in the setting unit 11. Next, the voltage command value is obtained (S3). Specifically, the voltage acquisition unit 122 acquires the set value (voltage command value) of the welding voltage set in the setting unit 11.

[0050] Next, it is determined whether the current command value or the voltage command value has changed (S4). If it has not changed (S4: NO), the process returns to step S2 and steps S2 to S4 are repeated. On the other hand, if it has changed (S4: YES), the time for which the current command value and voltage command value remained unchanged is obtained as the welding time (S5). Next, the amount consumed during that period is calculated (S6) and accumulated (S7). Specifically, the calculation unit 125 calculates the flux consumption C based on equation (3) above, according to the current command value and voltage command value before it was determined in step S4 to have changed, the welding time obtained in step S5, and the coefficient K obtained in step S1.

[0051] Next, it is determined whether or not welding is complete (S8). If welding is not complete (S8: NO), the process from steps S2 to S8 is repeated. On the other hand, if welding is complete (S8: YES), the accumulated value is displayed on the display unit 13 (S9), and the consumption calculation process is completed. Note that the process shown in the flowchart of Figure 2 is just one example, and the consumption calculation process performed by the flux consumption calculation unit 12 is not limited to that described above.

[0052] According to this modified example, even if the current command value or voltage command value is changed during welding, the flux consumption for each weld can be estimated. The flux consumption calculation unit 12 may also display on the display unit 13 not only the cumulative value of flux consumption, but also the flux consumption for each section in which the current command value or voltage command value was changed.

[0053] [Second variation] The flux consumption calculation unit 12 of the welding system A1 according to the first embodiment calculates the flux consumption C based on equation (3) above. The method by which the flux consumption calculation unit 12 calculates the flux consumption is not limited to this. A second modified example, which is an example of another method for calculating flux consumption, will be described. The overall configuration of the welding system A12 according to the second modified example, as well as the block diagram showing the internal configuration of the welding power supply unit 2 and the control device 1, are the same as those in Figure 1, so their description and explanation are omitted.

[0054] The calculation unit 125 in the second modified example calculates the flux consumption based on the current command value acquired by the current acquisition unit 121, the voltage command value acquired by the voltage acquisition unit 122, the welding time acquired by the time acquisition unit 123, and the coefficients α, β, γ, δ acquired by the coefficient acquisition unit 124. Specifically, the calculation unit 125 calculates the flux consumption C based on the following equation (5) according to the current command value I, the voltage command value V, and the welding time T. C=α·I+β·V+γ·T+δ (5)

[0055] The coefficients α, β, γ, and δ are stored in memory (not shown) for each flux type. The coefficient acquisition unit 124 reads and acquires the coefficients α, β, γ, and δ corresponding to the flux type set in the setting unit 11 from the memory. The coefficients α, β, γ, and δ are calculated by creating four equations by substituting the reference conditions (current command value, voltage command value, welding time, and flux consumption for these) into equation (5) above, solving a system of equations based on these four equations, and storing them in memory.

[0056] In this modified example as well, the flux consumption calculation unit 12 calculates the flux consumption based on the current command value, voltage command value, and welding time, so the flux consumption calculation unit 12 can estimate the flux consumption for each weld. Furthermore, since the flux consumption calculation unit 12 calculates the flux consumption based on equation (5) above, the flux consumption can be easily estimated.

[0057] [Third variation] Figure 3(a) is a diagram illustrating a third modified example of the welding system A1 according to the first embodiment. Figure 3(a) is a block diagram showing the internal configuration of the control device 1 of the welding system A13 according to the third modified example. Note that the overall configuration of the welding system A13 and the block diagram showing the internal configuration of the welding power supply device 2 are the same as those in Figure 1, so their description and explanation are omitted.

[0058] The flux consumption calculation unit 12 according to the third modified example does not include a time acquisition unit 123. In addition, the calculation unit 125 calculates the flux consumption amount Cu per unit time based on the following equation (6) and outputs it to the display unit 13. Cu = K·I·V ··· (6)

[0059] According to this modified example, the flux consumption calculation unit 12 calculates the flux consumption per unit time based on the current command value and the voltage command value. Therefore, the flux consumption calculation unit 12 can estimate the flux consumption per unit time for each weld. Furthermore, according to this modified example, the flux consumption calculation unit 12 obtains a coefficient K corresponding to the flux type and calculates the flux consumption per unit time based on equation (6) above. Therefore, the flux consumption calculation unit 12 can easily estimate the flux consumption per unit time.

[0060] In the third modified example, the flux consumption calculation unit 12 may include a time acquisition unit 123 to calculate the flux consumption per unit time and the flux consumption amount, respectively. Alternatively, the flux consumption calculation unit 12 according to the first embodiment may calculate the flux consumption amount and the flux consumption per unit time, respectively.

[0061] [Fourth variation] Figure 3(b) is a diagram illustrating a fourth modified example of the welding system A1 according to the first embodiment. Figure 3(b) is a block diagram showing the internal configuration of the control device 1 of the welding system A14 according to the fourth modified example. Note that the overall configuration of the welding system A14 and the block diagram showing the internal configuration of the welding power supply device 2 are the same as those in Figure 1, so their description and explanation are omitted.

[0062] The flux consumption calculation unit 12 according to the fourth modified example further includes a unit price acquisition unit 126. The unit price acquisition unit 126 acquires the unit price per weight of flux corresponding to the flux type set in the setting unit 11. The unit price is stored in a memory (not shown) for each flux type and is read from the memory and set according to the flux type set in the setting unit 11. The calculation unit 125 calculates the flux price for each weld by multiplying the calculated flux consumption by the unit price. The calculation unit 125 may output and display only the calculated flux price on the display unit 13, or it may output and display both the calculated flux consumption and the calculated flux price on the display unit 13.

[0063] In this modified example, the flux consumption calculation unit 12 can estimate the flux consumption for each weld. Furthermore, in this modified example, the flux consumption calculation unit 12 can easily estimate the flux consumption. Moreover, according to this modified example, the flux consumption calculation unit 12 can estimate the flux price for each weld.

[0064] In the first embodiment, the case in which the flux consumption calculation unit 12 calculates flux consumption based on the current command value, voltage command value, and welding time was described, but it is not limited to this. The flux consumption calculation unit 12 may also calculate flux consumption by considering influencing factors other than the current command value, voltage command value, and welding time. For example, the flux consumption increases as the welding speed (movement speed of the trolley 4) increases and as the overhang length increases, so the flux consumption calculation unit 12 may also consider these influencing factors when calculating flux consumption. Furthermore, the flux consumption calculation unit 12 may also consider influencing factors such as joint shape, torch angle, base material temperature, or heating temperature during flux drying when calculating flux consumption. The specific calculation formula for calculating flux consumption is not limited, and correction values ​​according to the set values ​​of these influencing factors may be added or multiplied.

[0065] [Second Embodiment] Figure 4 is a diagram illustrating the welding system A2 according to the second embodiment. Figure 4(a) is a block diagram showing the overall configuration of the welding system A2. Figure 4(b) is a block diagram showing the internal configuration of the welding power supply unit 2 and the control device 1. In Figure 4, elements that are the same as or similar to those in the first embodiment are denoted by the same reference numerals as those in the first embodiment. The welding system A2 according to this embodiment differs from the welding system A1 according to the first embodiment in that it performs so-called tandem welding.

[0066] The welding system A2 according to this embodiment includes two welding power supply units 2, two wire feeders 5, two wire reels 6, and two electrodes 8. The welding system A2 performs so-called tandem welding, where two electrodes 8 pass through the same welding point with a time difference, and each of the two electrodes 8 generates an arc, enabling highly efficient and high-speed welding. The two electrodes 8 are arranged side by side in the direction of travel of the trolley 4. Therefore, as the trolley 4 travels along the welding line of the workpiece W, one electrode 8 passes through a welding point, and then the other electrode 8 passes through the same welding point later than the first electrode 8. Each electrode 8 melts the workpiece W, forming a single weld bead. Hereinafter, the leading electrode 8 that passes through the welding point first may be referred to as electrode 8a, and the trailing electrode 8 that passes through the welding point later than electrode 8a may be referred to as electrode 8b. In addition, the welding power supply unit 2 that supplies power to electrode 8a may be described as welding power supply unit 2a, and the welding power supply unit 2 that supplies power to electrode 8b may be described as welding power supply unit 2b.

[0067] In this embodiment, the control device 1 instructs each wire feeder 5 to start, stop, and set the feeding speed of the welding wire. The control device 1 also instructs the welding power supply devices 2a and 2b to output power. The setting unit 11 of the control device 1 sets the welding conditions for the welding power supply devices 2a and 2b.

[0068] In the flux consumption calculation unit 12 according to this embodiment, the current acquisition unit 121 acquires the current command value of the welding power supply unit 2a and the current command value of the welding power supply unit 2b set in the setting unit 11. The voltage acquisition unit 122 acquires the voltage command value of the welding power supply unit 2a and the voltage command value of the welding power supply unit 2b set in the setting unit 11. The time acquisition unit 123 acquires the welding time of the welding power supply unit 2a and the welding time of the welding power supply unit 2b.

[0069] The calculation unit 125 calculates the flux consumption due to welding at electrode 8a based on equation (3) above, according to the current command value, voltage command value, welding time, and coefficient K of the welding power supply unit 2a. The calculation unit 125 also calculates the flux consumption due to welding at electrode 8b based on equation (3) above, according to the current command value, voltage command value, welding time, and coefficient K of the welding power supply unit 2b. Then, the calculation unit 125 calculates the flux consumption due to welding at welding system A2 by adding the flux consumption due to welding at electrode 8a and the flux consumption due to welding at electrode 8b.

[0070] In this embodiment as well, the flux consumption calculation unit 12 calculates the flux consumption based on the current command value, voltage command value, and welding time. Therefore, the flux consumption calculation unit 12 can estimate the flux consumption for each weld. Furthermore, according to this embodiment, the flux consumption calculation unit 12 obtains a coefficient K corresponding to the flux type and calculates the flux consumption based on equation (3) above. Therefore, the flux consumption calculation unit 12 can easily estimate the flux consumption. Moreover, according to this embodiment, welding system A2 has the same configuration as welding system A1 and achieves the same effects as welding system A1.

[0071] In this embodiment, the case in which welding system A2 is equipped with two welding power supply units 2 and two electrodes 8 has been described, but it is not limited to this. Welding system A2 may be equipped with three or more welding power supply units 2 and three or more electrodes 8.

[0072] [Third Embodiment] Figure 5 is a diagram illustrating a welding system A3 according to the third embodiment. Figure 5 is a block diagram showing the internal configuration of the welding power supply unit 2 and the control device 1 of the welding system A3. In Figure 5, elements that are the same as or similar to those in the first embodiment are denoted by the same reference numerals as in the first embodiment. The welding system A3 according to this embodiment differs from the welding system A1 according to the first embodiment in that the flux consumption calculation unit 12 is included in the welding power supply unit 2.

[0073] In the welding system A3 according to this embodiment, the control device 1 does not have a flux consumption calculation unit 12, while the welding power supply device 2 has a flux consumption calculation unit 12. The welding power supply device 2 also has a display unit 29. The display unit 29 has the same configuration as the display unit 13 and displays various information. In this embodiment, the display unit 29 displays the flux consumption amount input from the flux consumption calculation unit 12 on the display device.

[0074] In this embodiment as well, the flux consumption calculation unit 12 calculates the flux consumption based on the current command value, voltage command value, and welding time. Therefore, the flux consumption calculation unit 12 can estimate the flux consumption for each weld. Furthermore, according to this embodiment, the flux consumption calculation unit 12 obtains a coefficient K corresponding to the flux type and calculates the flux consumption based on equation (3) above. Therefore, the flux consumption calculation unit 12 can easily estimate the flux consumption. Moreover, according to this embodiment, welding system A3 has the same configuration as welding system A1 and achieves the same effects as welding system A1.

[0075] [Fourth Embodiment] Figure 6 is a diagram illustrating the welding system A4 according to the fourth embodiment. Figure 6(a) is a block diagram showing the overall configuration of the welding system A4. Figure 6(b) is a block diagram showing the internal configuration of the welding power supply unit 2, the control device 1, and the management device 3. In Figure 6, elements that are the same as or similar to those in the first embodiment are denoted by the same reference numerals as in the first embodiment. The welding system A4 according to this embodiment differs from the welding system A1 according to the first embodiment in that the flux consumption calculation unit 12 is included in the management device 3.

[0076] The welding system A4 according to this embodiment further comprises a management device 3. The management device 3 is a device that manages a plurality of welding power supply devices 2. The management device 3 is implemented by installing a management program on a general-purpose computer (for example, a notebook computer, a desktop computer, or a tablet terminal). The management program is provided stored on a storage medium such as a USB memory stick. Alternatively, the management program may be downloaded from a server via a communication line. The management device 3 may also be a dedicated device with the management program pre-stored on the computer.

[0077] Numerous welding power supply units 2 are registered in the management device 3. The management device 3 manages the operating status and error occurrences of each welding power supply unit 2. The management device 3 also acquires, records, and displays various information about each welding power supply unit 2. In this embodiment, the management device 3 calculates and manages the flux consumption of each welding power supply unit 2. As a configuration for calculating and managing flux consumption, the management device 3 is equipped with a flux consumption calculation unit 12 and a display unit 31, as shown in Figure 6(b). The management device 3 has other components, but their illustration and description are omitted.

[0078] The flux consumption calculation unit 12 of the control device 3 has the same configuration as the flux consumption calculation unit 12 according to the first embodiment. In welding system A4, the control device 1 does not have a flux consumption calculation unit 12, while the welding power supply device 2 has a flux consumption calculation unit 12. The flux consumption calculation unit 12 of the control device 3 calculates the flux consumption for each welding power supply device 2 and manages it centrally.

[0079] The display unit 31 is configured to display various information and is equipped with a display device. The display device is, for example, a liquid crystal display. The display unit 31 displays the operating status of each welding power supply unit 2, the occurrence of errors, and various other information on the display device. The display unit 13 also displays the flux consumption of each welding power supply unit 2, which is input from the flux consumption calculation unit 12, on the display device.

[0080] In this embodiment as well, the flux consumption calculation unit 12 calculates the flux consumption based on the current command value, voltage command value, and welding time. Therefore, the flux consumption calculation unit 12 can estimate the flux consumption for each weld. Furthermore, according to this embodiment, the flux consumption calculation unit 12 obtains a coefficient K corresponding to the flux type and calculates the flux consumption based on equation (3) above. Therefore, the flux consumption calculation unit 12 can easily estimate the flux consumption. Moreover, according to this embodiment, welding system A4 has the same configuration as welding system A1 and achieves the same effects as welding system A1.

[0081] As can be seen from the third and fourth embodiments, the flux consumption calculation unit 12 may be included in any configuration of the welding system. Alternatively, the flux consumption calculation unit 12 may not be included in any other configuration and may be included in the welding system as an independent flux consumption calculation device.

[0082] The flux consumption calculation device and submerged arc welding system according to the present invention are not limited to the embodiments described above. The specific configuration of each part of the flux consumption calculation device and submerged arc welding system according to the present invention can be modified in various ways. [Explanation of Symbols]

[0083] A1, A11~A14, A2~A4: Welding system, 1: Control device, 12: Flux consumption calculation unit, 121: Current acquisition unit, 122: Voltage acquisition unit, 123: Time acquisition unit, 125: Calculation unit, 2, 2a, 2b: Welding power supply unit

Claims

1. A current acquisition unit that acquires a current value indicating the welding current, A voltage acquisition unit that acquires a voltage value indicating the welding voltage, A calculation unit that calculates the flux consumption per unit time based on the current value and the voltage value, It is equipped with Flux consumption calculation device.

2. It further includes a time acquisition unit for acquiring welding time, The calculation unit further calculates the flux consumption based on the welding time. The flux consumption calculation device according to claim 1.

3. The current acquisition unit acquires the current command value as the current value, The voltage acquisition unit acquires a voltage command value as the voltage value, The calculation unit calculates the flux consumption C based on the following equation (1), assuming that the current command value is I, the voltage command value is V, the welding time is T, and K is a coefficient that varies depending on the type of flux. The flux consumption calculation device according to claim 2. C=K・I・V・T... (1)

4. The current acquisition unit acquires the current command value as the current value, The voltage acquisition unit acquires a voltage command value as the voltage value, The calculation unit calculates the flux consumption C based on the following equation (2), using coefficients α, β, γ, and δ which differ depending on the type of flux, when the current command value is I, the voltage command value is V, and the welding time is T. The flux consumption calculation device according to claim 2. C=α・I+β・V+γ・T+δ... (2)

5. A welding power supply unit that provides electricity, A control device for controlling the welding power supply device, A flux consumption calculation device according to any one of claims 1 to 4, Equipped with, The flux consumption calculation device is included in the control device. Submerged arc welding system.

Images