双丝旁路耦合电弧高效熔化极气体保护焊过程模拟及控制

Simulation and Control of Consumable DE-GMAW Process

采用等效电流路径的方法建立双丝旁路耦合电弧高效熔化极气体保护焊耦合电弧的动态数学模型,模拟表征焊接过程稳定性的电流、净干伸长信号的变化,得到与实际焊接过程相似的模拟结果。在此基础上,针对焊接过程中耦合电弧形态的剧烈变化会影响焊接过程稳定性与焊接质量的问题,提出通过调节旁路弧长控制耦合电弧稳定性的方案,并利用Matlab/Simulink软件和xPC-target快速原型控制平台,对控制方案进行模拟、分析、预测与试验。结果表明:所建立的数学动态模型能很好地反映双丝旁路耦合电弧高效GMAW焊接过程;模拟分析旁路弧长控制方案可以有效地解决焊接过程稳定性的问题;控制试验实现了焊接过程的稳定控制并获得了成形良好的焊缝形貌,验证了模拟阶段的分析与预测。

A mathematical model for consumable double-electrode gas metal arc welding（DE-GMAW） is established by using the equivalent path method and then the simulations about welding process are carried out which.During the simulation,aiming to the requirement of stably welding process,a control plan is proposed to control the stability of decoupling arc shape with the bypass wire extension as controlled object.Based on Matlab/Simulink and xPC-real-time target environment,the simulation,analysis,prediction and experiment about this control scheme are accomplished.The results show that mathematical model can reflect the process of consumable DE-GMAW well;Simulation and analysis can confirm the control scheme;the experiment can prove simulation results and obtain good weld formation on the basis of stable welding process.