单电源双丝旁路耦合电弧熔化极气体保护焊智能控制研究

Intelligent Control of Consumable DE-GMAW by Single Power Supply

提出单电源双丝旁路耦合电弧熔化极气体保护焊方法,采用特定的连接方法独立控制通过焊丝与基材的电流;引用逆向求解算法;搭建用来描述焊接过程中参数变化的数学模型。由于熔化母材的焊接电流易在主路电流和其他焊接条件变化时产生波动,提出利用改变旁路送丝速度调节旁路焊丝的熔化电流,实现控制母材电流的控制方案并进行仿真与试验。试验结果表明:单焊接电源的双丝旁路耦合电弧熔化极气体保护焊能够同时兼顾高熔敷率与基材低热输入的焊接;搭建的数学模型能够描述不同焊接参数的变化;利用提出的智能控制方案及算法,有效地解决了母材焊接电流易波动的问题,达到了焊接过程稳定性的控制,同时得到了成形良好的焊缝.

In order to simplify the equipment, a new type of consumable double-electrode gas metal arc welding (double-electrode gas metal arc welding, DE?GMAW) with single power supply is proposed. The welding current and the base metal current are controlled by a specific connection method independently. A new solving algorithm is put forward and a mathematical model describing the welding process is established. Aiming to the base metal current will be affected by the main current fluctuation or other conditions and cause weld defects, a closed-loop control scheme to adjust the bypass wire feeding speed is put forward. Fuzzy self-adaptive PID is used to simulate the experiment. Based on the simulation results, the intelligent control experiment is carried out based on the built xPC rapid prototyping platform. The experimental results show that high melting efficiency and low heat-input are acquired;arc voltage and welding current could image and directly describe by mathematical model;the base metal current can be controlled stably and a good weld performance is obtained.