Research on sinusoid modulated pulse MIG welding methodology

This article proposed a new methodology and the principle of sinusoid modulated pulse MIG welding, and systematically established the universal mathematical model of computation of the parameters of the sinusoid modulation pulse, achieving that the welding energy input can be effectively controlled and precisely regulated, the transition of pulse change is smooth and the welding process is stable and reliable. With the characteristics of sinusoidal waveform, such as infinite derivative continuity, eternal periodicity and limited control parameters, this article established the theoretical foundation for choiceness, unification and optimization of the parameters during the new sinusoid modulated pulse MIG welding. Bead-on-plate overlay welding is carried out on the pure aluminum sheet test sample for the test. The result indicated that during the welding process, the real-time current waveform is stable and clear; both the corresponding voltage and the instant welding energy waveform are very stable; the repeatability of the U-I graph plotted is high; its family of lines is clear, neat, and its distribution is concentrated showing that the welding process is stable and the neat and high quality ripple weld seam may be produced.

Noise wavelet-suppressing on electric signals in meso-spray process of pulse MIG welding of aluminum

An analysis with Fourier series on electric signals of meso-spray process of pulse MIG welding of aluminum shows many harmonic waves of different frequency in the signals, including the inherent high, low frequency elementary waves of short circuit and the harmonic waves from pulse current besides the noise signals of high frequency. The wavelet filtering with adjustable threshold is applied to study and handle the electric signals from meso-spray process of pulse MIG welding of aluminum, displaying a good solution on suppressing the noise in the signals.

Intelligent process expert database of double pulse MIG welding of AI-Si alloy

Based on double pulse welding process characteristics, expert database structure and work flow are designed. Further, multiple outstanding specifications of 1.0 ram-diameter wire are obtained through a large number of experiments. By making non-linear regression analysis on these groups of standards, the relationship between average welding current and other pulse parameters can be found out. Polynomial regression equation is set up for further realization of＂ parameter estimation function of the expert database. Finally, the preliminary developed expert database is tested. The result indicates that the unified adjusting and parameters estimation of the expert database leads to stable welding process and good weld appearance.

Weld pool image sensor for pulsed MIG welding

Visual image sensor is developed to detect the weld pool images in pulsed MIG welding. An exposure controller, which is composed of the modules of the voltage transforming, the exposure parameters presetting, the complex programmable logic device （CPLD） based logic controlling, exposure signal processing, the arc state detecting, the mechanical iris driving and so on, is designed at first. Then, a visual image sensor consists of an ordinary CCD camera, optical system and exposure controller is established. The exposure synchronic control logic is described with very-high-speed integrated circuit hardware description language （VHDL） and programmed with CPLD , to detect weld pool images at the stage of base current in pulsed MIG welding. Finally, both bead on plate welding and V groove filled welding are carried out, clear and consistent weld pool images are acquired.

Analysis of droplet transfer of pulsed MIG welding based on electrical signal and high-speed photography

In order to study how welding parameters affect welding quality and droplet transfer, a synchronous acquisition and analysis system is established to acquire and analyze electrical signal and instantaneous images of droplet transfer simultaneously, which is based on a self-developed soft-switching inverter. On the one hand, welding current and voltage signals are acquired and analyzed by a self-developed dynamic wavelet analyzer. On the other hand, images are filtered and optimized after they are captured by high-speed camera. The results show that instantaneous waveforms and statistical data of electrical signal contribute to make an overall assessment of welding quality, and that optimized high-speed images allow a visual and clear observation of droplet transfer process. The analysis of both waveforms and images leads to a further research on droplet transfer mechanism and provides a basis for precise control of droplet transfer.

Digital control system for pulsed MIG welding power based on STM32

Digital control system for pulsed MIG welding power based on STM32 is set up with 32-bit STM32FlO3ZET6 directing against the pulse waveform modulation of pulsed MIG welding. High-frequency inverter and medium-low frequency pulse waveform modulation of pulsed MIG welding are realized by using the integrated PWM module within STM32 to generate PWM signals of phase-shifted full-bridge soft-switching and constant-current control of output current is achieved by means of anti-windup PI control algorithm to improve the stability and reliability of control system. Experimental results demonstrate that the designed digital control system based on STM32 can achieve pegrect pulsed MIG welding technique with stable welding process and good weld appearance, fully demonstrating the advantages of digital control based on STM32.

Correction factor based double model fuzzy logic control strategy of arc voltage in pulsed MIG welding

According to the feature of arc voltage control in welding steel using pulsed MIG welding, a correction factor based double model fuzzy logic controller (FLC) was developed to realize the arc voltage control by means of arc voltage feedback. When the error of peak arc voltage was great, a coarse adjusting fuzzy logic control rules with correction factor was designed, in the controller, the peak arc voltage was controlled by the wire feeding speed by means of arc voltage feedback. When the error of peak arc voltage was small, a fine adjusting fuzzy logic control rules with correction factor was designed, in this controller, the peak arc voltage was controlled by the background time by means of arc voltage feedback. The FLC was realized in a Look-Up Table (LUT) method. Experiments had been carried out aiming at implementing the control strategy to control the arc length change in welding process. Experimental results show that the controller proposed enables the consistency of arc length and the stability of arc voltage and welding process to be achieved in pulsed MIG welding process.