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 modul...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.展开更多
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 comp...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.展开更多
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...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.展开更多
Bring forward a new analytical method in order to evaluate the stability of the process of aluminum alloy pulsed MIG welding. The ratio of the first and the second peak in arc voltage signal probability density was se...Bring forward a new analytical method in order to evaluate the stability of the process of aluminum alloy pulsed MIG welding. The ratio of the first and the second peak in arc voltage signal probability density was selected to evaluate aluminum alloy pulse MIG welding stability. By calculating the arc voltage signal probability density from 80 sets of welding experiments, the ratio of the two peaks in arc voltage probability in every set was captured. And the evaluation system of aluminum alloy pulse MIG welding stability was established. The smaller the ratio of peaks in arc voltage signal probability density is, the better the stability of the welding will be;the bigger the ratio of peaks in arc voltage signal probability density is, the poorer the stability of the welding will be.展开更多
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 d...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.展开更多
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 el...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.展开更多
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 freq...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.展开更多
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 ...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.展开更多
The objective of this investigation was to compare the fatigue properties of friction stir welds with those of MIG-pulse welds. The 5083 Al-Mg alloy was welded by single pass friction stir welding(FSW) and double-side...The objective of this investigation was to compare the fatigue properties of friction stir welds with those of MIG-pulse welds. The 5083 Al-Mg alloy was welded by single pass friction stir welding(FSW) and double-sided MIG-pulse welding. The results show that friction stir(FS) welds have a better appearance than MIG-pulse welds for the lack of voids, cracks and distortions. Compared with the parent plate, FSW welds exhibit similar fine grains, while MIG-pulse welds display a different cast microstructure due to the high heat input and the addition of welding wire. The S—N curves of FSW and MIG-pulse joints show that the fatigue life of FS welds is 1826 times longer than that of MIG-pulse welds under the stress ratio of 0.1 and the calculated fatigue characteristic values of each weld increase from 38.67MPa for MIG-pulse welds to 53.59MPa for FSW welds.展开更多
Arc welding robot is playing more and more important roles in modern welding manufacturing, but now available welding power sources seldom satisfy with robot system requirements. In this paper, study on fuzzy control ...Arc welding robot is playing more and more important roles in modern welding manufacturing, but now available welding power sources seldom satisfy with robot system requirements. In this paper, study on fuzzy control IGBT inverter arc welding power source for robot is developed to bring robotic advantages into full play. Firstly, fast response 500A IGBT inverter arc welding rectifier is developed. Secondly, fuzzy control system, which features multi-functions, fast response and wide using range, is developed and reliable measures for preventing interference are designed. Finally, technological experiments for carbon steel are made. The welding experimental results show that the goal of design is attained.展开更多
基金National Natural Science Foundation Project （50875088） Guangdong Province Science and Technology Research Project （2010B010700001）+1 种基金 Huangpu District Science and Technology Research Project （1021） Panyu District Science and Technology Research Project （2010-Z-22-1）.
文摘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.
基金This work was supported by the National High Technology Research and Development Program("863"Program) of China ( ContractNo 2007AA04Z258)
文摘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.
基金This work was supported by National Natural Science Foundation of China （No. 50875088） and Foundation h）r Distinguished Young Talents in Higher Education of Guaugdong （ No. LYM09099）.
文摘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.
文摘Bring forward a new analytical method in order to evaluate the stability of the process of aluminum alloy pulsed MIG welding. The ratio of the first and the second peak in arc voltage signal probability density was selected to evaluate aluminum alloy pulse MIG welding stability. By calculating the arc voltage signal probability density from 80 sets of welding experiments, the ratio of the two peaks in arc voltage probability in every set was captured. And the evaluation system of aluminum alloy pulse MIG welding stability was established. The smaller the ratio of peaks in arc voltage signal probability density is, the better the stability of the welding will be;the bigger the ratio of peaks in arc voltage signal probability density is, the poorer the stability of the welding will be.
基金This work was supported by National Natural Science Foundation of China （ No. 50875088） Natural Science Foundation of Guangdong Province, China （ No. 07006479）.
文摘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.
基金This project is supported by National Natural Science Foundation of China（59975068） and Science ＆ Technology Pillar Program of Tianjin（10ZCKFSF00200）.
文摘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.
基金This work was supported by the National Natural Science Foundation of China （Grant No. 51205136） , the Specialized Research Fund for the Doctoral Program of Higher Education of China （ Grant No. 20100172120003 ） and the Fundamental Research Funds for the Central Universities （Key Program） （ Grant No. 2013ZZ034）.
文摘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.
文摘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.
基金Project supported by China FSWCenter Beijing FSWTechnology Li mited Company , China
文摘The objective of this investigation was to compare the fatigue properties of friction stir welds with those of MIG-pulse welds. The 5083 Al-Mg alloy was welded by single pass friction stir welding(FSW) and double-sided MIG-pulse welding. The results show that friction stir(FS) welds have a better appearance than MIG-pulse welds for the lack of voids, cracks and distortions. Compared with the parent plate, FSW welds exhibit similar fine grains, while MIG-pulse welds display a different cast microstructure due to the high heat input and the addition of welding wire. The S—N curves of FSW and MIG-pulse joints show that the fatigue life of FS welds is 1826 times longer than that of MIG-pulse welds under the stress ratio of 0.1 and the calculated fatigue characteristic values of each weld increase from 38.67MPa for MIG-pulse welds to 53.59MPa for FSW welds.
文摘Arc welding robot is playing more and more important roles in modern welding manufacturing, but now available welding power sources seldom satisfy with robot system requirements. In this paper, study on fuzzy control IGBT inverter arc welding power source for robot is developed to bring robotic advantages into full play. Firstly, fast response 500A IGBT inverter arc welding rectifier is developed. Secondly, fuzzy control system, which features multi-functions, fast response and wide using range, is developed and reliable measures for preventing interference are designed. Finally, technological experiments for carbon steel are made. The welding experimental results show that the goal of design is attained.
