铝合金正弦波调制脉冲MIG焊电流波形控制及专家系统研究
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摘要
迅猛发展的现代信息技术，促进数字化弧焊电源的控制系统越来越智能化，这是弧焊电源不断发展的必然趋势。由于现代焊接条件的不断复杂化和焊接工艺过程控制的发展进步，人们对焊机的控制功能及其专家数据库系统的要求也不断提高，特别是诸如铝合金类难焊材料的广泛应用，对焊机的控制性能要求更高、更特殊。
论文基于DSP和ARM数字化控制的电源设计思路，针对越来越广泛应用的铝合金类轻质材料难焊的特点，提出了正弦波调制脉冲MIG焊的新型电流波形控制方法，并据此研发铝合金的焊接过程控制及专家数据库系统，从而建立新型的智能化弧焊电源以满足轻质难焊材料更高更特殊的需求。
论文提出了新型的正弦波调制脉冲MIG焊的电流波形参数设计原理，系统地建立了具有普适性的正弦波调制脉冲焊参数计算的数学模型，使得焊接能量输入可有效地精确调控、脉冲变化过渡平稳，焊接过程稳定可靠。利用正弦波形所具有的无限阶导数连续性、永恒周期性、控制参数少等特点，为新型正弦波调制脉冲MIG焊过程中的参数精确匹配、一元化及其最优化等奠定了理论基础。试验选择纯铝板试件进行平板堆焊，结果表明：焊接过程中电流瞬时波形稳定清晰，相应的电压与焊接能量的瞬时波形均很稳定，U－I图重复性好，其边缘线族清晰、分布集中，说明焊接过程稳定性好，获得了美观优质的鱼鳞纹焊缝。
基于铝合金类轻质材料焊接的低能量输入等难点的要求，论文建立了正弦波调制脉冲MIG焊铝控制参数关系式，可实现焊接能量有效精确调节，试验验证了所建立的正弦波调制脉冲控制参数关系式的正确性和实用性，且易于获得稳定的高质量鱼鳞纹焊缝。试验表明：关系式中疏密系数m的数值范围在2～3时，正弦波调制脉冲焊接具有参数匹配范围宽，受焊接外部环境因素影响小等优点，为正弦波调制脉冲MIG焊过程的参数一元化开发奠定了理论基础。
论文建立了正弦波调制脉冲MIG焊铝正弦振幅参数的简化关系式，试验验证了所建参数简化关系式的正确性，且易于稳定获得理想的鱼鳞纹焊缝。该简化关系式中振幅系数k的取值范围在[15.0%，23.1%]时，正弦波调制脉冲MIG焊参数值匹配区间宽、要求低，稳定工作点区域大，受外部环境干扰小。
针对铝合金焊接稳定性、控制参数优化与鲁棒性等问题，特别是其薄板极易焊穿等难点，论文通过引入降能系数k t以及正弦波电流振幅系数kAI与时间振幅系数kAt等，分别建立了可以通用的单脉冲与对称正弦波调制脉冲MIG焊参数关系式，通过1mm薄板铝合金焊接试验验证了其可行性，经试验对比证实了正弦波调制脉冲MIG焊参数取值范围宽、鲁棒性好、易于操控并能稳定地获得理想的鱼鳞纹焊缝。
论文进一步引入时间振幅系数k At、电流振幅系数k AI和降能系数kt，以及强脉冲群降能系数k tq、弱脉冲群降能系数k tr和电流增强系数kI等，建立了非对称正弦波调制脉冲MIG焊和的双脉冲MIG焊的通用参数关系式，对1mm薄板铝合金进行了焊接试验，验证了其可行性。试验对比表明：双脉冲MIG焊方法可以参照非对称正弦波调制脉冲MIG焊方法选定参数，但后者更具优势。
经统一归纳，论文通过引入能量系数k t、振幅系数kA以及正弦波负半周中脉冲个数n，同时引入最大脉冲平均电流I a概念及最小焊接电流即维弧电流Im，建立了可以通用的正弦波调制脉冲MIG焊参数的数学模型，采用正交试验对其参数取值进行优化匹配，建立了基于数学建模的铝合金正弦波调制脉冲MIG焊专家数据库系统。通过铝合金焊接试验验证了正弦波调制脉冲MIG焊参数取值范围宽、鲁棒性好、易于操控等特点。为研发高性能数字化焊接设备及其专家数据库提供了新的理论和试验基础。
The rapid development of modern information technology advances the controlsystem of the digital arc welding power supply intelligent more and more, and it is aninevitable trend of the continuous development of the arc welding power source. Onaccount of the increasing complexity of modern welding conditions and the progressof welding process control, the requirements of control functions and the expertdatabase system of welding machines are also enhanced continually, in particular,materials to weld difficultly, such as aluminum alloy, are widely used, performancerequirements of welding machine control are higher and more specific.Based on the power supply design thought for DSP and ARM to control digitally, inallusion to characters of difficult welding of lightweight materials which are usedmore and more widly, such as aluminum alloy, this paper advanced a new typecurrent waveform control methodology of the sinusoid modulation pulse MIGwelding, and hereby developed the welding process control of aluminum alloy and itsexpert database system, in order to establish a new type of intelligent arc weldingpower supply to meet the higher and more specific requirement of difficult welding oflightweight materials.
This article advanced a new current waveform parameter design principle of thesinusoid modulation pulse MIG welding, and systematically established the universalmathematical model of the parameter computation of the sinusoid modulation pulse,making that the welding energy input can be effectively controlled and preciselyregulated, the transition of pulse change is smooth and the welding process is stableand reliable. With the characteristics of sinusoidal waveform, such as infinitederivative continuity, eternal periodicity and limited control parameters, this articleestablished the theoretical foundation for exactitude matching, unification andoptimization of the parameters in the new sinusoid modulation pulse MIG weldingprocess. Bead-on-plate overlay welding was carried out on the pure aluminum sheettest sample for the test. The result indicated that during the welding process, theinstantaneous current waveform is stable and clear, the instant waveforms of both thecorresponding voltage and the welding energy are very stable, the repeatability of theU-I graph is good and its family of lines is clear and its distribution is concentrated,showing that the welding process is stable and the neat and high quality ripple weld seam may be produced.
Based on the difficulties in welding of light material like aluminum alloy, such aslow energy supply and other requirements, this article established the controlparameter relationship formulas in sinusoid modulation pulse MIG welding aluminum,achieving that the welding energy can be regulated effectively and precisely. And theexperiments validated the correctness and practicability of the control parameterrelationship formulas established by using sinusoid modulation pulse, and that thestable and high quality fish scale welding seams were attained easily. Theexperiments indicated that while the change range of values of the density coefficientm in the relationship formula is from2to3, there are advantages such as widerparameters matching range and less interference from external welding environmentalfactors in sinusoid modulation pulse MIG welding, and it has set the theoreticalfoundation for the parameter unification exploitation in the sinusoid modulation pulseMIG welding process.
This article deduced the simplified formulas to describe the sinusoidal swingparameters in the aluminum welding with sinusoid modulation pulse MIG welding.Then, some experiments carried out validated the correctness of the formulas, andthat ideal fish-scale welding seams are easily and stably formed. Experimental resultsindicate, when k is in the duration of [15.0%,23.1%], the sinusoid modulation pulseMIG welding is of wide parameter matching range, low parameter requirement, largerstable working region and low sensitivity to external interference.On problems of the stability, control parameter optimization and robustness inaluminum alloy welding, especially on difficulties that aluminum alloy sheets is veryeasy perforation in welding process, by introducing the decrease energy coefficientk t, sinusoid current swing coefficient k AI and time swing coefficient k At, this articlerespectively established the universal relationship formulas of parameters in themonopulse MIG welding and the symmetry sinusoid modulation pulse MIG welding.And processing1mm aluminum alloy sheet welding tests respectively validated theirfeasibility. The test contrast validated that the sinusoid modulation pulse MIGwelding is of large welding parameter working confine, good robustness, easy controland steadily producing ideal ripple weld seams.
Furthermore, by introducing the time swing coefficient k At, current swing coefficientk AI and decrease energy coefficient k t, and decrease energy coefficient k tqin dense pulses, decrease energy coefficient k trin sparse pulses andcurrent increase coefficient k I, this article respectively established the universalrelationship formulas of parameters in the double-pulsed MIG welding and thedissymmetry sinusoid modulation pulse MIG welding. And processing1mmaluminum alloy sheet welding tests respectively validated their feasibility. The testcontrast validated that parameters of the double-pulsed MIG welding are chosereferring to parameters of the dissymmetry sinusoid modulation pulse MIG welding,but the dissymmetry sinusoid modulation pulse MIG welding is more advantage.
In summary, by introducing the energy coefficient k t, the swing coefficient k A, thepulse number n in per negative half periods of sinusoid, the most average I aof currentpulses and the least welding current (i.e. maintaining arc current) I m, this articleestablished the universal mathematical models of parameters in the sinusoidmodulation pulse MIG welding, and by using orthogonal test to optimize and matchthe parameters, built the expert database system in sinusoid modulation pulse MIGwelding based on the mathematical models. And processing aluminum alloy weldingtests validated validated the advantages of large welding parameter working confine,good robustness, easy control, etc. in the sinusoid modulation pulse MIG welding.And these provide a new theory and test foundation on developing of digital highperformance welding machines equipped the expert database.
论文基于DSP和ARM数字化控制的电源设计思路，针对越来越广泛应用的铝合金类轻质材料难焊的特点，提出了正弦波调制脉冲MIG焊的新型电流波形控制方法，并据此研发铝合金的焊接过程控制及专家数据库系统，从而建立新型的智能化弧焊电源以满足轻质难焊材料更高更特殊的需求。
论文提出了新型的正弦波调制脉冲MIG焊的电流波形参数设计原理，系统地建立了具有普适性的正弦波调制脉冲焊参数计算的数学模型，使得焊接能量输入可有效地精确调控、脉冲变化过渡平稳，焊接过程稳定可靠。利用正弦波形所具有的无限阶导数连续性、永恒周期性、控制参数少等特点，为新型正弦波调制脉冲MIG焊过程中的参数精确匹配、一元化及其最优化等奠定了理论基础。试验选择纯铝板试件进行平板堆焊，结果表明：焊接过程中电流瞬时波形稳定清晰，相应的电压与焊接能量的瞬时波形均很稳定，U－I图重复性好，其边缘线族清晰、分布集中，说明焊接过程稳定性好，获得了美观优质的鱼鳞纹焊缝。
基于铝合金类轻质材料焊接的低能量输入等难点的要求，论文建立了正弦波调制脉冲MIG焊铝控制参数关系式，可实现焊接能量有效精确调节，试验验证了所建立的正弦波调制脉冲控制参数关系式的正确性和实用性，且易于获得稳定的高质量鱼鳞纹焊缝。试验表明：关系式中疏密系数m的数值范围在2～3时，正弦波调制脉冲焊接具有参数匹配范围宽，受焊接外部环境因素影响小等优点，为正弦波调制脉冲MIG焊过程的参数一元化开发奠定了理论基础。
论文建立了正弦波调制脉冲MIG焊铝正弦振幅参数的简化关系式，试验验证了所建参数简化关系式的正确性，且易于稳定获得理想的鱼鳞纹焊缝。该简化关系式中振幅系数k的取值范围在[15.0%，23.1%]时，正弦波调制脉冲MIG焊参数值匹配区间宽、要求低，稳定工作点区域大，受外部环境干扰小。
针对铝合金焊接稳定性、控制参数优化与鲁棒性等问题，特别是其薄板极易焊穿等难点，论文通过引入降能系数k t以及正弦波电流振幅系数kAI与时间振幅系数kAt等，分别建立了可以通用的单脉冲与对称正弦波调制脉冲MIG焊参数关系式，通过1mm薄板铝合金焊接试验验证了其可行性，经试验对比证实了正弦波调制脉冲MIG焊参数取值范围宽、鲁棒性好、易于操控并能稳定地获得理想的鱼鳞纹焊缝。
论文进一步引入时间振幅系数k At、电流振幅系数k AI和降能系数kt，以及强脉冲群降能系数k tq、弱脉冲群降能系数k tr和电流增强系数kI等，建立了非对称正弦波调制脉冲MIG焊和的双脉冲MIG焊的通用参数关系式，对1mm薄板铝合金进行了焊接试验，验证了其可行性。试验对比表明：双脉冲MIG焊方法可以参照非对称正弦波调制脉冲MIG焊方法选定参数，但后者更具优势。
经统一归纳，论文通过引入能量系数k t、振幅系数kA以及正弦波负半周中脉冲个数n，同时引入最大脉冲平均电流I a概念及最小焊接电流即维弧电流Im，建立了可以通用的正弦波调制脉冲MIG焊参数的数学模型，采用正交试验对其参数取值进行优化匹配，建立了基于数学建模的铝合金正弦波调制脉冲MIG焊专家数据库系统。通过铝合金焊接试验验证了正弦波调制脉冲MIG焊参数取值范围宽、鲁棒性好、易于操控等特点。为研发高性能数字化焊接设备及其专家数据库提供了新的理论和试验基础。
The rapid development of modern information technology advances the controlsystem of the digital arc welding power supply intelligent more and more, and it is aninevitable trend of the continuous development of the arc welding power source. Onaccount of the increasing complexity of modern welding conditions and the progressof welding process control, the requirements of control functions and the expertdatabase system of welding machines are also enhanced continually, in particular,materials to weld difficultly, such as aluminum alloy, are widely used, performancerequirements of welding machine control are higher and more specific.Based on the power supply design thought for DSP and ARM to control digitally, inallusion to characters of difficult welding of lightweight materials which are usedmore and more widly, such as aluminum alloy, this paper advanced a new typecurrent waveform control methodology of the sinusoid modulation pulse MIGwelding, and hereby developed the welding process control of aluminum alloy and itsexpert database system, in order to establish a new type of intelligent arc weldingpower supply to meet the higher and more specific requirement of difficult welding oflightweight materials.
This article advanced a new current waveform parameter design principle of thesinusoid modulation pulse MIG welding, and systematically established the universalmathematical model of the parameter computation of the sinusoid modulation pulse,making that the welding energy input can be effectively controlled and preciselyregulated, the transition of pulse change is smooth and the welding process is stableand reliable. With the characteristics of sinusoidal waveform, such as infinitederivative continuity, eternal periodicity and limited control parameters, this articleestablished the theoretical foundation for exactitude matching, unification andoptimization of the parameters in the new sinusoid modulation pulse MIG weldingprocess. Bead-on-plate overlay welding was carried out on the pure aluminum sheettest sample for the test. The result indicated that during the welding process, theinstantaneous current waveform is stable and clear, the instant waveforms of both thecorresponding voltage and the welding energy are very stable, the repeatability of theU-I graph is good and its family of lines is clear and its distribution is concentrated,showing that the welding process is stable and the neat and high quality ripple weld seam may be produced.
Based on the difficulties in welding of light material like aluminum alloy, such aslow energy supply and other requirements, this article established the controlparameter relationship formulas in sinusoid modulation pulse MIG welding aluminum,achieving that the welding energy can be regulated effectively and precisely. And theexperiments validated the correctness and practicability of the control parameterrelationship formulas established by using sinusoid modulation pulse, and that thestable and high quality fish scale welding seams were attained easily. Theexperiments indicated that while the change range of values of the density coefficientm in the relationship formula is from2to3, there are advantages such as widerparameters matching range and less interference from external welding environmentalfactors in sinusoid modulation pulse MIG welding, and it has set the theoreticalfoundation for the parameter unification exploitation in the sinusoid modulation pulseMIG welding process.
This article deduced the simplified formulas to describe the sinusoidal swingparameters in the aluminum welding with sinusoid modulation pulse MIG welding.Then, some experiments carried out validated the correctness of the formulas, andthat ideal fish-scale welding seams are easily and stably formed. Experimental resultsindicate, when k is in the duration of [15.0%,23.1%], the sinusoid modulation pulseMIG welding is of wide parameter matching range, low parameter requirement, largerstable working region and low sensitivity to external interference.On problems of the stability, control parameter optimization and robustness inaluminum alloy welding, especially on difficulties that aluminum alloy sheets is veryeasy perforation in welding process, by introducing the decrease energy coefficientk t, sinusoid current swing coefficient k AI and time swing coefficient k At, this articlerespectively established the universal relationship formulas of parameters in themonopulse MIG welding and the symmetry sinusoid modulation pulse MIG welding.And processing1mm aluminum alloy sheet welding tests respectively validated theirfeasibility. The test contrast validated that the sinusoid modulation pulse MIGwelding is of large welding parameter working confine, good robustness, easy controland steadily producing ideal ripple weld seams.
Furthermore, by introducing the time swing coefficient k At, current swing coefficientk AI and decrease energy coefficient k t, and decrease energy coefficient k tqin dense pulses, decrease energy coefficient k trin sparse pulses andcurrent increase coefficient k I, this article respectively established the universalrelationship formulas of parameters in the double-pulsed MIG welding and thedissymmetry sinusoid modulation pulse MIG welding. And processing1mmaluminum alloy sheet welding tests respectively validated their feasibility. The testcontrast validated that parameters of the double-pulsed MIG welding are chosereferring to parameters of the dissymmetry sinusoid modulation pulse MIG welding,but the dissymmetry sinusoid modulation pulse MIG welding is more advantage.
In summary, by introducing the energy coefficient k t, the swing coefficient k A, thepulse number n in per negative half periods of sinusoid, the most average I aof currentpulses and the least welding current (i.e. maintaining arc current) I m, this articleestablished the universal mathematical models of parameters in the sinusoidmodulation pulse MIG welding, and by using orthogonal test to optimize and matchthe parameters, built the expert database system in sinusoid modulation pulse MIGwelding based on the mathematical models. And processing aluminum alloy weldingtests validated validated the advantages of large welding parameter working confine,good robustness, easy control, etc. in the sinusoid modulation pulse MIG welding.And these provide a new theory and test foundation on developing of digital highperformance welding machines equipped the expert database.
引文
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