压电驱动GMAW短路过渡行为控制

肖珺; 王志浩; 陈树君; 盖胜男

doi:10.12073/j.hjxb.20220427001

压电驱动GMAW短路过渡行为控制

北京工业大学智能成形装备与系统研究所, 汽车结构部件先进制造技术教育部工程研究中心, 北京, 100124

基金项目: 国家自然科学基金面上项目(51975014，52275304)；北京市科技新星计划(20220484117)

详细信息

作者简介:
肖珺，教授，博士研究生导师；主要从事先进焊接方法与智能化焊接的研究；Emial: jun.xiao@bjut.edu.cn

通讯作者:
陈树君，教授，博士研究生导师；主要从事先进焊接方法、智能化焊接方面的研究；已发表论文200余篇；Email: sjchen@bjut.edu.cn

中图分类号: TG 444
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出版历程
- 收稿日期: 2022-04-26
- 网络出版日期: 2023-03-17
- 刊出日期: 2023-03-24

Piezo-driven short-circuiting metal transfer in GMAW

Insitute of Intelligent Forming System and Equipment, Engineering Research Center of Advanced Manufacturing Technology for Automotive Components, Ministry of Education, Beijing University of Technology, Beijing 100124, China

摘要

摘要: 文中提出了一种基于压电致动器的高动态焊丝启停控制技术，压电致动器膨胀锁止焊丝，收缩则释放焊丝. 在焊丝锁止−释放过程中，可以主动驱动熔滴与熔池短路，并利用这一动态过程产生的惯性力驱动短路液桥断裂完成一次熔滴过渡. 研究结果表明，组合压电致动器的加入对于小电流下GMAW短路过渡有显著的改善，短路开始和结束都稳定可控，避免了随机短路的发生，不再依赖大短路电流强制缩颈液桥，短路过渡频率显著提升，在DCEP 100 A焊接电流下可达130 Hz，DCEN模式下由于阴极斑点爬升导致电弧稳定性较差，但短路过渡频率也可达100 Hz.
- 熔化极电弧 /
- 压电致动 /
- 短路过渡 /
- 焊丝启停
Abstract: Gas metal arc welding (GMAW) is one of the most commonly used welding process. The strong coupling characteristics of its heat and mass transfer makes it difficult to produce stable droplet transfer under small current. This paper proposes a piezoelectric actuator based high dynamic wire lock-release control process, in which the piezoelectric actuator expands to lock the welding wire, and its contraction releases the wire. During the wire lock-release process, the droplet can be actively driven to short-circuit the molten pool, and the inertial force generated during this dynamic process can be used to actively neck and break the short-circuit liquid bridge. The research results show that the addition of the combined piezoelectric actuator can significantly improve the short-circuit transfer in GMAW under low current, and the start and end of the short-circuit are both stable and controllable, avoiding the occurrence of random short-circuits, and no longer relying on the rapid rising of short-circuit current to force the necking of the liquid bridge. The short-circuit transfer frequency is significantly improved, up to 130 Hz under DCEP 100 A welding current, and up to 100 Hz under DCEN mode.
- gas metal arc /
- piezo-actuating /
- short-circuiting transfer /
- wire lock-release control

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图 1 试验系统硬件图

Figure 1. Configuration of the experiment system

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图 2 压电驱动短路过渡原理示意图

Figure 2. Schematic diagram of piezo drive short-circuit transition principle

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图 3 40 Hz-10 ms压电驱动短路过渡

Figure 3. 40 Hz-10 ms piezo-driven short-circuit droplet transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) approaching weld pool; (e) short-circuiting and necking; (f) ending the transition

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图 4 60 Hz-10 ms压电驱动短路过渡

Figure 4. 60 Hz-10 ms piezo-driven short-circuit droplet transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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图 5 80 Hz-10 ms压电驱动短路过渡

Figure 5. 80 Hz-10 ms piezo-driven short-circuit droplet transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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图 6 100 Hz-7.5 ms压电驱动短路过渡

Figure 6. 100 Hz-7.5 ms piezo-driven short-circuit droplet transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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图 7 130 Hz-6.0 ms下压电驱动短路过渡

Figure 7. 130 Hz-6.0 ms piezo-driven short-circuit droplet transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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图 8 压电驱动40 Hz DCEN短路过渡

Figure 8. Piezo-driven 40 Hz DCEN short-circuit transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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图 9 压电驱动50 Hz DCEN短路过渡

Figure 9. Piezo-driven 50 Hz DCEN short-circuit. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition transfer

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图 10 压电驱动60 Hz DCEN短路过渡

Figure 10. Piezo-driven 60 Hz DCEN short-circuit transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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图 11 压电驱动100 Hz DCEN短路过渡

Figure 11. Piezo-driven 100 Hz DCEN short-circuit transfer. (a) initial stage; (b) starting locking; (c) releasing wire; (d) pushing the droplet; (e) contacting melting pool; (f) ending the transition

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表 1 压电驱动DCEP-GMA短路过渡试验参数

Table 1 Piezo-driven DCEP GMA short-circuit transfer experiment parameters

序号焊接电流I/A 压电频率f/Hz 锁止时间t/ms

1 100 40 10
2 100 50 10
3 100 60 10
4 100 70 10
5 100 80 10
6 100 100 7.5
7 100 110 7.0
8 100 120 6.5
9 100 130 6.0

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表 2 压电驱动DCEN-GMA短路过渡试验参数

Table 2 Piezo drive DCEN-GMA short-circuit transfer experiment parameters

序号焊接电压U/V 压电频率f/Hz 锁止时间t/ms

10 22 40 10
11 22 50 10
12 22 60 10
13 22 100 9.5

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