CN-120920861-B - GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing

Abstract

The invention relates to the field of aluminum alloy narrow gap welding, in particular to a GMAW-GTAW composite aluminum alloy narrow gap welding system and method based on arc sensing. Aiming at the problems of incomplete fusion of side walls and the like in the narrow-gap welding of aluminum alloy, a GMAW-GTAW composite aluminum alloy narrow-gap welding system and a method are provided. The method comprises the steps of controlling a wire filling position by using a GMAW-GTAW composite aluminum alloy narrow gap welding wire filling position control method based on arc sensing, controlling a double-gun swing amplitude by using a GMAW-GTAW composite aluminum alloy narrow gap welding swing amplitude control method based on arc sensing, and controlling a double-gun position relationship by using a GMAW-GTAW composite aluminum alloy narrow gap welding double-gun position relationship control method based on arc sensing.

Inventors

• JIA AITING
• MA YINGTAO
• YU JINGYI
• YIN LI
• LI YI
• LI XIANGWEN
• LI CHENGBO

Assignees

• 湘潭大学

Dates

Publication Date

20260508

Application Date

20250901

Claims (5)

1. 1. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is used for GMAW-GTAW composite aluminum alloy narrow gap welding and is characterized by comprising a sliding table system, a double-welding-gun adjustable torque ratio sliding rail system, a GMAW welding gun adjusting mechanism, a GTAW welding gun adjusting mechanism, a welding power supply system, a welding wire system, an arc signal acquisition system and a communication and control system, wherein the sliding table system consists of an X-direction guide rail, a Y-direction guide rail and a Z-direction guide rail, and the double-welding-gun adjustable torque ratio sliding rail system consists of a suspension arm, a suspension arm and a welding gun, the welding wire system comprises a boom rotating sliding block and an adjustable moment ratio sliding rail, wherein the upper part of the adjustable moment ratio sliding rail comprises a boom installation position, the lower part of the adjustable moment ratio sliding rail comprises a GTAW wire feeding mechanism installation position, a GTAW welding gun adjustment mechanism installation position and a GMAW welding gun adjustment mechanism installation position, the GTAW welding gun adjustment mechanism comprises a GTAW rotating sliding rail, a GTAW telescopic sliding block, a GTAW rotating arm, a GTAW rotating joint and a GTAW welding gun, the GMAW welding gun adjustment mechanism comprises a GMAW rotating sliding rail, a GMAW telescopic sliding rail, a GMAW rotating arm, a GMAW welding gun rotating joint and a GMAW welding gun, the welding power supply system comprises an alternating current GTAW welding power supply and a direct current GMAW welding power supply, and the welding wire system comprises a GMAW wire feeding machine, The electric arc signal acquisition system is used for acquiring a GTAW welding gun tungsten electrode end electric arc signal and a GMAW welding current signal, the communication and control system is composed of an electric control cabinet and a control cabinet, the electric control cabinet is used for distributing and converting an external power supply, supplying power to each part and guaranteeing electric safety, and the control cabinet precisely controls welding process parameters through PLC and the like, The communication and control system realizes the displacement of a double-welding gun adjustable moment ratio sliding rail system, a GMAW welding gun adjusting mechanism, a GTAW welding gun adjusting mechanism and a GTAW wire feeding mechanism in the X, Y Z direction by controlling the sliding table system, the communication and control system realizes the movement of the GMAW welding gun adjusting mechanism, the GTAW welding gun adjusting mechanism and the GTAW wire feeding mechanism on a sliding rail by the double-welding gun adjustable moment ratio sliding rail system, the GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing controls the double-gun position relation by a double-gun position relation control method of the GMAW-GTAW composite aluminum alloy narrow gap welding based on arc sensing, and the method comprises a path difference S control method of the GMAW welding gun and the GTAW welding gun on a welding line, the self-adaptive welding seam slope method comprises the steps of firstly welding a GTAW welding gun, recognizing a welding seam, preheating a side wall, waiting for a set time, then welding, when a broken line welding seam is entered, adjusting the moment ratio between the GTAW welding gun and the GMAW welding gun in real time through an adjustable moment ratio sliding rail, enabling the two welding guns to obtain proper split speeds respectively in the direction perpendicular to the adjustable moment ratio sliding rail and the adjustable moment ratio sliding rail direction so as to keep the combined speed on the welding seam unchanged, and controlling the path difference of the two welding guns.
2. 2. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing as claimed in claim 1, wherein one end of the suspension arm is arranged on a Z-direction guide rail of the sliding table system to realize X, Y displacement in the Z direction; the adjustable welding gun type welding gun is characterized in that one end of the boom rotating slide block is arranged above an adjustable moment ratio slide rail and can move along the adjustable moment ratio slide rail, the other end of the boom rotating slide block is connected with a shaft seat at the other end of the boom, the adjustable moment ratio slide rail can rotate 360 degrees around the Z direction, the GTAW wire feeding telescopic slide rail is arranged below the adjustable moment ratio slide rail and can move along the adjustable moment ratio slide rail, the GTAW wire feeding telescopic slide block is nested inside the GTAW wire feeding telescopic slide rail and can move along the Z direction, the 5-shaft adjusting mechanism is arranged below the GTAW wire feeding telescopic slide block and can rotate 360 degrees around the Z direction, the GTAW wire feeding pipe is fixed at the tail end of the 5-th shaft and can rotate 180 degrees, the GTAW rotating slide rail is arranged below the adjustable moment ratio slide rail and can rotate 360 degrees around the Z direction, the GTAW wire telescopic slide rail is arranged on the rotating slide rail and can move along the GTAW rotating slide rail, the GTAW wire feeding telescopic slide rail is nested inside the GTAW telescopic slide rail, the GTAW telescopic slide rail can move along the GTAW telescopic slide rail is arranged inside the GTAW telescopic slide rail, the GTAW telescopic slide rail is rotatably connected with the other end of the GTAW telescopic slide rail and can move along the Z direction, the GTAW joint is fixed at the end of the 5-th shaft seat, the GTAW telescopic slide seat can rotate about the GTAW telescopic slide rail and can rotate 180 degrees, the GTAW telescopic slide rail is connected with the GTAW telescopic slide rail and can rotate along the GTAW telescopic slide rail, the GTAW telescopic slide rail and can move along the one end, and can rotate along the axis, and the GTAX telescopic slide rail, the automatic welding machine comprises a GMAW rotating arm, a GMAW welding gun rotating joint, a GTAW wire feeding mechanism, a GTAW welding gun adjusting mechanism and a GMAW welding gun adjusting mechanism, wherein the GMAW rotating arm is fixedly connected with the GMAW telescopic sliding block, the other end shaft seat is connected with the GMAW welding gun rotating joint, the GMAW welding gun is fixedly connected with the GMAW welding gun rotating joint and can rotate 180 degrees, a GMAW built-in wire feeding pipe is installed in the GMAW welding gun and can simultaneously feed wires, the GTAW wire feeding mechanism, the GTAW welding gun adjusting mechanism and the GMAW welding gun adjusting mechanism are installed below an adjustable moment ratio sliding rail in sequence, and the GTAW and the GMAW welding gun adjusting mechanism respectively and independently move.
3. 3. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing as claimed in claim 1, wherein the wire filling position in the GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is controlled by a GMAW-GTAW composite aluminum alloy narrow gap welding wire filling position control method based on arc sensing, and the GMAW-GTAW composite wire filling position control method based on arc sensing is used for adjusting a GTAW wire feeding mechanism by an arc signal acquisition system and a communication and control system, The GTAW welding gun adjusting mechanism and the GMAW welding gun adjusting mechanism are used for controlling the wire filling position; after welding starts, the GTAW welding gun adjusting mechanism starts an arc firstly, after the arc starting is successful, the communication and control system lifts the GTAW welding gun to a designated height H 0 through a tungsten electrode end arc voltage U collected by an arc signal collecting system, the tungsten electrode end arc length of the height H 0 is L 1 , after the voltage is stabilized at U 0 , the GTAW welding gun advances along the welding direction and swings leftwards, when the tungsten electrode approaches to the P 1 position on one side of the side wall, the GTAW welding gun swings rightwards when the U is reduced to U 1 by the U 0 by the side wall, the U is increased to U 0 by the U 1 , when the U is reduced to the P 2 position on the other side wall by the U 0 as an initial welding line, the GTAW welding gun starts to move along the initial welding line direction and swings leftwards and rightwards, the tungsten electrode end arc voltage U, namely the voltage between the tungsten electrode end and a workpiece is positively related to the arc length L, the height H is the distance between the tungsten electrode end and the workpiece, the position P 1 、P 2 is separated from the side wall by one section, the distance D is not formed by the end to the side wall, the end is directly contacted with the end of the GTAW welding gun, the two end is not in accordance with the AW welding line, the distance between the two side wall is adjusted, the end is not directly reached to the end welding line, and the AW welding line is adjusted to the end is the end, and the end is directly reaches the end welding line, and the end is adjusted to the end, and the end is a welding line is divided to the end The adjustable moment of the double welding gun is turned over by the sliding rail system, welding is carried out along a broken line welding seam, the wire filling position of the GTAW wire feeding mechanism, namely the midpoint of a track connecting line from one side of the side wall to the other side, is set up to be in opposite phase with the GTAW welding gun according to the simple harmonic waveform track of the GTAW welding gun in front of the welding direction, and welding is carried out.
4. 4. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing according to claim 1, wherein the double-gun swing amplitude in the GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is controlled by a GMAW-GTAW composite aluminum alloy narrow gap welding double-gun swing amplitude control method based on arc sensing; the GMAW-GTAW composite aluminum alloy narrow gap welding swing amplitude control method based on arc sensing realizes the identification of a side wall and the control of the minimum distance between a GTAW welding gun and the side wall, wherein the minimum distance between the GTAW welding gun and the side wall is the speed of the GTAW welding gun swinging, the minimum distance between the GTAW welding gun and the side wall is controlled to be at the minimum distance D 1 = 2mm and the stay T3 = 0.5s corresponding to the minimum distance between the GTAW welding gun and the side wall through an arc signal acquisition system and a communication and control system in the tungsten electrode end voltage in U 1 , the position of a tungsten electrode is the side wall position whenever K is more than K 1 , the time T n at the moment is recorded, the narrow gap groove width D 0 =V 0 ·（T n+1 -T n ) is more than 1 and n epsilon Z, the minimum distance between the GTAW welding gun and the side wall is controlled to be the minimum distance between the GTAW welding gun and the side wall in the left and right, the minimum distance between the GTAW welding gun and the side wall is controlled to be more than the minimum distance between the GTAW welding gun and the side wall is controlled to be at the minimum distance between the GTAW welding gun and the side wall in the minimum distance of 35 = 2mm, the minimum distance between the GTAW welding gun and the side wall is controlled to be more than 0.5s, the minimum distance between the GTAW welding gun and the side wall is controlled to be more than 180 mm, and the minimum distance between the GTAW welding gun and the side wall is controlled to be compared with the minimum between the welding gun and the side wall is sufficient to be compared, symmetrically crossing along the weld.
5. 5. The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing as claimed in claim 1, wherein the control method of the path difference S of the GMAW welding gun and the GTAW welding gun on the welding line is characterized in that the path difference S of the two welding guns on the welding line is controlled by a GMAW welding gun adjusting mechanism, a GTAW wire feeding mechanism, a sliding table system and a double welding gun adjustable moment ratio sliding rail system, and after the welding is started, the GTAW welding gun adjusting mechanism, The GTAW wire feeding mechanism firstly carries out synchronous motion on a welding line according to a welding speed V 1 , identifies the side wall position and the welding line position to carry out swing welding, and carries out preheating on the side wall, the GMAW welding gun adjusting mechanism carries out anti-phase swing welding of a welding speed V 2 on the welding line according to a motion track of the GTAW welding gun adjusting mechanism after waiting for T 2 time, the waiting time T 2 =S 0 /V 1 ,S 0 is an initial path difference set between two welding guns and is set according to the proportion of GMAW-GTAW and the heat input, and the GMAW welding gun adjusting mechanism, When the GMAW welding gun adjusting mechanism and the GTAW welding gun adjusting mechanism enter a broken line welding seam, V 1 、V 2 which is respectively kept on the welding seam through a sliding table system and a double welding gun adjustable moment ratio sliding rail system is unchanged, a boom rotating sliding block above the adjustable moment ratio sliding rail changes the distance between the GMAW welding gun adjusting mechanism and the GTAW welding gun adjusting mechanism to dynamically adjust the moment ratio K 2 of the two, a rotating shaft at one end of the boom enables the adjustable moment ratio sliding rail to rotate around the boom rotating sliding block by an angle beta, and the GTAW welding gun adjusting mechanism, the GMAW welding gun adjusting mechanism is respectively provided with opposite partial speeds V 11 =sinβ·V 1 、V 21 =sin(θ-β)·V 2 in the direction perpendicular to the adjustable moment ratio sliding rail, and respectively adjusts the GTAW welding gun adjusting mechanism, The split speed V 12 =cosβ·V 1 、V 22 =(θ-β)·V 2 of the GMAW welding gun adjusting mechanism in the adjustable moment ratio slide rail direction ensures that the combined speed V 1 、V 2 of the two welding guns on the welding line is kept unchanged according to the set parameters, and can enter the broken line welding line at an angle theta; the torque ratio K 2 =V 11 /V 21 is that theta is an included angle of a broken line welding seam, beta is that an included angle of an adjustable torque ratio sliding rail and the broken line welding seam is obtained by tracking the welding seam based on arc sensing by a GTAW welding gun adjusting mechanism, beta is more than or equal to 0 and less than or equal to theta, and beta is reduced to 0 from theta, namely, the process from the GTAW welding gun entering the broken line welding seam to the GMAW welding gun also entering the broken line welding seam, and the self-adaptive welding seam slope method is that the self-adaptive welding seam slope method is implemented through the GMAW welding gun adjusting mechanism, GTAW welding gun adjusting mechanism, GTAW wire feeding mechanism, The welding method comprises the steps of realizing an arc signal acquisition system and a communication and control system, wherein when a GTAW welding gun is used for welding between side walls, the GTAW welding gun is influenced by the welding slope of an undelivered welding seam, the arc length L between a tungsten electrode end and a workpiece is changed, the arc voltage U between the tungsten electrode end and the workpiece fluctuates up and down at U 0 , the heights of the GTAW welding gun and a GTAW wire feeding pipe are raised when U is less than or equal to U 0 , the heights of the GTAW welding gun and the GTAW wire feeding pipe are lowered when U is more than or equal to U 0 so as to enable L to be stabilized at L 1 , when the GMAW welding gun is used for welding between the side walls, the arc length L between the GMAW welding wire and the workpiece is changed under the influence of the welding slope of the welded welding seam, the welding current I fluctuates up and down at I 0 , the GMAW welding gun height is lowered when I is less than or equal to I 0 , the GMAW welding gun height is raised when I is more than or equal to I 0 so as to enable L to be stabilized at L 2 , the welding current corresponding to the setting arc length L 1 of the GTAW welding gun is used for the welding current corresponding to the W welding length L 0 .

Description

GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing Technical Field The invention relates to the field of aluminum alloy narrow gap welding, in particular to a GMAW-GTAW composite aluminum alloy narrow gap welding system and method based on arc sensing. Background In recent years, with the continuous improvement of requirements of light weight and high strength of high-end equipment, narrow-gap welding has the advantages of low heat input, high welding efficiency, small shrinkage deformation of welding seams and the like, and becomes an important process for thick-wall aluminum alloy connection. However, problems such as poor sidewall fusion during narrow gap welding present a serious challenge to the automated regulatory capability of the welding system. The GTAW-GMAW composite welding technology provides a reliable method for aluminum alloy narrow-gap welding by virtue of the synergistic advantages of low heat input of GTAW (non-consumable electrode gas-shielded arc welding), excellent weld formation and high cladding efficiency and strong deep melting capability of GMAW (consumable electrode gas-shielded arc welding). The invention discloses a GMAW-GTAW composite aluminum alloy narrow-gap welding system based on arc sensing, which realizes the functions of double-gun independent movement, seam tracking, full fusion of side walls, welding fold line seam, self-adaptive seam slope and the like by controlling welding wires, welding guns and electric arcs in the welding process, and finally improves the quality of aluminum alloy narrow-gap welding. Disclosure of Invention The GMAW-GTAW composite aluminum alloy narrow gap welding system based on arc sensing is used for GMAW-GTAW composite aluminum alloy narrow gap welding and is characterized by comprising a sliding table system, a double-welding-gun adjustable moment ratio sliding rail system, a GMAW welding gun adjusting mechanism, a GTAW welding gun adjusting mechanism, a welding power supply system, a welding wire system, an arc signal acquisition system and a communication and control system; the sliding table system consists of an X-direction guide rail, a Y-direction guide rail and a Z-direction guide rail; the double-welding gun adjustable moment ratio sliding rail system consists of a suspension arm, a suspension arm rotating sliding block and an adjustable moment ratio sliding rail; the adjustable moment ratio sliding rail comprises a boom mounting position above the adjustable moment ratio sliding rail, a GTAW wire feeding mechanism mounting position, a GTAW welding gun adjusting mechanism mounting position and a GMAW welding gun adjusting mechanism mounting position below the adjustable moment ratio sliding rail, wherein the GTAW welding gun adjusting mechanism comprises a GTAW rotating sliding rail, a GTAW telescopic sliding block, a GTAW rotating arm, a GTAW welding gun rotating joint and a GTAW welding gun, the GMAW welding gun adjusting mechanism comprises a GMAW rotating sliding rail, a GMAW telescopic sliding block, a GMAW rotating arm, a GMAW rotating joint and a GMAW welding gun, the welding power supply system comprises an alternating current GTAW welding power supply and a direct current GMAW welding power supply, the welding wire system comprises a GTAW wire feeding machine, a GMAW built-in wire feeding pipe, a GTAW wire feeding machine and a GTAW wire feeding mechanism, the GTAW wire feeding telescopic sliding rail, a 5-axis adjusting mechanism and a GTAW wire feeding pipe, the electric arc signal acquisition system comprises a Hall voltage sensor, a Hall current sensor and a data card, and the electric arc signal acquisition system is used for acquiring an electric arc signal of the GTAW signal end, and the electric arc signal acquisition system comprises the electric arc signal acquisition system and the electric arc signal acquisition system The electric control cabinet is used for distributing and converting an external power supply, supplying power to all parts and guaranteeing electric safety, the control cabinet precisely controls welding process parameters, coordinates welding time sequence and links all mechanism parts through a PLC and the like, a data interaction channel is established between the electric arc signal acquisition system and the communication and control system through a communication bus to realize acquisition of the electric arc signal acquisition system, the communication and control system realizes displacement of the whole of the double-welding-gun adjustable torque ratio sliding rail system, the GMAW welding gun adjusting mechanism, the GTAW welding gun adjusting mechanism and the GTAW wire feeding mechanism in X, Y and Z directions through a control sliding table system, and the communication and control system realizes movement of the GMAW welding gun adjusting mechanism, the GTAW welding gun adjusting mechanism and the GTAW wire feeding mechanism on the sliding rail throug