CN-122007554-A - Low-energy consumption welding power supply self-adaptive regulation and control method and system based on full-period sensing of welding process

CN122007554ACN 122007554 ACN122007554 ACN 122007554ACN-122007554-A

Abstract

The invention discloses a low-energy consumption welding power supply self-adaptive regulation and control method and system based on full-period perception in a welding process, and relates to the technical field of power supply regulation and control, wherein the method comprises the steps of obtaining material characteristics, process characteristics, weld characteristics and joint characteristics, and calculating a total energy consumption theoretical value Q predicted ; dividing Q predicted into four stages of energy consumption target values, respectively preparing energy consumption regulation strategies, completing arc striking in 0.3s, comparing real-time accumulated energy consumption with the stage of energy consumption target values according to the progress, then adjusting dynamic power according to the current welding speed and the molten pool center temperature value measured by an infrared thermometer in real time, completing arc striking in 0.5s, reducing current slope, waiting for dormancy, and evaluating energy saving effect after welding. The invention greatly reduces the energy consumption of the power supply by carrying out sectional dynamic adjustment on the whole period.

Inventors

CHEN KELE
LI QINGHUA
AI KEHUA
ZHANG RENJUN

Assignees

四川英创力电子科技股份有限公司

Dates

Publication Date: 20260512
Application Date: 20260403

Claims (10)

1. A low-energy consumption welding power supply self-adaptive regulation and control method based on full-period sensing in a welding process is characterized by comprising the following steps: S1, acquiring material characteristics, process characteristics, weld characteristics and joint characteristics, respectively acquiring basic energy consumption Q base , a process coefficient K process , a weld formula L weld ×(1+α×N layer ) and a joint complexity coefficient K joint according to the four characteristics, and then calculating a total energy consumption theoretical value Q predicted ; Q predicted =Q base ×K joint ×K process ×L weld ×(1+α×N layer ) Q base =H req ×A weld /η H req =ρ×(c×ΔT req +L m ) A weld = (plate thickness-blunt edge) 2 ×tan (bevel angle/2) +root gap×plate thickness H req is the energy required for melting a unit volume of material, A weld is the cross-sectional area of a welding seam, eta is the thermal efficiency coefficient, rho is the density of the material, c is the specific heat capacity, deltaT req is the temperature difference from room temperature to the melting point, L m is the latent heat of melting, L weld is the length of the welding seam, alpha is the increment coefficient of welding energy consumption of 0.15-0.25, and N layer is the number of welding layers; S2, dividing the welding process into four stages of arc striking, arc stabilizing, arc receiving and standby, dividing the total energy consumption theoretical value Q predicted into energy consumption target values of the four stages, and respectively preparing energy consumption regulation strategies; The arc striking stage is that the arc striking is completed within 0.3s, and the peak power is less than or equal to 1.5 times of rated power; An arc stabilizing stage, namely comparing the real-time accumulated energy consumption with an energy consumption target value in the stage according to the progress, and then adjusting the dynamic power according to the current welding speed and a molten pool center temperature value measured in real time by an infrared thermometer; The arc-receiving stage is that the arc-receiving is completed within 0.5s, and the current is declined in a slope manner; A standby stage, namely dormancy; And S3, after welding is completed, calculating the ratio of the actual total energy consumption to the total energy consumption theoretical value, and taking the ratio as an evaluation index of the energy saving effect.
2. The method for adaptively controlling a low-energy welding power supply based on full cycle sensing of a welding process according to claim 1, wherein in the step S1, the material characteristics include a material type and a plate thickness, and the material type includes a material name, a material density, a specific heat capacity, a melting point and a latent heat of fusion.
3. The self-adaptive regulation and control method for the low-energy welding power supply based on full cycle perception of the welding process according to claim 1, wherein in the step S1, the process characteristics comprise a welding method, shielding gas and welding wire diameter, the welding method comprises one of submerged arc welding SAW, consumable electrode gas shielded welding GMAW, pulse consumable electrode gas shielded welding GMAW-P and tungsten inert gas welding GTAW, the shielding gas is pure CO 2 or Ar+CO 2 mixed gas, and the process coefficients K process of the submerged arc welding SAW, consumable electrode gas shielded welding GMAW, pulse consumable electrode gas shielded welding W-P and tungsten inert gas welding GTAW are respectively 0.8, 1.0, 0.9 and 1.4, and the thermal efficiency eta is respectively 0.9-0.99, 0.7-0.85, 0.75-0.90 and 0.5-0.7.
4. The method for adaptively controlling a low-energy welding power supply based on full-cycle sensing of a welding process according to claim 1, wherein in the step S1, the weld characteristics include a weld length, a weld position, and a number of layers, and the weld position includes one of flat welding, vertical welding, and horizontal welding.
5. The method for adaptively controlling a low-energy consumption welding power supply based on full cycle sensing of a welding process according to claim 1, wherein in the step S1, the joint characteristics include a joint form, a bevel angle, a root gap, and a blunt edge, the joint form includes one of butt joint, angle joint, and lap joint, and joint complexity coefficients K joint of the butt joint, the angle joint, and the lap joint are 1.0, 1.2, and 1.3, respectively.
6. The method for adaptively controlling a low-energy consumption welding power supply based on full-cycle sensing of a welding process according to claim 1, wherein in step S1, the joint form of the material characteristic, the process characteristic, the weld characteristic and the joint characteristic is obtained by reading work order information, and the bevel angle, the root gap and the blunt edge in the joint characteristic are obtained by a visual sensor.
7. The adaptive regulation and control method of a low-energy consumption welding power supply based on full-cycle sensing of a welding process according to claim 1, wherein in the step S2, the target energy consumption values in four stages of arc striking, arc stabilizing, arc receiving and standby are 3%, 85%, 5% and 7%, respectively.
8. The adaptive regulation and control method of a welding power supply with low energy consumption based on full cycle perception of a welding process according to claim 1, wherein the arc stabilization stage in step S2 has a dynamic power P stable formula: P stable =P nominal ×(1+β×（T measured -T target ）/T target ) P nominal =Q base ×K joint ×K process ×v×(1+α×N layer ) T target = material melting point +50 ℃ -150 °c P nominal is the theoretical power of the current welding task, beta is the temperature compensation coefficient 0.1-0.3, T measured is the center temperature of the molten pool measured by the infrared thermometer in real time, T target is the theoretical temperature of the molten pool, and v is the current welding speed.
9. The adaptive regulation and control method for a low-energy welding power supply based on full-cycle sensing of a welding process according to claim 1, wherein the arc-receiving stage in step S2 has a dynamic current I end formula: I end =I start ×(1-t/t ramp ) And the current when the arc starts to be received by the I start , t is the time from the beginning of arc receiving to the current time, t ramp is the total duration of arc receiving, and t ramp is less than 0.5s.
10. A low energy consumption welding power supply adaptive regulation and control system based on full cycle perception of a welding process, characterized in that it is used to implement the regulation and control method of any one of claims 1-9, the regulation and control system comprising: The welding task feature recognition module is used for completing comprehensive perception of a welding task and energy consumption demand prediction before welding begins; the full-period energy consumption dynamic regulation and control module is used for implementing refined energy consumption regulation and control on four key stages of arc striking, arc stabilizing, arc receiving and standby in the welding process; The control module is used for converting the regulation and control instruction of the upper module into a specific power supply control signal and monitoring the execution state in real time; the energy-saving effect evaluation module is used for quantitatively evaluating the energy consumption performance of the welding after the welding is completed; the knowledge base module is used for accumulating historical welding data and realizing continuous optimization of process parameters; And the standby dormancy module is used for managing the energy consumption of the welding power supply in a non-welding period.

Description

Low-energy consumption welding power supply self-adaptive regulation and control method and system based on full-period sensing of welding process Technical Field The invention relates to the technical field of power supply regulation and control, in particular to a low-energy consumption welding power supply self-adaptive regulation and control method and system based on full-period sensing in a welding process. Background The welding power source serves as a core energy supply unit for the welding system, the energy consumption level of which directly influences the degree of greenness of the manufacturing process. The energy saving and consumption reduction of welding equipment has become the necessary trend of industry development. However, the current welding power supply energy consumption control technology still has the following core problems: (1) The energy consumption optimization is limited to a single link, and lacks of full-period regulation and control The existing welding power supply energy-saving technology focuses on the optimization of specific links, focuses on the power supply stability, and does not establish a dynamic energy consumption regulation mechanism of the whole period of the welding process. (2) Welding task feature recognition and energy consumption prediction capability are weak The different welding tasks (material type, sheet thickness, joint form, weld length) differ significantly from the energy consumption requirements. The existing system mostly adopts fixed power output or simple parameter adjustment, and lacks energy consumption demand prediction and front-end optimization capability based on welding task feature recognition. (3) Adaptive optimization driven by a process knowledge base has not been established yet The existing welding power supply energy consumption control is dependent on real-time feedback regulation, and lacks experience learning and self-adaptive optimizing capability based on a historical process knowledge base, so that the continuous optimizing effect of 'more energy is saved more than needed' cannot be realized. Disclosure of Invention In order to solve the defects in the prior art, the invention provides a low-energy consumption welding power supply self-adaptive regulation and control method and system based on full-period sensing in a welding process, which can dynamically regulate the full period in a segmented manner and reduce the energy consumption of the power supply. In order to achieve the object of the invention, the following scheme is adopted: A low-energy consumption welding power supply self-adaptive regulation and control method based on full-period sensing in a welding process comprises the following steps: S1, acquiring material characteristics, process characteristics, weld characteristics and joint characteristics, respectively acquiring basic energy consumption Q base, a process coefficient K process, a weld formula L weld×(1+α×Nlayer) and a joint complexity coefficient K joint according to the four characteristics, and then calculating a total energy consumption theoretical value Q predicted; Qpredicted=Qbase×Kjoint×Kprocess×Lweld×(1+α×Nlayer) Qbase=Hreq×Aweld/η Hreq=ρ×(c×ΔTreq+Lm) A weld = (plate thickness-blunt edge) 2 ×tan (bevel angle/2) +root gap×plate thickness H req is the energy required for melting a unit volume of material, A weld is the cross-sectional area of a welding seam, eta is the thermal efficiency coefficient, rho is the density of the material, c is the specific heat capacity, deltaT req is the temperature difference from room temperature to the melting point, L m is the latent heat of melting, L weld is the length of the welding seam, alpha is the increment coefficient of welding energy consumption of 0.15-0.25, and N layer is the number of welding layers. S2, dividing the welding process into four stages of arc striking, arc stabilizing, arc receiving and standby, dividing the total energy consumption theoretical value Q predicted into energy consumption target values of the four stages, and respectively preparing energy consumption regulation strategies; The arc striking stage is that the arc striking is completed within 0.3s, and the peak power is less than or equal to 1.5 times of rated power; An arc stabilizing stage, namely comparing the real-time accumulated energy consumption with an energy consumption target value in the stage according to the progress, and then adjusting the dynamic power according to the current welding speed and a molten pool center temperature value measured in real time by an infrared thermometer; The arc-receiving stage is that the arc-receiving is completed within 0.5s, and the current is declined in a slope manner; and a standby stage, namely dormancy. And S3, after welding is completed, calculating the ratio of the actual total energy consumption to the total energy consumption theoretical value, and taking the ratio as an evaluation index of the energy saving effe