An important development trend of advanced manufacturing technology is the process design from empirical judgment to quantitative analysis. The method is to combine numerical simulation technology with physical simulation and artificial intelligence technology to determine process parameters, optimize process plans, predict processing quality, and make production process. From "theory - experiment - production" to "theory - computer simulation - production".
With the integration of artificial intelligence technology, computer vision technology, digital information processing technology and robot technology, the arc welding technology is becoming more efficient, the digitalization of welding power supply, the intelligent welding quality and the development of robotization in the production process. This application is an important research topic in this field.
Trend judgment and demand analysis
In the 21st century, the manufacturing industry tends to be globalized, networked, integrated, virtualized, remote, and digital. The rapid development of computers and information technology will promote the gradual integration of the manufacturing field. Welding is an important material processing and structure in the manufacturing field.
Productivity is also closely integrated with information technology. Due to the variability and complexity of the welding process, the use of digital technology to transform welding equipment from simple electromechanical products into a precision processing instrument will be the development direction of welding equipment.
The digitization of the welder includes two aspects. One is the digitization of the main circuit and the other is the digitization of the control circuit.
The advent of inverter technology has provided conditions for the digitization of the main circuit of the welder. The development of the welding power source from the analog welding machine to the inverter welding machine actually completed the leap of the main circuit from analog to digital. The digitization of the main circuit of the welding power source has improved the performance of the welding power source in at least two aspects: 1 The power loss of the welding power source is greatly reduced, so that the efficiency of the welding power source is more than 90%. 2 As the operating frequency increases, the ripple of the loop output current is smaller and the response speed is faster, so the welder can obtain better dynamic response characteristics.
As early as the early 70s, inverters have been used in the field of intermediate frequency heating. In 1982, Sweden's ESAB company first introduced the thyristor arc welding inverter products. The internationally renowned welding equipment companies such as Lincoln, Miller, Powcon, Finland's Kemppi, Switzerland's ELTRON, and Japan's Otsuka Transformer Co., Ltd. have successively launched. Individual arc welding inverter products. At the World Welding and Cutting Expo held in Essen, Germany in 1981, four manufacturers of thyristor and transistor arc welding inverters were exhibited for the first time, mainly for electrode arc welding and low-voltage arc-type tungsten-arc arc welding. And CO2 gas shielded welding, the maximum current is 350A. By 1989, more than 30 manufacturers had exhibited arc welding inverters at the same fair. In addition to the large increase in FET and transistor arc welding inverters, IGBT arc welding inverters have begun to appear, with a maximum capacity of 500A, and their use has further expanded to areas such as plasma cutting.
In 1993, at the Essen International Welding and Cutting Expo in Germany, arc welding inverters of various specifications and uses were exhibited. The applications range from manual arc welding, TIG welding, MIG/MAG welding and CO2 welding. The capacity is between 130-630A and the inverter frequency is 2-2OkHz. Among them, the field effect tube type strong welding inverter with rated current 130A and load duration of 35% has a weight of only 4Kg and an inverter frequency of 100-130KHz.
According to the survey, by 1996, Japan's Hitachi IGBT inverter welding machine accounted for 70% of its MIG/MAG welding machine, accounting for more than 95% of TIG welding machines, accounting for 100% of cutting machines. IGBT inverter welding power supply will become the development direction of inverter welding machine in the future.
In China, the development of arc welding inverters is very fast, and the prospects are also very impressive. In the late 1970s, China began to develop thyristor arc welding inverters, and achieved preliminary results in the early 1980s. Shanghai Weiteli Welding Equipment Manufacturing Co., Ltd. is a high-tech enterprise specializing in the production of IGBT inverter welding power supply and special welding equipment. It has a high reputation in the production field of inverter welding machine.
At the end of the 1990s, the Austrian Fronius all-digital welding machine entered the Chinese market, and the development of digital welding machines attracted wide attention. Compared with analog control systems, digital arc welding power supplies have the following distinctive features:
1 widening function. The power supply features the mountain software flexible control, easy to achieve a multi-purpose machine, for the automatic welder, you can increase the welding parameters preset, memory and reproduction. With precise digital control, high-efficiency gas shielded welding, including high-speed welding and high deposition rate welding, can be achieved using techniques such as electronic reactors and waveform control.
2 adaptability. Using the computer's storage function and high-speed, high-precision digital signal processing technology, the welder can be developed into a multi-functional and intelligent, and it is easy to introduce modern control methods such as adaptive control, fuzzy control, and neural network control in the welder. Optimization of welding parameters, control of welding quality, etc.
3 operability is good. Utilizing the high-speed computing power of the single-chip microcomputer and the dedicated digital signal processor and rich external interface and communication capability, on the basis of introducing intelligent control technology such as fuzzy control, simple adjustment of welding parameters can be realized, and the "inverted welding machine" can be realized. "operating.
4 easy to develop. Many tasks can be done either through hardware or through software. They can be built on a single power supply and can be combined with different control boxes to form different types of welders. The development cycle of the welding power supply is short and the cost is low.
5 easy to upgrade. The same type of welder, the function improvement can be realized only by software design, which can greatly improve the service life and use range of the welder in the era of today's technology update. When it is equipped for the welding special machine, the performance of the welding machine can be flexibly changed, and it is convenient to realize the special machine.
The development of digital welding power control system will lay the foundation for the production of serialized high-grade welding machine of Shanghai Weiteli Welding Equipment Manufacturing Co., Ltd. At the same time, due to the adoption of digital control technology, the welding power source is no longer a pure source of welding energy. It should also have a digital operating system platform, multi-feature adaptation, wire drive peripherals and interfaces, and dynamic adaptive adjustment of welding parameters. The concept of welding power supply has been broadened into a welding power system with the functions of process stability quality assessment, protection and self-diagnosis, remote network monitoring, and production quality management. Therefore, it is of great significance in terms of academic level and use value. The digital welding machine is only in the laboratory stage in China, but the digital welding machine will become the mainstream of welding equipment with its unparalleled strength, and it is the star of the future.
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