等离子MIG焊接控制系统的研制
摘要
随着焊接技术和控制技术的发展，等离子弧焊或MIG弧焊在自动控制下在铝及其合金方面工业生产中起着很大的作用；而作为新型的焊接方法等离子MIG焊，在国外有了较大的进步，国内却较少在这方向上进行研究。
本文所进行是利用等离子MIG焊这种新的方法，结合PLC进行自动焊接铝及其合金。在设计中，控制系统的核心单元采用S7—300型CPU以及对应I／O、AI／AO产品；焊接电源分别选用了TPS5000型MIG电焊机和ARGP300型TIG电焊机，对两台电焊机本身的控制进行的新改造，由PLC的控制信号来进行协调控制；焊胎、送丝系统、冷却水循环系统、三维步进电机行走支架等设备均由PLC进行控制；液晶触显示触摸屏提供了友好的人机界面。同时，控制软件利用STEP7的模块化设计方法，设计了共计12套程序，10套为带有固定参数的分别适用于不同厚度的管及板的不同工件，另2套为不带参数的程序，以用作用户的二次开发。
结果表明，本系统可以完成不同的型材不同厚度产品的焊接，在焊接中，焊枪准确到位，焊缝成形好，焊缝过渡平滑，焊接质量高；焊接速度快，生产效率高，对于8mm厚的型材，一次焊透，焊速达0.5m／min。
本文研制的控制系统，解决了从国外进口类似设备价格高的问题，在焊接质量相同的条件下，成本降低1／3以上；同时可以指导应用和研究参考。
With the development of technology of welding, single plasma arc welding or MIG arc welding plays more and more role in automatic welding aluminum and its alloy. A new way-plasma-MIG welding?has been adopted in abroad quickly, but it has few use in our country.
The research in this paper is a new system controlled by PLC which had been designed to weld AL and alloy of AL with plasma-MIG. The core of the system adopts one type of PLC of Simens, which is a sort of S7-300, and its additional devices, including DI,DO,AI.AO modules. Welding powers are different, one is TPS5000, the other is ARGP300. The two powers are manipulated harmoniously by single of PLC system. Varying mechanic, machine of supplying line, cooling system of cycling water, and mechanic of three version moved by
stepping motors are all controlled by the PLC. And touching panel
of LCD gives more friendly HMI. At the same time, the design of
software adopts the way of modules. There are twelve sorts of programs with fixed parameters to weld different workpieces in pipes and plates of AL and its alloy. Another two sorts of those without parameters are given to the user to input right parameters to weld the special workpieces of pipes and plates eachly.
The result of system indicates that it can weld different forms of workpieces with different thick. A welding torch can move precisely when welding products. The face of weld is smooth, and the quantity is good. The velocity of this system is quick, and the efficient is high. When welding plate of 8mm, the velocity can reach 0. 5m/min.
The controlling system of the design deals with the problem costing much money to buy the similar device so as to save 1/3 or more, the other role helps some application and some references of
research and it will throw a light on the new area of welding in Plasma-MIG welding.
本文所进行是利用等离子MIG焊这种新的方法，结合PLC进行自动焊接铝及其合金。在设计中，控制系统的核心单元采用S7—300型CPU以及对应I／O、AI／AO产品；焊接电源分别选用了TPS5000型MIG电焊机和ARGP300型TIG电焊机，对两台电焊机本身的控制进行的新改造，由PLC的控制信号来进行协调控制；焊胎、送丝系统、冷却水循环系统、三维步进电机行走支架等设备均由PLC进行控制；液晶触显示触摸屏提供了友好的人机界面。同时，控制软件利用STEP7的模块化设计方法，设计了共计12套程序，10套为带有固定参数的分别适用于不同厚度的管及板的不同工件，另2套为不带参数的程序，以用作用户的二次开发。
结果表明，本系统可以完成不同的型材不同厚度产品的焊接，在焊接中，焊枪准确到位，焊缝成形好，焊缝过渡平滑，焊接质量高；焊接速度快，生产效率高，对于8mm厚的型材，一次焊透，焊速达0.5m／min。
本文研制的控制系统，解决了从国外进口类似设备价格高的问题，在焊接质量相同的条件下，成本降低1／3以上；同时可以指导应用和研究参考。
With the development of technology of welding, single plasma arc welding or MIG arc welding plays more and more role in automatic welding aluminum and its alloy. A new way-plasma-MIG welding?has been adopted in abroad quickly, but it has few use in our country.
The research in this paper is a new system controlled by PLC which had been designed to weld AL and alloy of AL with plasma-MIG. The core of the system adopts one type of PLC of Simens, which is a sort of S7-300, and its additional devices, including DI,DO,AI.AO modules. Welding powers are different, one is TPS5000, the other is ARGP300. The two powers are manipulated harmoniously by single of PLC system. Varying mechanic, machine of supplying line, cooling system of cycling water, and mechanic of three version moved by
stepping motors are all controlled by the PLC. And touching panel
of LCD gives more friendly HMI. At the same time, the design of
software adopts the way of modules. There are twelve sorts of programs with fixed parameters to weld different workpieces in pipes and plates of AL and its alloy. Another two sorts of those without parameters are given to the user to input right parameters to weld the special workpieces of pipes and plates eachly.
The result of system indicates that it can weld different forms of workpieces with different thick. A welding torch can move precisely when welding products. The face of weld is smooth, and the quantity is good. The velocity of this system is quick, and the efficient is high. When welding plate of 8mm, the velocity can reach 0. 5m/min.
The controlling system of the design deals with the problem costing much money to buy the similar device so as to save 1/3 or more, the other role helps some application and some references of
research and it will throw a light on the new area of welding in Plasma-MIG welding.
引文
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3 周益龙．国内焊接自动化概况及发展方向．电焊机．1981(4)：1-5
4 R. J. BEATTIE, S.K. CHENG AND P. S. LOGUE. The Use of Sensors in Multipass Welding Application. Welding Journal. Nov. 1988: 28-33
5 Wang QL, et al. Arc Light Sensing of Droplet Transfer and its Analysis in Pulsed GMAW Process. Welding Journal. 1993,76(11): 62-70
6 S. Nagarajan, W.H. Chen, B.A. Chin. Infrared Sensing for Adaptive Arc Welding. Welding Journal. 1989,68(11): 462-466
7 W. Chen B. A. Chin. Monitoring Joint Penetration Using Infrared Sensing Techniques. Welding Journal. 1990,69(4): 181-185
8 Nagarajan S, et al. Control of the Welding Process Using Infrared Sensor. IEEE Transaction on Robotics and Automation. Vol. 8, 1992, 8(1)
9 C. W. Lee, S. J. Na. A Study on the Influence of Reflected Arc Light of Vision Sensors for Welding Automation. Welding Journal. 1996,75(12): 379-387
10 Reets Instruments Inc. CCTV Technology permits Monitoring of High-Speed Welding in All Environments. Welding Journal. June, 1992: 83-84
11 殷树言等．粗丝CO_2气体保护焊熔滴过渡与潜弧机理的研究．金属科学与工艺．1989，Vol．8，No．2：95-103
12 王其隆等．钢焊丝熔化极气电焊的跳弧现象与射流过渡．金属科学与工艺．1982，Vol．1，No．1：101-111
13 殷树言等．CO_2射滴过渡的实现．焊接学报．1990，Vol．11，No．3：
186-191
14 高进强等．熔池图象传感与几何参数检测．焊接技术．1999．8：3-4
15 D. E. HARDT AND J. M. KAIZ. Ultrasonic Measurement of Weld Penetration. WELDING JOURNAL. SEPTEMBER, 1984: 273-281
16 R. FENN. Ultrasonic Monitoring and Control During Arc Welding. WELDING JOURNAL. SEPTEMBER, 1985: 18-22
17 M. C. JON. Non-contact Acoustic Emission Monitoring of Laser Beam Welding. Welding Journal. SEPTEMBER, 1985: 43-48
18 N. M. CARLSON AND J. A. JOHNSON. Ultrasonic sensing of Weld Pool Penetration. Welding Journal. November, 1988: 239-245
19 刘满清．电阻点焊质量的超声波自动跟踪监视．第四届全国焊接学术会议
20 陈丙森．计算机辅助焊接技术．机械工业出版社．1999．11
21 A. E. Bentley and S. J. Marberger. Arc Welding Penetration Control Using Quantitative Feedback Theory. Welding Journal. 1992, 71(4): 397-405
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