CONSUMABLE ELECTRODE ARC WELDING METHOD AND CONSUMABLE ELECTRODE ARC WELDING DEVICE

• US 20120074114A1
• Filed: 06/16/2010
• Published: 03/29/2012
• Est. Priority Date: 06/19/2009
• Status: Active Grant

• Current Assignee: Panasonic Corporation (Panasonic Holdings Corporation)
• Original Assignee: Panasonic Corporation (Panasonic Holdings Corporation)
• Inventors: Kawamoto, Atsuhiro, Mukai, Yasushi, Fujiwara, Junji, Mishima, Toshiyuki, Kowa, Masaru
• Granted Patent: US 8,513,568 B2
• Time in Patent Office: Days
• US Class Current: 219/130.21
• CPC Class Codes: B23K 9/0731 Stabilising of the arc tension
• CPC Class Codes: B23K 9/0735 Stabilising of the arc length
• CPC Class Codes: B23K 9/09 Arrangements or circuits for arc welding with pulsed current or voltage
• CPC Class Codes: B23K 9/124 Circuits or methods for feeding welding wire
• CPC Class Codes: B23K 9/125 Feeding of electrodes for stabilising arc B23K9/073

Abstract

If a short circuit does not occur during deceleration of a wire feed speed in forward feed of a welding wire before the wire feed speed reaches a predetermined wire feed speed, a cyclic change is stopped and the wire feed speed is constantly controlled at the first feed speed. If a short circuit occurs during forward feed at the first feed speed, deceleration from the first feed speed starts, and the cyclic change is resumed for welding. This achieves uniform weld bead without increasing spatters even if any external disturbance such as change of distance between a tip and base material occurs.

Claims

1. A consumable electrode arc welding method in which welding takes place by feeding a welding wire at a wire feed speed with a cyclic change in a predetermined cycle and amplitude, the wire feed speed including forward feed for feeding the welding wire toward a workpiece to be welded and backward feed for feeding the welding wire in a direction opposite to the forward feed, the method comprising:

stopping the cyclic change and applying a constant control at a first feed speed of the wire feed speed if no short circuit occurs during deceleration of the wire feed speed in the forward feed of the welding wire before one of the wire feed speed reaching a predetermined wire feed speed, a predetermined time passing from arc generation, and a feed cycle of the welding wire reaching a predetermined angle when the predetermined cycle of feeding the welding wire is expressed by an angle; and

welding by starting deceleration from the first feed speed and resuming the cyclic change if the short circuit occurs during the forward feed at the first feed speed.

2. The consumable electrode arc welding method of claim 1, wherein the predetermined wire feed speed is the first feed speed.

5. The consumable electrode arc welding method of claim 1, wherein the cyclic change of the wire feed speed is one of a sinusoidal and trapezoidal change.

6. The consumable electrode arc welding method of claim 1, wherein the welding wire feed speed is an average wire feed speed corresponding to a set current.

7. The consumable electrode arc welding method of claim 6 in which welding takes place at the wire feed speed with a cyclic change in the predetermined cycle and amplitude,

wherein

an average cyclic wire feed speed of a cycle is calculated for each cycle;

if the average cyclic wire feed speed of one cycle is lower than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a higher speed than the average wire feed speed so that the average cyclic wire feed speed of a cycle on and after a next cycle of the one cycle becomes higher than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle; and

if the average cyclic wire feed speed of the one cycle is higher than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a lower speed than the average wire feed speed so that the average cyclic wire feed speed of the cycle on and after the next cycle of the one cycle becomes lower than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle.

8. The consumable electrode arc welding method of claim 7, wherein the cycle on and after the next cycle is a next one cycle.

9. The consumable electrode arc welding method of claim 7, wherein the cycle on and after the next cycle is a plurality of cycles on and after the next cycle.

13. The consumable electrode arc welding method of claim 2, wherein the cyclic change of the wire feed speed is one of a sinusoidal and trapezoidal change.

15. The consumable electrode arc welding method of claim 2, wherein the welding wire feed speed is an average wire feed speed corresponding to a set current.

17. The consumable electrode arc welding method of claim 15 in which welding takes place at the wire feed speed with a cyclic change in the predetermined cycle and amplitude,

wherein

an average cyclic wire feed speed of a cycle is calculated for each cycle;

if the average cyclic wire feed speed of one cycle is lower than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a higher speed than the average wire feed speed so that the average cyclic wire feed speed of a cycle on and after a next cycle of the one cycle becomes higher than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle; and

if the average cyclic wire feed speed of the one cycle is higher than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a lower speed than the average wire feed speed so that the average cyclic wire feed speed of the cycle on and after the next cycle of the one cycle becomes lower than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle.

19. The consumable electrode arc welding method of claim 17, wherein the cycle on and after the next cycle is a next one cycle.

21. The consumable electrode arc welding method of claim 17, wherein the cycle on and after the next cycle is a plurality of cycles on and after the next cycle.

3. A consumable electrode arc welding method in which welding takes place by feeding a welding wire at a wire feed speed with a cyclic change in a predetermined cycle and amplitude, the wire feed speed including forward feed for feeding the welding wire toward a workpiece to be welded and backward feed for feeding the welding wire in a direction opposite to the forward feed, the method comprising:

stopping the cyclic change and applying a constant control at a second feed speed of the wire feed speed if a short circuit is not opened during acceleration of the wire feed speed in the backward feed of the welding wire before one of the wire feed speed reaching a predetermined wire feed speed, a predetermined time passing from short circuit generation, and a feed cycle of the welding wire reaching a predetermined angle when the predetermined cycle of feeding the welding wire is expressed by an angle; and

welding by starting acceleration from the second feed speed and resuming the cyclic change if the short circuit is opened during the backward feed at the second feed speed.

4. The consumable electrode arc welding method of claim 3, wherein the predetermined wire feed speed is the second feed speed.

14. The consumable electrode arc welding method of claim 3, wherein the cyclic change of the wire feed speed is one of a sinusoidal and trapezoidal change.

16. The consumable electrode arc welding method of claim 3, wherein the welding wire feed speed is an average wire feed speed corresponding to a set current.

18. The consumable electrode arc welding method of claim 16 in which welding takes place at the wire feed speed with a cyclic change in the predetermined cycle and amplitude,

wherein

an average cyclic wire feed speed of a cycle is calculated for each cycle;

if the average cyclic wire feed speed of one cycle is lower than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a higher speed than the average wire feed speed so that the average cyclic wire feed speed of a cycle on and after a next cycle of the one cycle becomes higher than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle; and

if the average cyclic wire feed speed of the one cycle is higher than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a lower speed than the average wire feed speed so that the average cyclic wire feed speed of the cycle on and after the next cycle of the one cycle becomes lower than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle.

20. The consumable electrode arc welding method of claim 18, wherein the cycle on and after the next cycle is a next one cycle.

22. The consumable electrode arc welding method of claim 18, wherein the cycle on and after the next cycle is a plurality of cycles on and after the next cycle.

10. A consumable electrode arc welding device in which welding takes place by repeating an arc state and a short circuit state between a welding wire and a workpiece to be welded, the device comprising:

a switching element for controlling a welding output;

a welding voltage detector for detecting a welding voltage;

a welding condition setting unit for setting a set current;

a short circuit/arc detector for detecting one of the short circuit state and the arc state based on an output of the welding voltage detector;

a memory for storing the set current, an average feed speed of wire feed speed, a frequency of the wire feed speed, and an amplitude of the wire feed speed in a linked manner;

a wire feed speed determinator for determining the average feed speed of wire feed speed, the frequency of wire feed speed, and the amplitude of wire feed speed from the memory based on the set current set by the welding condition setting unit; and

a wire feed speed controller for receiving an output of the short circuit/arc detector and an output of the wire feed speed determinator, and controlling the wire feed speed in cyclic change of forward feed and backward feed,

wherein

the wire feed speed controller stops the cyclic change and starts a constant control of the wire feed speed at a first feed speed if no short circuit occurs during deceleration of the wire feed speed in the forward feed of the welding wire before one of the wire feed speed reaching a predetermined feed speed, a predetermined time passing from arc generation, and a feed cycle of the welding wire reaching a predetermined angle when one feed cycle of the welding wire is expressed by an angle; and

if the short circuit occurs during the forward feed at the first feed speed, deceleration from the first feed speed starts and the cyclic change is resumed for welding.

12. The consumable electrode arc welding device of claim 10, wherein the wire feed speed controller calculates an average cyclic wire feed speed of a cycle for each cycle;

if the average cyclic wire feed speed of one cycle is lower than an average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a higher speed than the average wire feed speed so that the average cyclic wire feed speed of a cycle on and after a next cycle of the one cycle becomes higher than the average wire feed speed, the wire feed speed being an average cyclic wire feed speed on and after the next cycle; and

if the average cyclic wire feed speed of the one cycle is higher than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a lower speed than the average wire feed so that the average cyclic wire feed speed of the cycle on and after the next cycle of the one cycle becomes lower than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle.

11. A consumable electrode arc welding device in which welding takes place by repeating an arc state and a short circuit state between a welding wire and a workpiece to be welded, the device comprising:

a switching element for controlling a welding output;

a welding voltage detector for detecting a welding voltage;

a welding condition setting unit for setting a set current;

a short circuit/arc detector for detecting one of the short circuit state and the arc state based on an output of the welding voltage detector;

a memory for storing the set current, an average feed speed of wire feed speed, frequency of the wire feed speed, and an amplitude of the wire feed speed in a linked manner;

a wire feed speed determinator for determining the average feed speed of wire feed speed, the frequency of wire feed speed, and the amplitude of wire feed speed from the memory based on the set current set by the welding condition setting unit; and

a wire feed speed controller for receiving an output of the short circuit/arc detector and an output of the wire feed speed determinator, and controlling the wire feed speed in cyclic change of forward feed and backward feed,

wherein

the wire feed speed controller stops the cyclic change and starts a constant control of the wire feed speed at a second feed speed if a short circuit is not opened during acceleration of the wire feed speed in the backward feed of the welding wire before one of the wire feed speed reaching a predetermined feed speed, a predetermined time passing from short circuit generation, and a feed cycle of the welding wire reaching a predetermined angle when one feed cycle of the welding wire is expressed by angle; and

if the short circuit is opened during the backward feed at the second feed speed, acceleration from the second feed speed starts and the cyclic change is resumed for welding.

23. The consumable electrode arc welding device of claim 11, wherein the wire feed speed controller calculates an average cyclic wire feed speed of a cycle for each cycle;

if the average cyclic wire feed speed of one cycle is lower than an average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a higher speed than the average wire feed speed so that the average cyclic wire feed speed of a cycle on and after a next cycle of the one cycle becomes higher than the average wire feed speed, the wire feed speed being an average cyclic wire feed speed on and after the next cycle; and

if the average cyclic wire feed speed of the one cycle is higher than the average wire feed speed, welding takes place at the wire feed speed shifted in parallel to a lower speed than the average wire feed so that the average cyclic wire feed speed of the cycle on and after the next cycle of the one cycle becomes lower than the average wire feed speed, the wire feed speed being the average cyclic wire feed speed on and after the next cycle.