U-I方式脉冲MAG焊的研究（双丝MAG焊前期研究）
摘要
随着世界经济的发展，如何提高焊接的生产效率成为各相关企业所要解决的主要问题之一。双丝MIG／MAG是一种提高焊接效率的新型焊接工艺，它具有焊接速度高，熔敷率高，线能量小等诸多特点。国外对其进行了一定的研究工作，但是国内研究甚少，而且国外该种工艺所用的设备价格高昂，因此对其在国内广泛应用非常不利。本课题旨在对双丝MIG／MAG焊接系统进行前期研究，即对双丝理论方面的探讨和对双丝焊接所用的U-I方式的脉冲MAG焊接过程的稳定性的研究以及双丝MIG／MAG焊接系统的建立。
首先，在对相关理论问题分析的基础上设计双丝MIG／MAG焊接方案。从电弧和熔滴过渡角度分析了用于双丝的脉冲GMAW的特点；从熔池角度指出双丝焊可以解决常规焊接方法提高焊速后所带来的问题。总结出如果参数设置不当，就会由于电弧间的相互干扰而使焊接过程不稳，因此可以采用交替脉冲的方法力图减小电弧的干扰程度。在总体设计方案中焊接电源是主要部分。由于常规I-I方式脉冲焊自身控制特点不适合于双丝焊接，因此本系统采用U-I方式的脉冲焊电源，并为其设计了脉冲控制系统。
其次，根据总体设计方案，设计出了电源各部分电路，包括以逆变器为核心的电源主电路、以单片机检测控制和PWM为核心的电源控制电路部分。控制电路中还包括了驱动电路、保护电路、面板电路、送丝机调速电路和双机通信电路，并利用单片机的软件实现了电源电压的给定、时序控制等各种功能。
最后，对电源进行了波形测试，通过改变参数调节出所需要的外特性，获得较好的动态响应性能。通过单丝工艺实验寻找U-I方式脉冲参数对熔滴过渡的影响规律，并建立了双丝焊接系统，经过初步实验实现交替脉冲电流的输出，对下一步的双丝实验提出了建议。
总之，本课题研制了用于双丝MIG／MAG焊接的U-I方式脉冲焊电源，并得出这种工艺形式脉冲参数对熔滴过渡稳定性的影响规律，又建立了双丝焊接系统，为下一阶段的研究工作做了必要的准备。
With the development of the world's economy, how to improve the productivity of weld was one of the most important problems of the relevant enterprises. Two-wire MIG/MAG is a new welding technology to improve welding efficiency, its characteristics including high travel speed, high deposition rates and low line energy, etc. Many countries have done some research work on it, but in our country study about it is very few. The equipment of this technology is very expensive in foreign counties.,and it isn't beneficial to its spreading in our country. The paper is to make fundamental study of two-wire MIG/MAG welding system, inquire into the theory of two-wire MIG/MAG, study the stability of U-I pulse used in two-wire welding and build the two-wire MIG/MAG welding system.
First of all, the related theories were analyzed and on these bases the two-wire MIG/MAG welding scheme was designed. From the point of arc and droplet transfer , the characteristics of pulse GMAW used in two-wire was analyzed. From the point of weld pool, two-wire welding can resolve the questions resulted from improving the welding speed of traditional welding. If the parameter was unproper, the welding process was unstable because of the arc's disturb each other. So we could take shift phase pulse to reduce the degree of arc's disturbance. The power source was the main part in total design scheme, and traditional I-I pulse welding mode was unfit for two-wire welding because of its output characteristics. So U-I pulse mode was adopted, and pulse control scheme was designed.
Secondly, based on total designed scheme, we designed main circuit whose core is inverter, and control circuit whose core is testing and controlling of MCU and PWM. In control circuit, it includs driving circuit, protection circuit, board circuit, timing circuit of feeder and Two-MCU correspond circuit. And the function of reference signal of output current and voltage, time order control, etc was realized through software of MCU.
Finally, waveform of current and voltage was tested, output characterise of
power source we needed was got by adjusting parameters and good dynamic respondence characteristic was got. We found out by single wire welding test. Two-wire welding system was built and shift phase pulse current was realized. And some advices was given to the two-wire welding.
In brief, this paper developed U-I pulse welding power source used for two-wire MIG/MAG welding, and found out relationship between droplet transfer and power source parameters in U-I pulse welding process, then built two-wire welding system.
首先，在对相关理论问题分析的基础上设计双丝MIG／MAG焊接方案。从电弧和熔滴过渡角度分析了用于双丝的脉冲GMAW的特点；从熔池角度指出双丝焊可以解决常规焊接方法提高焊速后所带来的问题。总结出如果参数设置不当，就会由于电弧间的相互干扰而使焊接过程不稳，因此可以采用交替脉冲的方法力图减小电弧的干扰程度。在总体设计方案中焊接电源是主要部分。由于常规I-I方式脉冲焊自身控制特点不适合于双丝焊接，因此本系统采用U-I方式的脉冲焊电源，并为其设计了脉冲控制系统。
其次，根据总体设计方案，设计出了电源各部分电路，包括以逆变器为核心的电源主电路、以单片机检测控制和PWM为核心的电源控制电路部分。控制电路中还包括了驱动电路、保护电路、面板电路、送丝机调速电路和双机通信电路，并利用单片机的软件实现了电源电压的给定、时序控制等各种功能。
最后，对电源进行了波形测试，通过改变参数调节出所需要的外特性，获得较好的动态响应性能。通过单丝工艺实验寻找U-I方式脉冲参数对熔滴过渡的影响规律，并建立了双丝焊接系统，经过初步实验实现交替脉冲电流的输出，对下一步的双丝实验提出了建议。
总之，本课题研制了用于双丝MIG／MAG焊接的U-I方式脉冲焊电源，并得出这种工艺形式脉冲参数对熔滴过渡稳定性的影响规律，又建立了双丝焊接系统，为下一阶段的研究工作做了必要的准备。
With the development of the world's economy, how to improve the productivity of weld was one of the most important problems of the relevant enterprises. Two-wire MIG/MAG is a new welding technology to improve welding efficiency, its characteristics including high travel speed, high deposition rates and low line energy, etc. Many countries have done some research work on it, but in our country study about it is very few. The equipment of this technology is very expensive in foreign counties.,and it isn't beneficial to its spreading in our country. The paper is to make fundamental study of two-wire MIG/MAG welding system, inquire into the theory of two-wire MIG/MAG, study the stability of U-I pulse used in two-wire welding and build the two-wire MIG/MAG welding system.
First of all, the related theories were analyzed and on these bases the two-wire MIG/MAG welding scheme was designed. From the point of arc and droplet transfer , the characteristics of pulse GMAW used in two-wire was analyzed. From the point of weld pool, two-wire welding can resolve the questions resulted from improving the welding speed of traditional welding. If the parameter was unproper, the welding process was unstable because of the arc's disturb each other. So we could take shift phase pulse to reduce the degree of arc's disturbance. The power source was the main part in total design scheme, and traditional I-I pulse welding mode was unfit for two-wire welding because of its output characteristics. So U-I pulse mode was adopted, and pulse control scheme was designed.
Secondly, based on total designed scheme, we designed main circuit whose core is inverter, and control circuit whose core is testing and controlling of MCU and PWM. In control circuit, it includs driving circuit, protection circuit, board circuit, timing circuit of feeder and Two-MCU correspond circuit. And the function of reference signal of output current and voltage, time order control, etc was realized through software of MCU.
Finally, waveform of current and voltage was tested, output characterise of
power source we needed was got by adjusting parameters and good dynamic respondence characteristic was got. We found out by single wire welding test. Two-wire welding system was built and shift phase pulse current was realized. And some advices was given to the two-wire welding.
In brief, this paper developed U-I pulse welding power source used for two-wire MIG/MAG welding, and found out relationship between droplet transfer and power source parameters in U-I pulse welding process, then built two-wire welding system.
引文
1 殷树言，徐鲁宁，丁京柱．熔化极气体保护焊的高效化研究．焊接技术．2000，(S1)：4～7
2 张孔群，周国胜．美国高效焊接技术一瞥．造船技术．1997，(2)：7～10
3 庄建清．高效MAG焊的应用．焊接技术．1999，(5)：29～32
4 冯雷，陈树君，殷树言．高速焊接时焊缝咬边的形成机理．焊接学报．1999，20(1)：16～21
5 冯雷，陈树君，丁京柱，殷树言．高速CO_2焊接中的熔池稳定性及焊缝成形．焊接学报．1999，20(3)：164～169
6 徐鲁宁，殷树言，卢振洋．T.I.M.E.焊工艺与高效MAG焊的发展．电焊机．2000，(5)：3～7
7 Ken Michine, Stephen Blackman. Twin-Wire GMAW: Process Characteristics and Applications. Welding Journal. 1999, (5):31～34
8 E.Lassaline, B.Zajaczkowski, T. H. North. Narrow Groove Twin-Wire GMAW of High-Strength Steel. Welding Journal. 1989,19(9):53～58
9 Bill Lucos. FCAW, Multiwire&Gas Selection-Techniques to Enhance MIG Productivity. Welding & Metal Fabrication. 1997, (5): 10～12
10 D. Sc. Janez Tusek. Mathematical Modeling of Melting Rate in Twin-Wire Welding. Journal of materials Processing Technology. 2000:250～256
11 Heinrich Hadkl. TIME TWIN - High-Speed GMA Welding with Two Wire Electrodes. Fronius Schweissmaschinen KG, Austria
12 D. S. Bohme, N.A Sluchanko. MAG Double-Wire Welding —A Process to Reach High Welding Speed. Iiw-Doc.Ⅻ-11379-94
13 Malinovska, E. Pavelka. Properties of Welded Joints Produced by Twin-Arc Tandem Submerged-Arc Welding. Welding international. 1988,2(5):473～479
14 Hikaru Yamamoto, Yutaka Takano. Development of A Double Wire MAG Welding System for Robots. ⅡW DOC. Ⅻ-1682-0
15 D. Mctoughlin. Studies on The Development of Arc Sensors When Using Shielding Gas Two Wire Welding. Noutate editoriala, 2001, (1):34～40
16 H. Nomurh. Twin-Wire Gas Tungsten Arc Cladding Offers Increased Deposition Rates. Welding Journal. 1999, (10):31～39
17 Gunter Kaulich, Peter Kaiber. Tandem MIG/MAG Welding. Schweissen & Schneiden. 2001, (2):24～28
18 董德祥，陶伯华．双丝窄间隙埋弧焊微机控制系统的研究．电焊机，1994，(2)：12～16
19 王元良，周友龙，胡久富．高效节能的细丝双丝自动化焊接研究．焊接技术，2000，29(12)：39～42
20 高洪明，吴林．提高焊接生产率的途径．焊接．2000，(2)：6～10
21 蒙永民，黄石生，薛家祥，王秀媛．GMAW-P焊熔滴过渡及其控制的研究现状与发展．电焊机．2000，30(1)：1～5
22 杨运强，李俊岳，李桓．脉冲熔化极气体保护焊的过程控制．焊管．2000，24(2)：22～61
23 殷树言，张九海．气体保护焊原理，哈尔滨工业大学出版社．1989
24 潘际銮．现代弧焊控制．机械工业出版社．2000
25 M Amin. Pulse Current Parameters for Arc Stability and Controlled Metal Transfer in Arc Welding. Metal Construction. 1983, 15(5):272～278
26 W. G. Essers, M. R. M. Van Gompel. Arc Control with GMA Welding. Welding Journal. 1984, (6):26～32
27 P. K. Ghosh. Universality of Correlationships Among Pulse Parameters for Different MIG Welding Power Sources. International Journal for the Joining of Materials. 2001, 13(2): 40～47
28 Grubic, Kajo, Andric. Factors of Pulse MIG Welding, Their Relationships and Effects. International Journal for the Joining of Materials. 1996, 8(2):63～66
29 P. K. Ghosh. Analysis of Weld Characteristics as A Function of Pulse Current MIG Welding Parameters. International Journal for the Joining of Materials. 1996, 8(4):157～161
30 M. Amin. Synergic Pulse MIG Welding. Metal Construction. 1981,13(6):349～353
31 Pixley, Mike. Power Sources for Pulsed MIG Welding. Joining & Materials. 1989, 2(6):268～269, 271
32 Danut. Electromagnetic Interaction in Two-Wires in MIG/MAG Welding(TWW). Institute of Welding and Material Testing(ISIM),Timisoara,RO
33 殷树言，刘嘉，黄鹏飞，黄继强，王冬平．从电弧物理的角度看GMA焊的发展．焊接技术．2001，30(11)：5～8
34 王其隆，殷树言，钱乙余．脉冲电流熔化极气电焊电弧形态的控制及其实际意义．焊接学报．1980，1(1)：34～41
35 王其隆，殷树言．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．1982，4(3)：101～112
36 王其隆，殷树言，张九海，钱乙余．熔化极脉冲焊电弧形态的可控性及其与熔滴过渡的关系．哈尔滨：工业大学学报，1980，(4)：103～115
37 殷树言，钢铁，卜华全．协同式脉冲MIG焊的微机控制系统．焊接学报．1991，12(1)：46～51
38 Maruo, Hiroshi, Hirata, Yoshinori, Noda, Yoshitaka. Wire Melting Rate in Pulsed MIG Welding—Study on Arc Welding (Report 3). Journal of the Japan Welding Society. 1985, 3(1):191～196
39 Mauro, Hiroshi, Hirata, Yoshinori, Noda, Yoshitaka. Effects of Welding Current Waveform on Metal Transfer and Bead Formation in Pulsed MIG Welding. Journal of the Japan Welding Society. 1984, 2(1):443～454
40 Norrish, John, Nixon, John. History of Pulsed MIG Welding Source. Joining & Materials. 1989, 2(6):264～266, 268
41 Dzelnitzki, Dirk. Increasing the Deposition Volume or the Welding Speed?--Advantages of Heavy-Duty MAG Welding. Welding Research Abroad. 1999, 45(3):10～17
42 Horita, Motoshi, Makita, Shinya, Hori, Hisashi; Hino, Harumichi. Development of High Speed MIG Welding Process.(1st Report Arc Phenomena and Formation Mechanism of Surface Defect). Journal of Light Metal Welding and Construction. 1998, 36(9): 1～7
43 Geometry Mandal, Parmar, R. S. Effects of Pulse Parameters on Weld Bead Source. International Journal for the Joining of Materials. 1996, 8(2):69～75
44 P. Boughton, G. J. Mac Gregor, Control of Short Circuiting in MIG Welding. Welding Research International. 1974, 4(2):31～53
45 殷树言．CO_2焊接设备原理与调试．机械工业出版社，2000
46 赵家瑞．逆变焊接与切割电源．机械工业出版社．1995
47 刘嘉．弧焊逆变电源的数字化控制．北京工业大学博士论文．2002
48 刘星平，李炎斌．IGBT驱动电路的研究．电气开关．2002，(5)：19～21
49 程远楚．EXB841(840)驱动模块应用分析．电气传动自动化．1997，(11)：64～66
50 何跃军，韩旭，彭登峰．大功率IGBT驱动电路的研究．南昌航空工业学院学报．2002，16(3)：76～78
51 刘星平，唐勇奇，赵葵根．基于SG3525控制的可逆直流脉宽调速系统．湖南工程学院学报．2002，12(1)：27～30
52 陈宝红，翟涌．MCS单片机应用系统使用指南．机械工业出版社，1997
53 孙涵芳．Intel 16位单片机．北京航空航天大学出版社，1995
2 张孔群，周国胜．美国高效焊接技术一瞥．造船技术．1997，(2)：7～10
3 庄建清．高效MAG焊的应用．焊接技术．1999，(5)：29～32
4 冯雷，陈树君，殷树言．高速焊接时焊缝咬边的形成机理．焊接学报．1999，20(1)：16～21
5 冯雷，陈树君，丁京柱，殷树言．高速CO_2焊接中的熔池稳定性及焊缝成形．焊接学报．1999，20(3)：164～169
6 徐鲁宁，殷树言，卢振洋．T.I.M.E.焊工艺与高效MAG焊的发展．电焊机．2000，(5)：3～7
7 Ken Michine, Stephen Blackman. Twin-Wire GMAW: Process Characteristics and Applications. Welding Journal. 1999, (5):31～34
8 E.Lassaline, B.Zajaczkowski, T. H. North. Narrow Groove Twin-Wire GMAW of High-Strength Steel. Welding Journal. 1989,19(9):53～58
9 Bill Lucos. FCAW, Multiwire&Gas Selection-Techniques to Enhance MIG Productivity. Welding & Metal Fabrication. 1997, (5): 10～12
10 D. Sc. Janez Tusek. Mathematical Modeling of Melting Rate in Twin-Wire Welding. Journal of materials Processing Technology. 2000:250～256
11 Heinrich Hadkl. TIME TWIN - High-Speed GMA Welding with Two Wire Electrodes. Fronius Schweissmaschinen KG, Austria
12 D. S. Bohme, N.A Sluchanko. MAG Double-Wire Welding —A Process to Reach High Welding Speed. Iiw-Doc.Ⅻ-11379-94
13 Malinovska, E. Pavelka. Properties of Welded Joints Produced by Twin-Arc Tandem Submerged-Arc Welding. Welding international. 1988,2(5):473～479
14 Hikaru Yamamoto, Yutaka Takano. Development of A Double Wire MAG Welding System for Robots. ⅡW DOC. Ⅻ-1682-0
15 D. Mctoughlin. Studies on The Development of Arc Sensors When Using Shielding Gas Two Wire Welding. Noutate editoriala, 2001, (1):34～40
16 H. Nomurh. Twin-Wire Gas Tungsten Arc Cladding Offers Increased Deposition Rates. Welding Journal. 1999, (10):31～39
17 Gunter Kaulich, Peter Kaiber. Tandem MIG/MAG Welding. Schweissen & Schneiden. 2001, (2):24～28
18 董德祥，陶伯华．双丝窄间隙埋弧焊微机控制系统的研究．电焊机，1994，(2)：12～16
19 王元良，周友龙，胡久富．高效节能的细丝双丝自动化焊接研究．焊接技术，2000，29(12)：39～42
20 高洪明，吴林．提高焊接生产率的途径．焊接．2000，(2)：6～10
21 蒙永民，黄石生，薛家祥，王秀媛．GMAW-P焊熔滴过渡及其控制的研究现状与发展．电焊机．2000，30(1)：1～5
22 杨运强，李俊岳，李桓．脉冲熔化极气体保护焊的过程控制．焊管．2000，24(2)：22～61
23 殷树言，张九海．气体保护焊原理，哈尔滨工业大学出版社．1989
24 潘际銮．现代弧焊控制．机械工业出版社．2000
25 M Amin. Pulse Current Parameters for Arc Stability and Controlled Metal Transfer in Arc Welding. Metal Construction. 1983, 15(5):272～278
26 W. G. Essers, M. R. M. Van Gompel. Arc Control with GMA Welding. Welding Journal. 1984, (6):26～32
27 P. K. Ghosh. Universality of Correlationships Among Pulse Parameters for Different MIG Welding Power Sources. International Journal for the Joining of Materials. 2001, 13(2): 40～47
28 Grubic, Kajo, Andric. Factors of Pulse MIG Welding, Their Relationships and Effects. International Journal for the Joining of Materials. 1996, 8(2):63～66
29 P. K. Ghosh. Analysis of Weld Characteristics as A Function of Pulse Current MIG Welding Parameters. International Journal for the Joining of Materials. 1996, 8(4):157～161
30 M. Amin. Synergic Pulse MIG Welding. Metal Construction. 1981,13(6):349～353
31 Pixley, Mike. Power Sources for Pulsed MIG Welding. Joining & Materials. 1989, 2(6):268～269, 271
32 Danut. Electromagnetic Interaction in Two-Wires in MIG/MAG Welding(TWW). Institute of Welding and Material Testing(ISIM),Timisoara,RO
33 殷树言，刘嘉，黄鹏飞，黄继强，王冬平．从电弧物理的角度看GMA焊的发展．焊接技术．2001，30(11)：5～8
34 王其隆，殷树言，钱乙余．脉冲电流熔化极气电焊电弧形态的控制及其实际意义．焊接学报．1980，1(1)：34～41
35 王其隆，殷树言．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．1982，4(3)：101～112
36 王其隆，殷树言，张九海，钱乙余．熔化极脉冲焊电弧形态的可控性及其与熔滴过渡的关系．哈尔滨：工业大学学报，1980，(4)：103～115
37 殷树言，钢铁，卜华全．协同式脉冲MIG焊的微机控制系统．焊接学报．1991，12(1)：46～51
38 Maruo, Hiroshi, Hirata, Yoshinori, Noda, Yoshitaka. Wire Melting Rate in Pulsed MIG Welding—Study on Arc Welding (Report 3). Journal of the Japan Welding Society. 1985, 3(1):191～196
39 Mauro, Hiroshi, Hirata, Yoshinori, Noda, Yoshitaka. Effects of Welding Current Waveform on Metal Transfer and Bead Formation in Pulsed MIG Welding. Journal of the Japan Welding Society. 1984, 2(1):443～454
40 Norrish, John, Nixon, John. History of Pulsed MIG Welding Source. Joining & Materials. 1989, 2(6):264～266, 268
41 Dzelnitzki, Dirk. Increasing the Deposition Volume or the Welding Speed?--Advantages of Heavy-Duty MAG Welding. Welding Research Abroad. 1999, 45(3):10～17
42 Horita, Motoshi, Makita, Shinya, Hori, Hisashi; Hino, Harumichi. Development of High Speed MIG Welding Process.(1st Report Arc Phenomena and Formation Mechanism of Surface Defect). Journal of Light Metal Welding and Construction. 1998, 36(9): 1～7
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