WO2025187525A1 - Arc welding method - Google Patents
Arc welding methodInfo
- Publication number
- WO2025187525A1 WO2025187525A1 PCT/JP2025/006852 JP2025006852W WO2025187525A1 WO 2025187525 A1 WO2025187525 A1 WO 2025187525A1 JP 2025006852 W JP2025006852 W JP 2025006852W WO 2025187525 A1 WO2025187525 A1 WO 2025187525A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- change point
- period
- welding
- arc
- current
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
- B23K9/073—Stabilising the arc
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
Definitions
- the present invention relates to an arc welding method.
- Patent Document 1 discloses an arc welding machine that, after a predetermined time has elapsed since the short circuit was released, applies constant current control for a predetermined period at a current value higher than the current value output under conventional constant voltage control, thereby suppressing the occurrence of a short circuit immediately after the short circuit is released and suppressing the generation of spatter.
- the amount of molten metal needs to be increased to ensure sufficient bead width and penetration.
- the first aspect is an arc welding method that performs welding by cyclically repeating forward and reverse feed of a welding wire, which is a consumable electrode, and alternating between short-circuit periods in a short-circuit state and arc periods in an arc state, wherein the arc period includes a first period and a second period that follows the first period, and the point at which the welding current starts to change in the first period is defined as a first change point, the point at which the welding current starts to change in the second period is defined as a second change point, and the point at which the welding current reaches a peak current in the second period is defined as a third change point, and the method includes a first step of changing the welding current in the first period so that the welding current is larger than an imaginary line connecting the first change point and the second change point, and a second step of changing the welding current in the second period along a line connecting the second change point and the third change point.
- the heat input to the welding wire is ensured by changing the welding current during the first period so that it is greater than the imaginary line connecting the first change point and the second change point. This allows droplets to be stably formed at the tip of the welding wire in the initial state of the arc period.
- the welding current is changed in a linear fashion connecting the second change point and the third change point, thereby ensuring that the heat input to the welding wire is increased at a constant rate.
- droplets from the initial droplet formation stage through to their growth, to be constantly maintained at the tip of the welding wire. Furthermore, by ensuring stable droplet growth until the peak current is reached, droplets of the desired size can be formed.
- the molten droplets held at the tip of the welding wire can be transferred stably toward the molten pool. As a result, it becomes easier to form a wide bead and the generation of spatter due to micro-short circuits can be suppressed.
- the welding current is changed along an arc-shaped curve in which the welding current is greater than the virtual straight line.
- the welding current is changed along an arc-shaped curve during the first period to ensure the heat input to the welding wire. This allows for stable formation of droplets at the tip of the welding wire during the initial state of the arc period.
- a predetermined point between the first change point and the second change point is designated as a fourth change point, and in the first step, the welding current is changed in a linear fashion connecting the first change point and the fourth change point, and then the welding current is changed in a linear fashion connecting the fourth change point and the second change point.
- the welding current is changed in a linear fashion connecting the first change point and the fourth change point, and then the welding current is changed in a linear fashion connecting the fourth change point and the second change point, thereby ensuring the heat input to the welding wire.
- a fourth aspect is an arc welding method according to any one of the first to third aspects, wherein the slope of the line connecting the second change point and the third change point is 200 A/msec or more and 1500 A/msec or less.
- the slope of the line connecting the second and third change points is less than 200 A/msec, the heat input to the welding wire is small, and droplet growth at the tip of the welding wire becomes unstable. As a result, the periodicity between the short-circuit period and the arc period is disrupted, which may result in unstable welding.
- the heat input to the welding wire will be excessive, increasing the arc pressure applied to the molten pool. This increased arc pressure will then cause the molten pool to vibrate, which could result in spatter. Furthermore, if the heat input to the welding wire is excessive, the tip of the welding wire will rise significantly from the droplet, which could cause unstable droplet transfer to the molten pool and unstable bead formation.
- the slope of the line connecting the second change point and the third change point is set to satisfy the above-mentioned condition.
- the slope of the line connecting the second change point and the third change point is 1200 A/msec.
- the occurrence of spatter can be suppressed by appropriately changing the welding current during the arc period.
- FIG. 1 is a diagram showing a schematic configuration of an arc welding apparatus according to the first embodiment.
- FIG. 2 is a graph showing the time waveforms of the welding wire feed speed and the welding current.
- FIG. 3 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 1.
- FIG. 4 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 2.
- FIG. 5 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 3.
- FIG. 6 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 4.
- FIG. 7 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 5.
- FIG. 8 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 6.
- FIG. 9 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 7.
- FIG. 10 is a graph showing the time waveforms of the welding wire feed rate and the welding current in Comparative Example 8.
- FIG. 11 is a graph showing the time waveforms of the welding wire feed speed and the welding current according to the second embodiment.
- FIG. 12 is a graph showing the time waveforms of the welding wire feed rate and the welding current according to the third embodiment.
- the arc welding device 1 periodically repeats forward and reverse feed of the welding wire 15, and alternates between a short-circuit period in a short-circuit state and an arc period in an arc state between the welding wire 15 and the workpiece W to generate an arc 16, thereby welding the workpiece W.
- the arc welding device 1 has a welding unit 10 and a control unit 30.
- the welding unit 10 has a welding torch 11, a feed motor 12, and a power conversion unit 20.
- the feed motor 12 feeds the welding wire 15 to the welding torch 11 at a predetermined feed speed.
- the power conversion unit 20 includes a primary side rectifier 21, a switching unit 22, a main transformer 23, a secondary side rectifier 24, a reactor 25, a voltage detection unit 26, and a current detection unit 27.
- the primary side rectifier 21 rectifies and outputs the output of the input power source 5.
- the switching unit 22 converts the DC output from the primary side rectifier 21 into AC.
- the switching unit 22 controls the welding output, which consists of the welding current and welding voltage.
- the main transformer 23 converts the AC voltage output by the switching unit 22.
- the output of the main transformer 23 is output as a welding output via the secondary side rectifier 24 and reactor 25.
- the secondary side rectifier 24 rectifies the secondary side output of the main transformer 23.
- the voltage detection unit 26 detects the welding voltage.
- the current detection unit 27 detects the welding current.
- the control unit 30 has a drive unit 31, a state detection unit 32, a short-circuit control unit 33, an arc control unit 34, a set current setting unit 35, a basic frequency setting unit 36, a basic speed amplitude setting unit 37, and an average feed speed setting unit 38.
- the drive unit 31 controls the switching unit 22.
- the state detection unit 32 detects whether the state is a short circuit state or an arc state based on the detection result of the voltage detection unit 26. Specifically, the state detection unit 32 determines whether the welding output voltage is above or below a certain value based on the signal from the voltage detection unit 26. Based on this determination result, it determines whether the state is a short circuit state in which the welding wire 15 is in contact with the workpiece W and short-circuited, or an arc state in which a welding arc is generated in a non-contact state. A determination signal indicating the determination result of the state detection unit 32 is output to the short circuit control unit 33 and the arc control unit 34.
- the short-circuit control unit 33 receives a short-circuit signal from the state detection unit 32 and controls the short-circuit current during the short-circuit period. Based on the set current, the short-circuit control unit 33 outputs a command to the drive unit 31 so that the short-circuit current has a predetermined waveform.
- the arc control unit 34 receives an arc signal from the state detection unit 32 and controls the arc voltage during the arc period when the arc is in an arc state.
- the arc control unit 34 outputs a command to the drive unit 31 to output peak current IP and base current IB for a predetermined time during the arc period.
- the transition period from peak current IP to base current IB during the arc period is controlled by current control.
- the set current setting unit 35 sets the set current.
- a signal indicating the set current is output to the short circuit control unit 33 and the arc control unit 34.
- the basic frequency setting unit 36 determines the wire feed frequency appropriate for each set current based on the set current. Specifically, the basic frequency setting unit 36 is provided with a table or relational expression that correlates the set current with the frequency, and the frequency is determined from this table or the like based on the set current. A signal indicating the frequency is output to the feed motor 12.
- the speed amplitude basic setting unit 37 determines the wire feed speed amplitude appropriate for each set current based on the set current. Specifically, the speed amplitude basic setting unit 37 is provided with a table or relational expression that correlates the set current with the speed amplitude, and the speed amplitude is determined from this table or the like based on the set current. A signal indicating the speed amplitude is output to the feed motor 12.
- the average feed speed setting unit 38 determines the welding wire feed speed, which is the average wire feed speed appropriate for each set current, based on the set current. Specifically, the average feed speed setting unit 38 is provided with a table or relational expression that correlates the set current with the average feed speed, and the average feed speed is determined from this table or the like based on the set current. A signal indicating the welding wire feed speed is output to the feed motor 12.
- the feed motor 12 controls the feeding of the welding wire 15 in a repeated, cyclical manner between forward and reverse feed based on the frequency, speed amplitude, and welding wire feed speed.
- the wire feed speed command is a command that repeats sinusoidal forward and reverse feed using the frequency and speed amplitude in accordance with the average wire feed speed appropriate for the set current value.
- time t1 indicates the time when the short circuit starts.
- an initial short circuit current is output for a predetermined period from time t1, and then the welding current is gradually increased.
- Time t2 indicates the time when the short-circuit state ends and an arc state occurs.
- the period from time t2 to time t3 is an arc period in which an arc 16 is generated between the welding wire 15 and the workpiece W.
- an arc 16 is generated between the welding wire 15 and the workpiece W, and the heat of the arc 16 forms a molten droplet at the tip of the welding wire 15 and melts part of the workpiece W.
- the welding current is increased from base current IB to peak current IP. If the welding current is increased at a steep slope from base current IB to peak current IP, spatter is more likely to occur.
- the arc period includes a first period and a second period that follows the first period.
- the welding current is changed in a linear fashion connecting the second change point P2 and the third change point P3.
- the molten droplet held at the tip of the welding wire 15 can be stably transferred toward the molten pool. As a result, it becomes easier to form a wide bead and the generation of spatter due to micro-short circuits can be suppressed.
- the slope of the line connecting the second change point P2 and the third change point P3 is less than 200 A/msec, the heat input to the welding wire 15 is small, and droplet growth at the tip of the welding wire 15 becomes unstable. As a result, the periodicity between the short-circuit period and the arc period is disrupted, which may result in unstable welding.
- the tip of the welding wire 15 will rise significantly from the droplet, which may cause unstable droplet transfer to the molten pool and unstable bead formation.
- the slope of the line connecting the second change point P2 and the third change point P3 is set to be greater than or equal to 200 A/msec and less than or equal to 1500 A/msec.
- the slope of the line connecting the second change point P2 and the third change point P3 is set to be 1200 A/msec.
- Time t3 indicates the time when the next short circuit occurs, and is in the same state as time t1.
- welding wire feed control is performed with a predetermined frequency and a predetermined speed amplitude, with forward and reverse feed alternately repeated multiple times in a sinusoidal waveform based on this basic waveform.
- a short circuit occurs around time t1
- an arc 16 occurs around time t2.
- another short circuit occurs around time t3.
- the period from time t1 to time t3 constitutes one control cycle, and welding is performed by repeating this cycle.
- Comparative Example 1 The following describes time waveforms when the welding current is changed during the arc period by a method different from that of the arc welding method according to the present embodiment.
- the change in the welding current according to the present embodiment is shown by a virtual line to facilitate comparison with the change in the welding current according to the comparative example.
- Comparative Example 2 4 in a first period, the welding current is changed along an arc-shaped curve where the welding current is greater than the imaginary line connecting the first change point P1 and the second change point P2. Then, in a second period, the welding current is changed along an arc-shaped curve where the welding current is greater than the imaginary line connecting the second change point P2 and the third change point P3.
- Comparative Example 3 In Comparative Example 3 shown in Figure 5, during the first period, the welding current is changed along an arc-shaped curve that increases the welding current more than the imaginary line connecting the first change point P1 and the second change point P2. Then, during the second period, the welding current is changed along a straight line connecting the second change point P2 and the third change point P3'.
- the third change point P3' is later than the third change point P3 in the above embodiment.
- the slope of the line connecting the second change point P2 and the third change point P3' is gentler than the slope of the line connecting the second change point P2 and the third change point P3 in the above embodiment.
- the amount of heat input to the welding wire 15 decreases during the period from the second change point P2 to the third change point P3', causing droplet growth at the tip of the welding wire 15 to become unstable, disrupting the periodicity between the short-circuit period and the arc period, which could result in unstable welding.
- Comparative Example 4 In Comparative Example 4 shown in Figure 6, the welding current is changed from the first period to the second period along an arc-shaped curve in which the welding current is greater than the imaginary line connecting the first change point P1' and the third change point P3'.
- the first change point P1' is later than the first change point P1 in the above embodiment.
- the wire feed speed is slower than the wire feed speed in the above embodiment, and the peak current IP' at the third change point P3' is smaller than the peak current IP at the third change point P3 in the above embodiment.
- the welding current is changed along an arc-shaped curve from the first period to the second period, where the welding current is greater than the imaginary line connecting the first change point P1′ and the third change point P3.
- the first change point P1′ is later than the first change point P1 in the above embodiment.
- the change in welding current becomes steeper overall during the period from the first change point P1' to the third change point P3, and the welding current also increases when rising.
- the arc pressure applied to the molten pool increases, causing the molten pool to vibrate, which may cause spatter to fly off during the second arc growth, as shown in the figure.
- Comparative Example 6 In Comparative Example 6 shown in Figure 8, the welding current is changed from the first period to the second period along an arc-shaped curve in which the welding current is greater than the virtual line connecting the first change point P1' and the third change point P3.
- the first change point P1' is a point in time after the first change point P1 in the above embodiment.
- Comparative Example 6 and Comparative Example 5 have the same change in welding current, but the cause of the welding defect in Comparative Example 6 will be described, which is different from that in Comparative Example 5.
- Comparative Example 7 In Comparative Example 7 shown in Figure 9, the welding current is changed linearly from the first period to the second period, connecting the first change point P1' and the third change point P3'.
- the first change point P1' is later than the first change point P1 in the above embodiment.
- the wire feed speed is slower than the wire feed speed in the above embodiment, and the peak current IP' at the third change point P3' is smaller than the peak current IP at the third change point P3 in the above embodiment.
- the welding current is changed linearly from the first period to the second period, connecting the first change point P1′ and the third change point P3.
- the first change point P1′ is a point in time later than the first change point P1 in the above embodiment.
- the change in welding current becomes steeper overall during the period from the first change point P1' to the third change point P3, and the welding current also increases when rising.
- the arc pressure applied to the molten pool increases, causing the molten pool to vibrate, which may cause spatter to fly off during the second arc growth, as shown in the figure.
- the heat input to the welding wire 15 can be ensured by changing the welding current in the first period so that the welding current is greater than the imaginary line connecting the first change point P1 and the second change point P2.
- the welding speed can be set to a range of 0.6 to 1.5 m/min. Furthermore, productivity can be improved by improving the gap tolerance.
- the arc period includes a first period and a second period that follows the first period.
- the point at which the welding current begins to change in the first period is the first change point P1
- the point at which the welding current begins to change in the second period is the second change point P2
- the point at which the welding current reaches the peak current IP in the second period is the third change point P3
- a predetermined point between the first change point P1 and the second change point P2 is the fourth change point P4.
- the welding current is changed so that it is greater than the imaginary line connecting the first change point P1 and the second change point P2.
- the welding current is changed along a line connecting the first change point P1 and the fourth change point P4, and then the welding current is changed along a line connecting the fourth change point P4 and the second change point P2.
- the welding current is changed along a line connecting the second change point P2 and the third change point P3.
- the arc welding method according to the second embodiment allows droplets to be stably formed at the tip of the welding wire 15 in the initial state of the arc period.
- the arc period includes a first period and a second period that follows the first period.
- the point in time when the welding current begins to change during the first period is the first change point P1
- the point in time when the welding current begins to change during the second period is the second change point P2
- the point in time when the welding current reaches the peak current IP during the second period is the third change point P3
- a predetermined point in time between the first change point P1 and the second change point P2 is the fourth change point P4
- a predetermined point in time between the first change point P1 and the fourth change point P4 is the fifth change point P5.
- the welding current is changed so that it is greater than the imaginary line connecting the first change point P1 and the second change point P2.
- the welding current is changed along a line connecting the first change point P1 and the fifth change point P5, then along a line connecting the fifth change point P5 and the fourth change point P4, and then along a line connecting the fourth change point P4 and the second change point P2.
- the welding current is changed along a line connecting the second change point P2 and the third change point P3.
- the arc welding method according to the third embodiment allows stable formation of droplets at the tip of the welding wire in the initial state of the arc period.
- the present invention has the highly practical effect of suppressing the generation of spatter by appropriately changing the welding current during the arc period, making it extremely useful and highly applicable industrially.
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Abstract
Description
本発明は、アーク溶接方法に関するものである。 The present invention relates to an arc welding method.
特許文献1には、短絡が解除された時より所定の時間経過後に、従来からの定電圧制御で出力される電流値よりも高い電流値で所定の期間、定電流制御することで、短絡解除直後の短絡の発生を抑制し、スパッタの発生を抑制するようにしたアーク溶接機が開示されている。 Patent Document 1 discloses an arc welding machine that, after a predetermined time has elapsed since the short circuit was released, applies constant current control for a predetermined period at a current value higher than the current value output under conventional constant voltage control, thereby suppressing the occurrence of a short circuit immediately after the short circuit is released and suppressing the generation of spatter.
ところで、アーク溶接において、ビード幅や溶込み量を確保するためには、溶融金属の量を増加させる必要がある。 In arc welding, the amount of molten metal needs to be increased to ensure sufficient bead width and penetration.
しかしながら、溶融金属の量を増加させるために、例えば、溶接電流を急峻な傾きでピーク電流に達するまで上昇させると、スパッタが発生し易くなるという問題がある。 However, if the welding current is increased at a steep rate until it reaches a peak current in order to increase the amount of molten metal, there is a problem in that spatter is more likely to occur.
本開示の態様は、かかる点に鑑みてなされたものであり、その目的は、アーク期間において溶接電流を適切に変化させることで、スパッタの発生を抑えることにある。 The aspects of the present disclosure were made in consideration of these points, and their purpose is to reduce the generation of spatter by appropriately changing the welding current during the arc period.
第1の態様は、消耗電極である溶接ワイヤの正送と逆送とを周期的に繰り返し、短絡状態の短絡期間と、アーク状態のアーク期間とを交互に繰り返して溶接を行うアーク溶接方法であって、前記アーク期間は、第1期間と、前記第1期間よりも後の第2期間と、を含み、前記第1期間において溶接電流の変化が開始する時点を第1変化点、前記第2期間において前記溶接電流の変化が開始する時点を第2変化点、前記第2期間において前記溶接電流がピーク電流に達する時点を第3変化点とし、前記第1期間において、前記第1変化点と前記第2変化点とを繋ぐ仮想直線よりも前記溶接電流が大きくなるように、前記溶接電流を変化させる第1工程と、前記第2期間において、前記第2変化点と前記第3変化点とを繋ぐ直線状に前記溶接電流を変化させる第2工程と、を備える。 The first aspect is an arc welding method that performs welding by cyclically repeating forward and reverse feed of a welding wire, which is a consumable electrode, and alternating between short-circuit periods in a short-circuit state and arc periods in an arc state, wherein the arc period includes a first period and a second period that follows the first period, and the point at which the welding current starts to change in the first period is defined as a first change point, the point at which the welding current starts to change in the second period is defined as a second change point, and the point at which the welding current reaches a peak current in the second period is defined as a third change point, and the method includes a first step of changing the welding current in the first period so that the welding current is larger than an imaginary line connecting the first change point and the second change point, and a second step of changing the welding current in the second period along a line connecting the second change point and the third change point.
第1の態様では、第1期間において、第1変化点と第2変化点とを繋ぐ仮想直線よりも溶接電流が大きくなるように、溶接電流を変化させることで、溶接ワイヤの入熱量を確保するようにしている。これにより、アーク期間の初期状態において、溶接ワイヤの先端部に溶滴を安定して形成することができる。 In the first aspect, the heat input to the welding wire is ensured by changing the welding current during the first period so that it is greater than the imaginary line connecting the first change point and the second change point. This allows droplets to be stably formed at the tip of the welding wire in the initial state of the arc period.
また、第2期間において、第2変化点と第3変化点とを繋ぐ直線状に溶接電流を変化させることで、溶接ワイヤに対する入熱量を一定の増加率で確保するようにしている。 Furthermore, during the second period, the welding current is changed in a linear fashion connecting the second change point and the third change point, thereby ensuring that the heat input to the welding wire is increased at a constant rate.
これにより、溶滴形成の初期状態から成長過程の溶滴を、溶接ワイヤの先端部に常に保持することができる。また、ピーク電流に達するまでの間、溶滴成長を安定して行うことで、所望のサイズの溶滴を形成することができる。 This allows droplets, from the initial droplet formation stage through to their growth, to be constantly maintained at the tip of the welding wire. Furthermore, by ensuring stable droplet growth until the peak current is reached, droplets of the desired size can be formed.
さらに、溶接ワイヤの先端部に保持された溶滴を、溶融池に向けて安定して移行させることができる。その結果、幅広のビードを形成し易くなるとともに、微小短絡によるスパッタの発生を抑えることができる。 Furthermore, the molten droplets held at the tip of the welding wire can be transferred stably toward the molten pool. As a result, it becomes easier to form a wide bead and the generation of spatter due to micro-short circuits can be suppressed.
第2の態様は、第1の態様のアーク溶接方法において、前記第1工程では、前記仮想直線よりも前記溶接電流が大きくなる円弧状の曲線に沿って、前記溶接電流を変化させる。 In a second aspect, in the arc welding method of the first aspect, in the first step, the welding current is changed along an arc-shaped curve in which the welding current is greater than the virtual straight line.
第2の態様では、第1期間において、円弧状の曲線に沿って溶接電流を変化させることで、溶接ワイヤの入熱量を確保するようにしている。これにより、アーク期間の初期状態において、溶接ワイヤの先端部に溶滴を安定して形成することができる。 In the second aspect, the welding current is changed along an arc-shaped curve during the first period to ensure the heat input to the welding wire. This allows for stable formation of droplets at the tip of the welding wire during the initial state of the arc period.
第3の態様は、第1の態様のアーク溶接方法において、前記第1変化点と前記第2変化点との間の所定の時点を第4変化点とし、前記第1工程では、前記第1変化点と前記第4変化点とを繋ぐ直線状に前記溶接電流を変化させた後で、前記第4変化点と前記第2変化点とを繋ぐ直線状に前記溶接電流を変化させる。 In a third aspect, in the arc welding method of the first aspect, a predetermined point between the first change point and the second change point is designated as a fourth change point, and in the first step, the welding current is changed in a linear fashion connecting the first change point and the fourth change point, and then the welding current is changed in a linear fashion connecting the fourth change point and the second change point.
第3の態様では、第1期間において、第1変化点と第4変化点とを繋ぐ直線状に溶接電流を変化させた後で、第4変化点と第2変化点とを繋ぐ直線状に溶接電流を変化させることで、溶接ワイヤの入熱量を確保するようにしている。これにより、アーク期間の初期状態において、溶接ワイヤの先端部に溶滴を安定して形成することができる。 In the third aspect, during the first period, the welding current is changed in a linear fashion connecting the first change point and the fourth change point, and then the welding current is changed in a linear fashion connecting the fourth change point and the second change point, thereby ensuring the heat input to the welding wire. This allows droplets to be stably formed at the tip of the welding wire in the initial state of the arc period.
第4の態様は、第1~3の態様の何れか1つのアーク溶接方法において、前記第2変化点と前記第3変化点とを繋ぐ直線の傾きは、200A/msec以上で且つ1500A/msec以下である。 A fourth aspect is an arc welding method according to any one of the first to third aspects, wherein the slope of the line connecting the second change point and the third change point is 200 A/msec or more and 1500 A/msec or less.
第4の態様では、第2変化点と第3変化点とを繋ぐ直線の傾きを適切に設定することで、溶接ワイヤの入熱量を確保しつつ、スパッタの発生を抑えることができる。 In the fourth aspect, by appropriately setting the gradient of the line connecting the second change point and the third change point, it is possible to ensure the heat input to the welding wire while suppressing the generation of spatter.
具体的に、第2変化点と第3変化点とを繋ぐ直線の傾きが200A/msecよりも小さい場合には、溶接ワイヤの入熱量が少なく、溶接ワイヤの先端部において溶滴成長が安定しなくなる。その結果、短絡期間とアーク期間との周期性が乱れてしまい、溶接が不安定となるおそれがある。 Specifically, if the slope of the line connecting the second and third change points is less than 200 A/msec, the heat input to the welding wire is small, and droplet growth at the tip of the welding wire becomes unstable. As a result, the periodicity between the short-circuit period and the arc period is disrupted, which may result in unstable welding.
一方、第2変化点と第3変化点とを繋ぐ直線の傾きが1500A/msecよりも大きい場合には、溶接ワイヤの入熱量が過多となり、溶融池に加わるアーク圧力が増大する。そして、アーク圧力が増大することで、溶融池を振動させてしまい、スパッタが発生するおそれがある。また、溶接ワイヤの入熱量が過多の場合には、溶接ワイヤの先端部の溶滴からのせり上がりが顕著になり、溶融池への溶滴移行が安定せず、ビード形成が不安定になるおそれがある。 On the other hand, if the slope of the line connecting the second and third change points is greater than 1500 A/msec, the heat input to the welding wire will be excessive, increasing the arc pressure applied to the molten pool. This increased arc pressure will then cause the molten pool to vibrate, which could result in spatter. Furthermore, if the heat input to the welding wire is excessive, the tip of the welding wire will rise significantly from the droplet, which could cause unstable droplet transfer to the molten pool and unstable bead formation.
そこで、本開示の態様では、第2変化点と第3変化点とを繋ぐ直線の傾きを、上述した条件を満たすように設定するようにしている。 Therefore, in this aspect of the present disclosure, the slope of the line connecting the second change point and the third change point is set to satisfy the above-mentioned condition.
第5の態様は、第4の態様のアーク溶接方法において、前記第2変化点と前記第3変化点とを繋ぐ直線の傾きは、1200A/msecである。 In a fifth aspect, in the arc welding method of the fourth aspect, the slope of the line connecting the second change point and the third change point is 1200 A/msec.
第5の態様では、第2変化点と第3変化点とを繋ぐ直線の傾きを適切に設定することで、溶接ワイヤの入熱量を確保しつつ、スパッタの発生を抑えることができる。 In the fifth aspect, by appropriately setting the gradient of the line connecting the second change point and the third change point, it is possible to ensure the heat input to the welding wire while suppressing the generation of spatter.
本開示の態様によれば、アーク期間において溶接電流を適切に変化させることで、スパッタの発生を抑えることができる。 According to this aspect of the disclosure, the occurrence of spatter can be suppressed by appropriately changing the welding current during the arc period.
以下、本発明の実施形態を図面に基づいて説明する。なお、以下の好ましい実施形態の説明は、本質的に例示に過ぎず、本発明、その適用物或いはその用途を制限することを意図するものではない。 Embodiments of the present invention will now be described with reference to the drawings. Note that the following description of the preferred embodiment is merely exemplary in nature and is not intended to limit the present invention, its applications, or its uses.
《実施形態1》
図1に示すように、アーク溶接装置1は、溶接ワイヤ15の正送と逆送とを周期的に繰り返し、溶接ワイヤ15とワークWとの間で、短絡状態の短絡期間と、アーク状態のアーク期間とを交互に繰り返してアーク16を発生させることで、ワークWを溶接する。
First Embodiment
As shown in FIG. 1 , the arc welding device 1 periodically repeats forward and reverse feed of the welding wire 15, and alternates between a short-circuit period in a short-circuit state and an arc period in an arc state between the welding wire 15 and the workpiece W to generate an arc 16, thereby welding the workpiece W.
アーク溶接装置1は、溶接ユニット10と、制御部30と、を有する。溶接ユニット10は、溶接トーチ11と、送給モータ12と、電力変換部20と、を有する。送給モータ12は、所定の送給速度で、溶接ワイヤ15を溶接トーチ11に送給する。 The arc welding device 1 has a welding unit 10 and a control unit 30. The welding unit 10 has a welding torch 11, a feed motor 12, and a power conversion unit 20. The feed motor 12 feeds the welding wire 15 to the welding torch 11 at a predetermined feed speed.
電力変換部20は、一次側整流部21と、スイッチング部22と、主変圧器23と、二次側整流部24と、リアクトル25と、電圧検出部26と、電流検出部27とを有する。 The power conversion unit 20 includes a primary side rectifier 21, a switching unit 22, a main transformer 23, a secondary side rectifier 24, a reactor 25, a voltage detection unit 26, and a current detection unit 27.
一次側整流部21は、入力電源5の出力を整流して出力する。スイッチング部22は、一次側整流部21からの直流出力を交流に変換する。スイッチング部22は、溶接電流と溶接電圧よりなる溶接出力を制御する。 The primary side rectifier 21 rectifies and outputs the output of the input power source 5. The switching unit 22 converts the DC output from the primary side rectifier 21 into AC. The switching unit 22 controls the welding output, which consists of the welding current and welding voltage.
主変圧器23は、スイッチング部22の出力する交流の電圧を変換する。主変圧器23の出力は、二次側整流部24とリアクトル25とを介して、溶接出力として出力される。二次側整流部24は、主変圧器23の二次側出力を整流する。電圧検出部26は、溶接電圧を検出する。電流検出部27は、溶接電流を検出する。 The main transformer 23 converts the AC voltage output by the switching unit 22. The output of the main transformer 23 is output as a welding output via the secondary side rectifier 24 and reactor 25. The secondary side rectifier 24 rectifies the secondary side output of the main transformer 23. The voltage detection unit 26 detects the welding voltage. The current detection unit 27 detects the welding current.
制御部30は、駆動部31と、状態検出部32と、短絡制御部33と、アーク制御部34と、設定電流設定部35と、周波数基本設定部36と、速度振幅基本設定部37と、平均送給速度設定部38と、を有する。駆動部31は、スイッチング部22を制御する。 The control unit 30 has a drive unit 31, a state detection unit 32, a short-circuit control unit 33, an arc control unit 34, a set current setting unit 35, a basic frequency setting unit 36, a basic speed amplitude setting unit 37, and an average feed speed setting unit 38. The drive unit 31 controls the switching unit 22.
状態検出部32は、電圧検出部26の検出結果に基づいて、短絡状態又はアーク状態であるかを検出する。具体的に、状態検出部32は、電圧検出部26からの信号に基づいて、溶接出力電圧が一定値以上か未満かを判定する。この判定結果により、溶接ワイヤ15がワークWに接触し短絡している短絡状態であるのか、非接触状態で溶接アークを発生しているアーク状態であるのかを判定する。状態検出部32の判定結果を示す判定信号は、短絡制御部33及びアーク制御部34に出力される。 The state detection unit 32 detects whether the state is a short circuit state or an arc state based on the detection result of the voltage detection unit 26. Specifically, the state detection unit 32 determines whether the welding output voltage is above or below a certain value based on the signal from the voltage detection unit 26. Based on this determination result, it determines whether the state is a short circuit state in which the welding wire 15 is in contact with the workpiece W and short-circuited, or an arc state in which a welding arc is generated in a non-contact state. A determination signal indicating the determination result of the state detection unit 32 is output to the short circuit control unit 33 and the arc control unit 34.
短絡制御部33は、状態検出部32からの短絡の信号を受けて、短絡状態である短絡期間に、短絡電流の制御を行う。短絡制御部33は、設定した設定電流に基づいて、短絡電流が所定の波形となるように、駆動部31に指令を出力する。 The short-circuit control unit 33 receives a short-circuit signal from the state detection unit 32 and controls the short-circuit current during the short-circuit period. Based on the set current, the short-circuit control unit 33 outputs a command to the drive unit 31 so that the short-circuit current has a predetermined waveform.
アーク制御部34は、状態検出部32からのアークの信号を受けて、アーク状態であるアーク期間に、アーク電圧の制御を行う。 The arc control unit 34 receives an arc signal from the state detection unit 32 and controls the arc voltage during the arc period when the arc is in an arc state.
アーク制御部34は、アーク期間において、ピーク電流IP及びベース電流IBを所定時間の間、出力するように、駆動部31に指令を出力する。なお、本実施形態では、アーク期間において、ピーク電流IPからベース電流IBへ移行する期間の制御を、電流制御で行うようにしている。 The arc control unit 34 outputs a command to the drive unit 31 to output peak current IP and base current IB for a predetermined time during the arc period. In this embodiment, the transition period from peak current IP to base current IB during the arc period is controlled by current control.
設定電流設定部35は、設定電流を設定する。設定電流を示す信号は、短絡制御部33及びアーク制御部34に出力される。 The set current setting unit 35 sets the set current. A signal indicating the set current is output to the short circuit control unit 33 and the arc control unit 34.
周波数基本設定部36は、設定電流に基づいて、設定電流毎に適したワイヤ送給の周波数を決定する。具体的に、周波数基本設定部36には、設定電流と周波数とを関係付けたテーブル又は関係式が設けられており、設定電流に基づいて、このテーブルなどから周波数が決定される。周波数を示す信号は、送給モータ12に出力される。 The basic frequency setting unit 36 determines the wire feed frequency appropriate for each set current based on the set current. Specifically, the basic frequency setting unit 36 is provided with a table or relational expression that correlates the set current with the frequency, and the frequency is determined from this table or the like based on the set current. A signal indicating the frequency is output to the feed motor 12.
速度振幅基本設定部37は、設定電流に基づいて、設定電流毎に適したワイヤ送給の速度振幅を決定する。具体的に、速度振幅基本設定部37には、設定電流と速度振幅とを関係付けたテーブル又は関係式が設けられており、設定電流に基づいて、このテーブルなどから速度振幅が決定される。速度振幅を示す信号は、送給モータ12に出力される。 The speed amplitude basic setting unit 37 determines the wire feed speed amplitude appropriate for each set current based on the set current. Specifically, the speed amplitude basic setting unit 37 is provided with a table or relational expression that correlates the set current with the speed amplitude, and the speed amplitude is determined from this table or the like based on the set current. A signal indicating the speed amplitude is output to the feed motor 12.
平均送給速度設定部38は、設定電流に基づいて、設定電流毎に適したワイヤ送給の平均送給速度である溶接ワイヤ送給速度を決定する。具体的に、平均送給速度設定部38には、設定電流と平均送給速度とを関係付けたテーブル又は関係式が設けられており、設定電流に基づいて、このテーブルなどから平均送給速度が決定される。溶接ワイヤ送給速度を示す信号は、送給モータ12に出力される。 The average feed speed setting unit 38 determines the welding wire feed speed, which is the average wire feed speed appropriate for each set current, based on the set current. Specifically, the average feed speed setting unit 38 is provided with a table or relational expression that correlates the set current with the average feed speed, and the average feed speed is determined from this table or the like based on the set current. A signal indicating the welding wire feed speed is output to the feed motor 12.
送給モータ12は、周波数、速度振幅、及び溶接ワイヤ送給速度に基づいて、溶接ワイヤ15を正送と逆送の方向に周期的に繰り返し送給制御する。ワイヤ送給速度指令は、設定電流の電流値に適したワイヤ送給速度の平均送給速度に応じて、周波数と速度振幅による正弦波状の正送と逆送とを繰り返す指令である。 The feed motor 12 controls the feeding of the welding wire 15 in a repeated, cyclical manner between forward and reverse feed based on the frequency, speed amplitude, and welding wire feed speed. The wire feed speed command is a command that repeats sinusoidal forward and reverse feed using the frequency and speed amplitude in accordance with the average wire feed speed appropriate for the set current value.
〈溶接電流の時間波形について〉
図2において、時点t1は、短絡を開始した時点を示す。時点t1から時点t2の短絡期間において、時点t1から短絡初期電流を所定時間出力した後、溶接電流を徐々に増加する。
<Welding current time waveform>
2, time t1 indicates the time when the short circuit starts. During the short circuit period from time t1 to time t2, an initial short circuit current is output for a predetermined period from time t1, and then the welding current is gradually increased.
時点t1から時点t2の間において、溶融池と溶接ワイヤ15の先端部との間に生じた溶滴のくびれが検出される。溶滴のくびれが検出されると、溶接電流は、低電流に瞬時に移行して、短絡状態が終了する。 Between time t1 and time t2, a constriction of the droplet between the molten pool and the tip of the welding wire 15 is detected. When the constriction of the droplet is detected, the welding current is instantly shifted to a low current, and the short-circuit state ends.
時点t2は、短絡状態が終了してアーク状態が発生した時点を示す。時点t2から時点t3は、溶接ワイヤ15とワークWとの間にアーク16が発生するアーク状態であるアーク期間である。このアーク期間により溶接ワイヤ15とワークWとの間にアーク16を発生させ、アーク16の熱で溶接ワイヤ15の先端部に溶滴を形成するとともにワークWの一部を溶かす。 Time t2 indicates the time when the short-circuit state ends and an arc state occurs. The period from time t2 to time t3 is an arc period in which an arc 16 is generated between the welding wire 15 and the workpiece W. During this arc period, an arc 16 is generated between the welding wire 15 and the workpiece W, and the heat of the arc 16 forms a molten droplet at the tip of the welding wire 15 and melts part of the workpiece W.
時点t2から時点t3のアーク期間において、ベース電流IBからピーク電流IPまで溶接電流を上昇させる。ここで、溶接電流を急峻な傾きで、ベース電流IBからピーク電流IPに達するまで上昇させると、スパッタが発生し易くなる。 During the arc period from time t2 to time t3, the welding current is increased from base current IB to peak current IP. If the welding current is increased at a steep slope from base current IB to peak current IP, spatter is more likely to occur.
そこで、本実施形態では、アーク期間において溶接電流を適切に変化させることで、スパッタの発生を抑えるようにした。 In this embodiment, the welding current is appropriately changed during the arc period to suppress the generation of spatter.
具体的に、アーク期間は、第1期間と、第1期間よりも後の第2期間と、を含む。 Specifically, the arc period includes a first period and a second period that follows the first period.
第1期間において溶接電流の変化が開始する時点を第1変化点P1、第2期間において溶接電流の変化が開始する時点を第2変化点P2、第2期間において溶接電流がピーク電流IPに達する時点を第3変化点P3とする。 The point at which the welding current begins to change during the first period is the first change point P1, the point at which the welding current begins to change during the second period is the second change point P2, and the point at which the welding current reaches the peak current IP during the second period is the third change point P3.
第1期間において、第1変化点P1と第2変化点P2とを繋ぐ仮想直線よりも溶接電流が大きくなるように、溶接電流を変化させる。図2に示す例では、仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。 During the first period, the welding current is changed so that it is greater than the imaginary line connecting the first change point P1 and the second change point P2. In the example shown in Figure 2, the welding current is changed along an arc-shaped curve where the welding current is greater than the imaginary line.
これにより、溶接ワイヤ15の入熱量を確保して、アーク期間の初期状態において、溶接ワイヤ15の先端部に溶滴を安定して形成することができる。 This ensures the heat input to the welding wire 15, allowing droplets to be stably formed at the tip of the welding wire 15 in the initial state of the arc period.
次に、第2期間において、第2変化点P2と第3変化点P3とを繋ぐ直線状に溶接電流を変化させる。 Next, during the second period, the welding current is changed in a linear fashion connecting the second change point P2 and the third change point P3.
これにより、溶接ワイヤ15に対する入熱量を一定の増加率で確保して、ピーク電流IPに達するまでの間、溶滴成長を安定して行うことで、所望のサイズの溶滴を形成することができる。 This ensures that the heat input to the welding wire 15 increases at a constant rate, allowing droplet growth to occur stably until the peak current IP is reached, thereby forming droplets of the desired size.
さらに、溶接ワイヤ15の先端部に保持された溶滴を、溶融池に向けて安定して移行させることができる。その結果、幅広のビードを形成し易くなるとともに、微小短絡によるスパッタの発生を抑えることができる。 Furthermore, the molten droplet held at the tip of the welding wire 15 can be stably transferred toward the molten pool. As a result, it becomes easier to form a wide bead and the generation of spatter due to micro-short circuits can be suppressed.
ここで、第2変化点P2と第3変化点P3とを繋ぐ直線の傾きが200A/msecよりも小さい場合には、溶接ワイヤ15の入熱量が少なく、溶接ワイヤ15の先端部において溶滴成長が安定しなくなる。その結果、短絡期間とアーク期間との周期性が乱れてしまい、溶接が不安定となるおそれがある。 Here, if the slope of the line connecting the second change point P2 and the third change point P3 is less than 200 A/msec, the heat input to the welding wire 15 is small, and droplet growth at the tip of the welding wire 15 becomes unstable. As a result, the periodicity between the short-circuit period and the arc period is disrupted, which may result in unstable welding.
一方、第2変化点P2と第3変化点P3とを繋ぐ直線の傾きが1500A/msecよりも大きい場合には、溶接ワイヤ15の入熱量が過多となり、溶融池に加わるアーク圧力が増大する。そして、アーク圧力が増大することで、溶融池を振動させてしまい、スパッタが発生するおそれがある。 On the other hand, if the slope of the line connecting the second change point P2 and the third change point P3 is greater than 1500 A/msec, the heat input to the welding wire 15 will be excessive, and the arc pressure applied to the molten pool will increase. This increased arc pressure will then cause the molten pool to vibrate, potentially resulting in spatter.
また、溶接ワイヤ15の入熱量が過多の場合には、溶接ワイヤ15の先端部の溶滴からのせり上がりが顕著になり、溶融池への溶滴移行が安定せず、ビード形成が不安定になるおそれがある。 Furthermore, if the heat input to the welding wire 15 is excessive, the tip of the welding wire 15 will rise significantly from the droplet, which may cause unstable droplet transfer to the molten pool and unstable bead formation.
そこで、本実施形態では、第2変化点P2と第3変化点P3とを繋ぐ直線の傾きを、200A/msec以上で且つ1500A/msec以下に設定するようにした。なお、好ましくは、第2変化点P2と第3変化点P3とを繋ぐ直線の傾きは、1200A/msecに設定すればよい。 Therefore, in this embodiment, the slope of the line connecting the second change point P2 and the third change point P3 is set to be greater than or equal to 200 A/msec and less than or equal to 1500 A/msec. Preferably, the slope of the line connecting the second change point P2 and the third change point P3 is set to be 1200 A/msec.
このように、第2変化点P2と第3変化点P3とを繋ぐ直線の傾きを適切に設定することで、溶接ワイヤ15の入熱量を確保しつつ、スパッタの発生を抑えることができる。 In this way, by appropriately setting the gradient of the line connecting the second change point P2 and the third change point P3, it is possible to ensure the heat input to the welding wire 15 while suppressing the generation of spatter.
時点t2から時点t3までのアーク期間では、溶接ワイヤ15の先端部と、ワークWの溶融池との間の距離が、T1(第1アーク成長)、T2(第2アーク成長)、T3(第3アーク成長)、T4(アーク長確保)へと移行する。ここで、T1<T2<T3<T4である。 During the arc period from time t2 to time t3, the distance between the tip of the welding wire 15 and the molten pool of the workpiece W transitions from T1 (first arc growth), to T2 (second arc growth), to T3 (third arc growth), to T4 (securing arc length). Here, T1 < T2 < T3 < T4.
これにより、溶滴形成の初期状態から成長過程の溶滴を、溶接ワイヤ15の先端部に常に保持することができる。また、ピーク電流IPに達するまでの間、溶滴成長を安定して行うことで、所望のサイズの溶滴を形成することができる。 This allows droplets, from the initial droplet formation stage through to their growth, to be constantly held at the tip of the welding wire 15. Furthermore, by stably growing the droplets until the peak current IP is reached, droplets of the desired size can be formed.
時点t3は、次の短絡が発生した時点を示しており、時点t1と同様の状態である。溶接ワイヤ15とワークWとが接触し短絡することにより、アーク期間で形成された溶接ワイヤ15の先端部の溶滴を、ワークWに短絡移行し、溶融池を形成して短絡溶接を行う。 Time t3 indicates the time when the next short circuit occurs, and is in the same state as time t1. When the welding wire 15 and workpiece W come into contact and short-circuit, the molten metal droplet formed at the tip of the welding wire 15 during the arc period is transferred to the workpiece W by short-circuiting, forming a molten pool and performing short-circuit welding.
また、図2に示す例では、所定の周波数と所定の速度振幅であって、これを基本波形とした正弦波状に、正送と逆送とを交互に周期的に複数回繰り返す溶接ワイヤ送給制御を行う。そして、正送側のピーク時では、時点t1周辺で短絡が発生し、逆送側のピーク時では、時点t2周辺でアーク16が発生することとなる。また、時点t2の後の正送のピーク時に、時点t3周辺で次の短絡が発生する。 In the example shown in Figure 2, welding wire feed control is performed with a predetermined frequency and a predetermined speed amplitude, with forward and reverse feed alternately repeated multiple times in a sinusoidal waveform based on this basic waveform. At the peak of the forward feed, a short circuit occurs around time t1, and at the peak of the reverse feed, an arc 16 occurs around time t2. At the peak of the forward feed after time t2, another short circuit occurs around time t3.
以上のように、時点t1から時点t3までを制御の1周期とし、これを繰り返して溶接を行う。 As described above, the period from time t1 to time t3 constitutes one control cycle, and welding is performed by repeating this cycle.
〈比較例1〉
以下、本実施形態に係るアーク溶接方法とは異なる方法で、アーク期間において溶接電流を変化させた場合の時間波形について説明する。なお、以下の比較例を説明する図には、本実施形態の溶接電流の変化を仮想線で示すことで、比較例の溶接電流の変化と比較し易くしている。
Comparative Example 1
The following describes time waveforms when the welding current is changed during the arc period by a method different from that of the arc welding method according to the present embodiment. In the figures illustrating the comparative examples below, the change in the welding current according to the present embodiment is shown by a virtual line to facilitate comparison with the change in the welding current according to the comparative example.
図3に示す比較例1では、第1期間において、第1変化点P1と第2変化点P2とを繋ぐ直線状に溶接電流を変化させる。その後、第2期間において、第2変化点P2と第3変化点P3とを繋ぐ直線状に溶接電流を変化させる。 In Comparative Example 1 shown in Figure 3, during the first period, the welding current is changed in a linear fashion connecting the first change point P1 and the second change point P2. Then, during the second period, the welding current is changed in a linear fashion connecting the second change point P2 and the third change point P3.
この場合、第1変化点P1から第2変化点P2までの期間において、溶接ワイヤ15に印加される溶接電流が小さく、入熱不足となることから、溶接ワイヤ15の先端部の溶滴成長が相対的に小さくなる。その結果、ビード幅が細くなるおそれがある。 In this case, during the period from the first change point P1 to the second change point P2, the welding current applied to the welding wire 15 is small, resulting in insufficient heat input, and the growth of the droplet at the tip of the welding wire 15 becomes relatively small. As a result, there is a risk that the bead width will become narrow.
〈比較例2〉
図4に示す比較例2では、第1期間において、第1変化点P1と第2変化点P2とを繋ぐ仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。その後、第2期間において、第2変化点P2と第3変化点P3とを繋ぐ仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。
Comparative Example 2
4 , in a first period, the welding current is changed along an arc-shaped curve where the welding current is greater than the imaginary line connecting the first change point P1 and the second change point P2. Then, in a second period, the welding current is changed along an arc-shaped curve where the welding current is greater than the imaginary line connecting the second change point P2 and the third change point P3.
この場合、第2変化点P2から第3変化点P3までの期間において、溶接電流がピーク電流IPに近づくほど、溶滴成長が鈍化するため、溶接ワイヤ15の溶滴が小さいままでピーク電流IPに到達する。そのため、トータルの入熱量が不足し、相対的に溶滴が小さい状態で溶融池に移行することとなり、溶接ビードの幅が細くなるおそれがある。 In this case, during the period from the second change point P2 to the third change point P3, as the welding current approaches the peak current IP, the growth of the droplets slows down, and the droplets of the welding wire 15 reach the peak current IP while still small. As a result, the total heat input is insufficient, and the droplets transfer to the molten pool in a relatively small state, which may result in a narrower weld bead.
〈比較例3〉
図5に示す比較例3では、第1期間において、第1変化点P1と第2変化点P2とを繋ぐ仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。その後、第2期間において、第2変化点P2と第3変化点P3’とを繋ぐ直線状に溶接電流を変化させる。ここで、第3変化点P3’は、前記実施形態の第3変化点P3よりも後の時点である。
Comparative Example 3
In Comparative Example 3 shown in Figure 5, during the first period, the welding current is changed along an arc-shaped curve that increases the welding current more than the imaginary line connecting the first change point P1 and the second change point P2. Then, during the second period, the welding current is changed along a straight line connecting the second change point P2 and the third change point P3'. Here, the third change point P3' is later than the third change point P3 in the above embodiment.
そのため、第2変化点P2と第3変化点P3’とを繋ぐ直線の傾きが、前記実施形態の場合の第2変化点P2と第3変化点P3とを繋ぐ直線の傾きに比べて、緩やかとなっている。 As a result, the slope of the line connecting the second change point P2 and the third change point P3' is gentler than the slope of the line connecting the second change point P2 and the third change point P3 in the above embodiment.
この場合、第2変化点P2から第3変化点P3’までの期間において、溶接ワイヤ15に対する入熱量が小さくなり、溶接ワイヤ15の先端部での溶滴成長が安定せず、短絡期間とアーク期間との周期性が乱れることとなり、溶接が不安定となるおそれがある。 In this case, the amount of heat input to the welding wire 15 decreases during the period from the second change point P2 to the third change point P3', causing droplet growth at the tip of the welding wire 15 to become unstable, disrupting the periodicity between the short-circuit period and the arc period, which could result in unstable welding.
〈比較例4〉
図6に示す比較例4では、第1期間から第2期間にかけて、第1変化点P1’と第3変化点P3’とを繋ぐ仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。ここで、第1変化点P1’は、前記実施形態の第1変化点P1よりも後の時点である。また、ワイヤ送給速度は、前記実施形態のワイヤ送給速度よりも遅く、第3変化点P3’におけるピーク電流IP’は、前記実施形態の第3変化点P3におけるピーク電流IPよりも小さい。
Comparative Example 4
In Comparative Example 4 shown in Figure 6, the welding current is changed from the first period to the second period along an arc-shaped curve in which the welding current is greater than the imaginary line connecting the first change point P1' and the third change point P3'. Here, the first change point P1' is later than the first change point P1 in the above embodiment. Furthermore, the wire feed speed is slower than the wire feed speed in the above embodiment, and the peak current IP' at the third change point P3' is smaller than the peak current IP at the third change point P3 in the above embodiment.
この場合、第1変化点P1’から第3変化点P3’までの期間において、溶接ワイヤ15に印加される溶接電流が小さく、入熱不足となることから、溶接ワイヤ15の先端部の溶滴成長が相対的に小さくなる。その結果、ビード幅が細くなるおそれがある。 In this case, during the period from the first change point P1' to the third change point P3', the welding current applied to the welding wire 15 is small, resulting in insufficient heat input, and therefore the growth of the droplet at the tip of the welding wire 15 becomes relatively small. As a result, there is a risk that the bead width will become narrower.
〈比較例5〉
図7に示す比較例5では、第1期間から第2期間にかけて、第1変化点P1’と第3変化点P3とを繋ぐ仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。ここで、第1変化点P1’は、前記実施形態の第1変化点P1よりも後の時点である。
Comparative Example 5
7, the welding current is changed along an arc-shaped curve from the first period to the second period, where the welding current is greater than the imaginary line connecting the first change point P1′ and the third change point P3. Here, the first change point P1′ is later than the first change point P1 in the above embodiment.
この場合、第1変化点P1’から第3変化点P3までの期間において、溶接電流の変化が全体的に急峻になるので、上昇時の溶接電流も増加する。そのため、溶融池に加わるアーク圧力が大きくなって溶融池を振動させてしまい、第2アーク成長において図示するように、スパッタとなって飛散するおそれがある。 In this case, the change in welding current becomes steeper overall during the period from the first change point P1' to the third change point P3, and the welding current also increases when rising. As a result, the arc pressure applied to the molten pool increases, causing the molten pool to vibrate, which may cause spatter to fly off during the second arc growth, as shown in the figure.
〈比較例6〉
図8に示す比較例6では、第1期間から第2期間にかけて、第1変化点P1’と第3変化点P3とを繋ぐ仮想直線よりも溶接電流が大きくなる円弧状の曲線に沿って、溶接電流を変化させる。ここで、第1変化点P1’は、前記実施形態の第1変化点P1よりも後の時点である。なお、比較例6と、比較例5とは、溶接電流の変化が同じであるが、比較例6では、比較例5とは異なる溶接不具合の発生原因について説明する。
Comparative Example 6
In Comparative Example 6 shown in Figure 8, the welding current is changed from the first period to the second period along an arc-shaped curve in which the welding current is greater than the virtual line connecting the first change point P1' and the third change point P3. Here, the first change point P1' is a point in time after the first change point P1 in the above embodiment. Note that Comparative Example 6 and Comparative Example 5 have the same change in welding current, but the cause of the welding defect in Comparative Example 6 will be described, which is different from that in Comparative Example 5.
この場合、第1変化点P1’から第3変化点P3までの期間において、溶接ワイヤ15への入熱過多により、溶接ワイヤ15の先端部で成長した溶滴が、溶接ワイヤ15の側部に移行し、短絡期間とアーク期間との周期性を乱してビード外観が不安定となり、さらに、微小短絡によるスパッタ飛散に繋がるおそれがある。 In this case, during the period from the first change point P1' to the third change point P3, excessive heat input to the welding wire 15 causes droplets that have grown at the tip of the welding wire 15 to migrate to the side of the welding wire 15, disrupting the periodicity between the short circuit period and the arc period and making the bead appearance unstable, which may also lead to spatter scattering due to micro-short circuits.
〈比較例7〉
図9に示す比較例7では、第1期間から第2期間にかけて、第1変化点P1’と第3変化点P3’とを繋ぐ直線状に溶接電流を変化させる。ここで、第1変化点P1’は、前記実施形態の第1変化点P1よりも後の時点である。また、ワイヤ送給速度は、前記実施形態のワイヤ送給速度よりも遅く、第3変化点P3’におけるピーク電流IP’は、前記実施形態の第3変化点P3におけるピーク電流IPよりも小さい。
Comparative Example 7
In Comparative Example 7 shown in Figure 9, the welding current is changed linearly from the first period to the second period, connecting the first change point P1' and the third change point P3'. Here, the first change point P1' is later than the first change point P1 in the above embodiment. The wire feed speed is slower than the wire feed speed in the above embodiment, and the peak current IP' at the third change point P3' is smaller than the peak current IP at the third change point P3 in the above embodiment.
この場合、第1変化点P1’から第3変化点P3’までの期間において、溶接ワイヤ15に印加される溶接電流が小さく、入熱不足となることから、溶接ワイヤ15の先端部の溶滴成長が相対的に小さくなる。その結果、ビード幅が細くなるおそれがある。 In this case, during the period from the first change point P1' to the third change point P3', the welding current applied to the welding wire 15 is small, resulting in insufficient heat input, and therefore the growth of the droplet at the tip of the welding wire 15 becomes relatively small. As a result, there is a risk that the bead width will become narrower.
〈比較例8〉
図10に示す比較例8では、第1期間から第2期間にかけて、第1変化点P1’と第3変化点P3とを繋ぐ直線状に溶接電流を変化させる。ここで、第1変化点P1’は、前記実施形態の第1変化点P1よりも後の時点である。
Comparative Example 8
10, the welding current is changed linearly from the first period to the second period, connecting the first change point P1′ and the third change point P3. Here, the first change point P1′ is a point in time later than the first change point P1 in the above embodiment.
この場合、第1変化点P1’から第3変化点P3までの期間において、溶接電流の変化が全体的に急峻になるので、上昇時の溶接電流も増加する。そのため、溶融池に加わるアーク圧力が大きくなって溶融池を振動させてしまい、第2アーク成長において図示するように、スパッタとなって飛散するおそれがある。 In this case, the change in welding current becomes steeper overall during the period from the first change point P1' to the third change point P3, and the welding current also increases when rising. As a result, the arc pressure applied to the molten pool increases, causing the molten pool to vibrate, which may cause spatter to fly off during the second arc growth, as shown in the figure.
-実施形態1の効果-
以上のように、本実施形態1に係るアーク溶接方法によれば、第1期間において、第1変化点P1と第2変化点P2とを繋ぐ仮想直線よりも溶接電流が大きくなるように、溶接電流を変化させることで、溶接ワイヤ15の入熱量を確保することができる。
-Effects of the first embodiment-
As described above, according to the arc welding method of the first embodiment, the heat input to the welding wire 15 can be ensured by changing the welding current in the first period so that the welding current is greater than the imaginary line connecting the first change point P1 and the second change point P2.
また、第2期間において、第2変化点P2と第3変化点P3とを繋ぐ直線状に溶接電流を変化させることで、溶接ワイヤ15に対する入熱量を一定の増加率で確保することができる。 Furthermore, during the second period, by changing the welding current in a linear fashion connecting the second change point P2 and the third change point P3, the heat input to the welding wire 15 can be ensured at a constant rate of increase.
これにより、溶接ワイヤ15の先端部に保持された溶滴を、溶融池に向けて安定して移行させることができる。その結果、幅広のビードを形成し易くなるとともに、微小短絡によるスパッタの発生を抑えることができる。 This allows the molten droplet held at the tip of the welding wire 15 to be transferred stably toward the molten pool. As a result, it becomes easier to form a wide bead and the generation of spatter due to micro-short circuits can be suppressed.
また、溶接ワイヤ15の送給速度を高速化させても、溶接を安定させることができるので、タクトタイムの短縮を図ることができる。 Furthermore, even if the welding wire 15 feed speed is increased, welding can be stabilized, thereby shortening the tact time.
例えば、ワークWとして、板厚が1.6~6.0mmの板材を2枚重ね合わせて溶接する場合、溶接速度を0.6~1.5m/minの範囲に設定することができる。また、ギャップ裕度向上による生産性の向上を図ることができる。 For example, when welding two overlapping workpieces W each having a thickness of 1.6 to 6.0 mm, the welding speed can be set to a range of 0.6 to 1.5 m/min. Furthermore, productivity can be improved by improving the gap tolerance.
《実施形態2》
以下、前記実施形態1と同じ部分については同じ符号を付し、相違点についてのみ説明する。
Second Embodiment
Hereinafter, the same parts as those in the first embodiment will be denoted by the same reference numerals, and only the differences will be described.
図11に示すように、アーク期間は、第1期間と、第1期間よりも後の第2期間と、を含む。 As shown in FIG. 11, the arc period includes a first period and a second period that follows the first period.
第1期間において溶接電流の変化が開始する時点を第1変化点P1、第2期間において溶接電流の変化が開始する時点を第2変化点P2、第2期間において溶接電流がピーク電流IPに達する時点を第3変化点P3、第1変化点P1と第2変化点P2との間の所定の時点を第4変化点P4とする。 The point at which the welding current begins to change in the first period is the first change point P1, the point at which the welding current begins to change in the second period is the second change point P2, the point at which the welding current reaches the peak current IP in the second period is the third change point P3, and a predetermined point between the first change point P1 and the second change point P2 is the fourth change point P4.
第1期間において、第1変化点P1と第2変化点P2とを繋ぐ仮想直線よりも溶接電流が大きくなるように、溶接電流を変化させる。図11に示す例では、第1変化点P1と第4変化点P4とを繋ぐ直線状に溶接電流を変化させた後で、第4変化点P4と第2変化点P2とを繋ぐ直線状に溶接電流を変化させる。その後、第2変化点P2と第3変化点P3とを繋ぐ直線状に溶接電流を変化させる。 During the first period, the welding current is changed so that it is greater than the imaginary line connecting the first change point P1 and the second change point P2. In the example shown in Figure 11, the welding current is changed along a line connecting the first change point P1 and the fourth change point P4, and then the welding current is changed along a line connecting the fourth change point P4 and the second change point P2. After that, the welding current is changed along a line connecting the second change point P2 and the third change point P3.
以上のように、本実施形態2に係るアーク溶接方法によれば、アーク期間の初期状態において、溶接ワイヤ15の先端部に溶滴を安定して形成することができる。 As described above, the arc welding method according to the second embodiment allows droplets to be stably formed at the tip of the welding wire 15 in the initial state of the arc period.
《実施形態3》
図12に示すように、アーク期間は、第1期間と、第1期間よりも後の第2期間と、を含む。
Third Embodiment
As shown in FIG. 12, the arc period includes a first period and a second period that follows the first period.
第1期間において溶接電流の変化が開始する時点を第1変化点P1、第2期間において溶接電流の変化が開始する時点を第2変化点P2、第2期間において溶接電流がピーク電流IPに達する時点を第3変化点P3、第1変化点P1と第2変化点P2との間の所定の時点を第4変化点P4、第1変化点P1と第4変化点P4との間の所定の時点を第5変化点P5とする。 The point in time when the welding current begins to change during the first period is the first change point P1, the point in time when the welding current begins to change during the second period is the second change point P2, the point in time when the welding current reaches the peak current IP during the second period is the third change point P3, a predetermined point in time between the first change point P1 and the second change point P2 is the fourth change point P4, and a predetermined point in time between the first change point P1 and the fourth change point P4 is the fifth change point P5.
第1期間において、第1変化点P1と第2変化点P2とを繋ぐ仮想直線よりも溶接電流が大きくなるように、溶接電流を変化させる。図12に示す例では、第1変化点P1と第5変化点P5とを繋ぐ直線状に溶接電流を変化させ、第5変化点P5と第4変化点P4とを繋ぐ直線状に溶接電流を変化させ、第4変化点P4と第2変化点P2とを繋ぐ直線状に溶接電流を変化させる。その後、第2変化点P2と第3変化点P3とを繋ぐ直線状に溶接電流を変化させる。 During the first period, the welding current is changed so that it is greater than the imaginary line connecting the first change point P1 and the second change point P2. In the example shown in Figure 12, the welding current is changed along a line connecting the first change point P1 and the fifth change point P5, then along a line connecting the fifth change point P5 and the fourth change point P4, and then along a line connecting the fourth change point P4 and the second change point P2. Thereafter, the welding current is changed along a line connecting the second change point P2 and the third change point P3.
以上のように、本実施形態3に係るアーク溶接方法によれば、アーク期間の初期状態において、溶接ワイヤの先端部に溶滴を安定して形成することができる。 As described above, the arc welding method according to the third embodiment allows stable formation of droplets at the tip of the welding wire in the initial state of the arc period.
以上説明したように、本発明は、アーク期間において溶接電流を適切に変化させることで、スパッタの発生を抑えることができるという実用性の高い効果が得られることから、きわめて有用で産業上の利用可能性は高い。 As explained above, the present invention has the highly practical effect of suppressing the generation of spatter by appropriately changing the welding current during the arc period, making it extremely useful and highly applicable industrially.
1 アーク溶接装置
15 溶接ワイヤ
IP ピーク電流
P1 第1変化点
P2 第2変化点
P3 第3変化点
P4 第4変化点
1 Arc welding device 15 Welding wire IP Peak current P1 First change point P2 Second change point P3 Third change point P4 Fourth change point
Claims (5)
前記アーク期間は、第1期間と、前記第1期間よりも後の第2期間と、を含み、
前記第1期間において溶接電流の変化が開始する時点を第1変化点、前記第2期間において前記溶接電流の変化が開始する時点を第2変化点、前記第2期間において前記溶接電流がピーク電流に達する時点を第3変化点とし、
前記第1期間において、前記第1変化点と前記第2変化点とを繋ぐ仮想直線よりも前記溶接電流が大きくなるように、前記溶接電流を変化させる第1工程と、
前記第2期間において、前記第2変化点と前記第3変化点とを繋ぐ直線状に前記溶接電流を変化させる第2工程と、を備える
アーク溶接方法。 An arc welding method in which welding is performed by periodically repeating forward and reverse feeding of a welding wire, which is a consumable electrode, and alternately repeating a short circuit period in a short circuit state and an arc period in an arc state,
the arc period includes a first period and a second period subsequent to the first period,
a first change point is a point in time when the welding current starts to change in the first period, a second change point is a point in time when the welding current starts to change in the second period, and a third change point is a point in time when the welding current reaches a peak current in the second period;
a first step of changing the welding current so that the welding current is greater than a virtual line connecting the first change point and the second change point during the first period;
a second step of varying the welding current in a linear fashion connecting the second change point and the third change point during the second period.
前記第1工程では、前記仮想直線よりも前記溶接電流が大きくなる円弧状の曲線に沿って、前記溶接電流を変化させる
アーク溶接方法。 The arc welding method of claim 1,
In the first step, the welding current is changed along an arc-shaped curve in which the welding current is greater than the virtual straight line.
前記第1変化点と前記第2変化点との間の所定の時点を第4変化点とし、
前記第1工程では、前記第1変化点と前記第4変化点とを繋ぐ直線状に前記溶接電流を変化させた後で、前記第4変化点と前記第2変化点とを繋ぐ直線状に前記溶接電流を変化させる
アーク溶接方法。 The arc welding method of claim 1,
a predetermined point between the first change point and the second change point is set as a fourth change point;
In the first step, the welding current is changed in a linear fashion connecting the first change point and the fourth change point, and then the welding current is changed in a linear fashion connecting the fourth change point and the second change point.
前記第2変化点と前記第3変化点とを繋ぐ直線の傾きは、200A/msec以上で且つ1500A/msec以下である
アーク溶接方法。 In the arc welding method according to any one of claims 1 to 3,
an arc welding method, wherein a gradient of a straight line connecting the second change point and the third change point is 200 A/msec or more and 1500 A/msec or less;
前記第2変化点と前記第3変化点とを繋ぐ直線の傾きは、1200A/msecである
アーク溶接方法。 The arc welding method of claim 4,
An arc welding method, wherein a gradient of a line connecting the second change point and the third change point is 1200 A/msec.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0985439A (en) * | 1995-09-19 | 1997-03-31 | Mitsubishi Heavy Ind Ltd | Consumable electrode gas shielded metal-arc welding method and equipment therefor |
| JP2014014835A (en) * | 2012-07-09 | 2014-01-30 | Daihen Corp | Constriction detection time current control method of consumable electrode arc welding |
| WO2014054261A1 (en) * | 2012-10-01 | 2014-04-10 | パナソニック株式会社 | Arc welding control method |
| JP2020182959A (en) * | 2019-05-07 | 2020-11-12 | 株式会社ダイヘン | Arc welding control method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0985439A (en) * | 1995-09-19 | 1997-03-31 | Mitsubishi Heavy Ind Ltd | Consumable electrode gas shielded metal-arc welding method and equipment therefor |
| JP2014014835A (en) * | 2012-07-09 | 2014-01-30 | Daihen Corp | Constriction detection time current control method of consumable electrode arc welding |
| WO2014054261A1 (en) * | 2012-10-01 | 2014-04-10 | パナソニック株式会社 | Arc welding control method |
| JP2020182959A (en) * | 2019-05-07 | 2020-11-12 | 株式会社ダイヘン | Arc welding control method |
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