| Conventional GMAW welding is a high quality method.With the development of modern advances in welding technology,to improve the welding quality and welding manufacturing productivity has become the an urgent requirement.In response to this weakness,a novel process,referred to as Double-Electrode Gas Metal Coupling Arc Welding or DE-GMAW has been proposed in this paper.The welding model contains two MIG torch,and its arc is the coupling of two arcs.It is possible to ensure the deposition rate while the base metal current can be reduced,because the increased part of the melting current would be bypassed by adding a bypass torch.In the beginning,the passage studied the angle between the two torches,welding speed,Wire feed speed and so on,which are matched with each other.According to the welding experiment,it was showed the instability of welding process and the big welding spatter in open-loop.In the case,a rapid prototyping control system about xpc real-time target was designed to control the welding process with various control method.The result shows that,controlling effect of fuzzy controller is better than PID controller and nine-point controller.Second,based on the constraint of the equipment,the high-speed welding with the fuzzy controller been attempted,for experiment of ordinary carbon steel with the thickness of 4mm,the main GMAW torch wire feed was 25m/min,the welding total current was 550A,and welding speed was 1.5 m/min,it can form a good weld,gain good weld shape and no welding road hump.Finally,the model of the non-consumable DE-GMAW and consumable DE-GMAW are built,and simulation is carried out,which on the basis of the welding experiment.Simulation coincide with the welding experiment results,and to some extent,has certain significance to welding.DE-GMAW has the lower requirement of welding power source,which can be conventional welding power source.So it is a low-cost method of welding and will have broad application prospoects in high efficiency welding.
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