| With the rapid development of all kinds of digital elements, micro-plasma arc welding machine in domestic has already reached a certain level of digitization, but the research of micro-plasma arc welding machine was mainly focused on improving the degree of digitization, the integrated of welding machine control system has not realized. The control accuracy of ultra thin stainless steel sheet welding has a high requirement decided by its material characteristics. Besides the adjustment of welding current and speed in ultra thin stainless steel sheet welding, there was need measurement of deformation, burr and butt joint centre line by visual sensing technology, and also need to adjust the arc length. Multiple devices was needed in welding process to achieve multitasking, in this case, the multitasking coordination control and multiple devices integrate were questions needs to solved. Therefore, the research of digital micro plasma arc welding machine control system integration has realistic significance. The realization of multitasking coordination control and multiple devices integrate in ultra-thin plate welding was helpful to improve system stability, but also can promote the development of industrial production, improve the welding quality and production efficiency.In this paper, the integration of digital micro-plasma arc welding machine control system was studied, the primary coverage includes integrated structure of control system, integrated communications and multitasking coordination control.Based on the multiple welding task including adjustment of current, speed and arc-length, and detection of deformation, burr, and butt joint centre line, the concept of control system was proposed. Firstly, the overall hardware integration structure of digital micro-plasma arc welding machine control system was researched, the realization process of different welding task by multiple devices in ultra-thin stainless steel plate welding was analyzed. Secondly, the integration structure of control system based on each welding task was studied respectively, and the realization process of each task were analyzed. Finally, aim at the problem of circuit interference in system operation, series hardware anti-jamming measurements of control system integration structure were discussed. At this time, a stable working environment of hardware circuit was provided to ultra-thin stainless steel plate welding.Based on the characteristic of ultra-thin stainless plate easily deform during welding process, a non-contact detection method of ultra-thin plate deformation was proposed. The deformation of ultra-thin stainless plate was detected and processed with the help of auxiliary light source, and information of ultra-thin stainless plate deform was distinguished successfully. According to the heat input changing by ultra-thin plate deformation, the cooperative control mechanism to ensure t he invariant of welding heat input was studied, and calculation expression of current increment was calculated. So welding defect caused by ultra-thin plate deformation was eliminated effectively.Because of the burr of ultra-thin stainless plate cannot a void in cutting process, vision sensor system was using to acquisition burr information and then morphological information was obtained. The butt joint of ultra-thin stainless plate is only 30-120 um and the stainless is very thin, while burr size is much larger than plate thickness and butt joint gap, so the existence of burr was seriously influenced to welding quality. According to the burr information collected by vision sensor system and the amount of metal reducing, the cooperative control process of anti-burr in ultra-thin plate welding was studied. The torch deviation and arc length were adjusted reasonable on the basis of burr information recognized by vision sensor system. Consequently, the welding quality of ultra-thin stainless plate was improved, and the cooperative control of digital micro-plasma arc welding machine integrated control system was realized. |
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