Swing Torch P-GMAW Arc Sensing Test System Design

Smaller sectional area of narrow gap can reduce wire filling,energy consumption,cost,welding time and improve production efficiency.Narrow gap welding has smaller heat input,smaller weld microstructure,better joint toughness,and excellent comprehensive mechanical properties.But small angle between the side wall and the narrow gap welding wire caused the arc on the sidewall of the groove heat input is insufficient easily,resulting in the side wall of incomplete fusion defection.The advantages of narrow gap groove can be fully utilized to improve the fusion defection on the narrow gap side wall by welding the narrow gap with the swing torch P-GMAW.In order to study the arc behavior and sensing characteristics of P-GMAW welding swing torch,swing arc sensor was developed based on P-GMAW narrow gap weld tracking technology.It is necessary to design the swing torch arc sensor P-GMAW experimental system to meet the narrow gap welding swing torch P-GMAW functional requirements.First,based on research and analysis of automatic welding system national and international,the overall design and selection of P-GMAW arc sensor testing system for swing welding torch is carried out aiming at the experimental requirements of arc sensing characteristics and seam tracking technology research.Secondly,the welding torch wiggler,motion mechanism,data acquisition,processing module and the communication control module of welding machine were designed respectively.Welding torch wiggler comprises a horizontal swing mechanism and a lifting adjusting mechanism,scheme of stepping motor and high precision ball screw driving overall welding torch swing and lifting was selected,two modes of motion mechanism were welding torch walking and specimens walking,welding actuator control system can adjust the welding torch swing,swing speed,side stop time,welding speed and other parameters;welding wiggler manual wiggler,the automatic deviation control method of transverse and vertical direction was designed.The interface circuit of AD7606 and DSP was designed.Welding current and voltage signal can be collected synchronously by software program control.The system has high accuracy,small error and strong real-time performance.Through the ROB5000 communication interface and the DSP controller,the communication control of the Fronius welding machine was realized.Arcing,wire feeding and welding current were controlled remotely.For the features of swing torch P-GMAW arc sensor testing system many nodes,each node needs to communicate with each other,a distributed communication network based on CAN bus was established,the data transfer timely and effectively between each node and access to information was ensured by the CAN bus communication protocol between each module of the test system.Finally,based on the analysis of the variation rule of the P-GMAW signal of the swing torch,the arc sensor test system was used to complete the narrow gap weld tracking control experiment of the thick plate,which further verifies the performance of the test system and meets the functional requirements.