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Throughout the three major welding exhibitions in 2009, the 14th Beijing Essen Welding and Cutting Exhibition held in Shanghai in June 2009 and the 17th German Essen Welding in Essen, Germany in September 2009. Cutting exhibition, the 23rd China Welding Expo held in Tianjin in October 2009, we are deeply impressed by the development trend of domestic and international welding technology and the new demands and new trends in welding production development: the role of core technology has emerged. There has been development in numerical control and power supply, and laser welding technology has become a bright spot, and robot applications have become popular. It can be considered that the world welding technology has taken a new step and made new progress in high efficiency, automation and environmental friendliness; the types of welding materials are more abundant, welding automation, high efficiency and cleanliness are more prominent; the integration of welding technology The cost is lower and the welding service to the industry is more extensive. At the same time, the manual, rough, dirty and low speed existing in the welding has been basically eliminated, and replaced by automatic, precise, clean and efficient.
1. Inverter welding technology development trend
The inverter welding machine continues to develop in several aspects: the popularity is improved, the power manufacturing capability is enhanced, and the miniaturization is achieved.
Increased popularity: The participation rate of inverter welding machines is getting higher and higher, and the exhibition surface is getting wider and wider. At this year's show, almost all the big companies showed a variety of inverter welders and new technologies and new products with a larger trend, but their respective varieties, power, performance, functions and manufacturing levels were different. In addition, the variety, performance, function, welding method and application range of the inverter welder have also been improved, increased and expanded.
Power manufacturing capacity enhancement: In the past, it was believed that the inverter welding machine is mainly suitable for small and medium power applications due to its advantages of small size, convenient movement and power saving. At this year's show, many companies have exhibited thousands of technical products.
Miniaturization: By increasing the frequency and using high-performance magnets, optimizing the structure, etc., the low-power inverter welder is made as small as possible. For example, a small welder for thin plate welding in assembly and maintenance work with frequent welding position changes is only 3.4 kg.
At the exhibition, the inverter welding machine appeared on the booth of all the welding machine exhibitors, which indicates that the inverter welding machine has become the mainstream trend of the welding machine industry. At present, the inverter welding machine has matured on the basic technology level. The current technical competition is mainly reflected in the extension of the power technology of the inverter welding machine and the deepening of the welding technology related to the inverter welding machine.
1.1 Soft Switch Technology
The soft-switching power supply technology in foreign inverter welding machines is not very common. In particular, most of the 20 kHz inverter welding machines are still hard-switched, but the capacity of the switching devices used is much larger than that of domestic welding machines. The high reliability of the inverter power supply. This is due to the different labor costs, because the manufacturing and assembly costs of the additional electromagnetic components required for the soft switching circuit exceed the material cost of increasing the capacity of the switching device where labor costs are higher. The soft-switching power supply technology abroad is mainly for high-frequency and high-power welding machines operating at 60-120 kHz, mainly to improve the response speed of the power supply and facilitate more precise waveform control processes.
1.2 Transformer material and structure
The inverter transformer is a key component in the inverter welder. In this respect, domestic high-power welding machines use a large proportion of amorphous iron cores, while most foreign countries also use ferrite cores. At present, the most used 20kHz inverter frequency, amorphous iron core should be said to have more material cost advantages than ferrite, but due to the material characteristics, the current amorphous iron core can only be supplied in a ring manner, which is not convenient. The coil is automatically wound. Foreign companies mostly use ferrite cores and are reluctant to switch to amorphous iron cores, while domestic companies use amorphous iron cores extensively for material cost considerations.
1.3 Digital control promotes the upgrading and development of welding technology
Five years ago, digitally controlled welders were just a "smart technology" of a few internationally renowned companies. From this year's show, digital control is commonplace in the world, and digital control welding machines are no longer the selling point of sales. Driven by KEMPPI in Finland and Fronius in Austria, digital welding machines have entered the stage of large-scale production.
The high response speed of the inverter power supply provides an ideal power platform for the welding control technology. The application of digital technology in the welding power supply further improves the level and operability of the power control technology. The digital control of the inverter welding machine will undoubtedly have a strong development, because it greatly simplifies the circuit structure in terms of control, improves the stability of the welding machine control system, and facilitates the application. At present, the biggest gap between domestic digital welding machines and foreign digital welding machines lies in the welding process performance. It can be said that the biggest selling point of the digital welding machine is not the digital technology itself, but the advanced welding technology. At the same time, the biggest advantage of digitalization is that it can carry advanced welding technology when combined with inverter welding machine.
1.4 Relationship between inverter welding machine and welding process
The impact of inverter welding machine on the welding machine industry is undoubtedly a revolution in power technology, but for the entire welding field, it is not so much a revolution in power technology, but a revolution in welding technology. It can be said that the inverter welding machine promotes the deepening of the welding process technology.
In particular, the digital technology is mounted on the technology platform of the inverter welder to further change the technical state of the electric welder industry. Through the exhibition, we can see that the combination of pure power technology and advanced welding technology has become a trend. Studying welding arc behavior will become an important aspect of the future development of the welding machine industry.
1.5 Dependence on digital control of wire feeder
The biggest advantage of the digitally controlled inverter welder is reflected in the GMAW process, so in addition to the power supply problem, the control of the wire feeder is also very important. If there is no stable wire feeding speed, many advanced control methods cannot be realized. For example, the core problem of pulse MIG is the reasonable matching between current waveform and wire feeding speed. At present, the main gap of the domestic pulse MIG welder is not in the power supply, but in the wire feeder. Foreign similar products use wire feeders with speed feedback control, while most domestic wire feeders using voltage feedback control. As the welding process requirements increase, the requirements for the wire feeder are not only speed stability, but also the requirements for response speed. For example, the core of CMT technology is the back pumping control of the wire, which also plays a key role in the arc ignition technology. The digitally controlled AC servo motor has replaced the traditional DC motor in the wire feeder in the high-grade welder. It can be seen that the digital control of the inverter welder is also a development trend from the power supply part to the wire feeder.
1.6 Digital technology for high performance and versatility
As is known, digital technology can improve the interference and control accuracy of the control system, thereby improving the overall performance of the welder's welding accuracy, reliability and stability. At the same time, it can also realize the adjustment of various welding methods, various welding consumables, multi-function, multi-welding parameters and the best matching control by transforming the external characteristic curve, output current waveform, dynamic characteristic parameters, etc. At the same time of making "fine", the welding process and welding parts are also made "fine". The Finnis CMT (Cold Metal Transition) welding system is well described in this respect. The CMT droplet transfer method is novel. Compared with the traditional welding process, the transition droplet temperature is relatively low, and the dissimilar metal connection can be realized. The melting and transition of the welding wire can be respectively become two relatively independent processes, and the welding line energy is controlled. More flexible. Through precise arc length control, the CMT process combined with pulsed arcs, practiced spatter-free soldering, greatly reducing the heat input to the weld. By controlling the pulse arc to affect the heat input, the droplet transfer in the current-free state is realized; the melting time of the base material is extremely short, the arcing speed is increased by two times, the heat input is low, the welding deformation is small, the bridging ability is remarkably improved, and the welding performance is improved. Excellent; the weld is beautifully formed.
It is understood that many universities in China are actively carrying out research on cold metal transition welding systems.
2. Achieve high speed and efficient gas shielded welding
In addition to the high efficiency of welding robot automation, it is ubiquitous that a large number of exhibitors of fusion electrode welding are widely used. In addition to a few special cases, the melting electrode welding is almost all MIG/MAG welding machine, which meets the needs of high-speed and high-efficiency welding of thin plates required by the container industry. The TANDEM welding system exhibited by the German company Cruises in Zhuhai, the welding speed of welding 2~3mm thin plates can reach 6m/min, and the welding efficiency of welding 8mm or more thick plates can reach 24kg/h. Gas shielded welding is the latest alternative to submerged arc welding when welding materials such as low-alloy high-strength steels that require control of line energy.
3. Development trend of CO2 welding equipment
3.1 Reverse change, digitization, intelligence, automation
In order to achieve efficient welding, in the past it was only limited to methods such as changing welding parameters and shielding gas. Today, the inverter welder has shown great vitality because of its high operating frequency, which makes the welder have the characteristics of small size, light weight, energy saving, material saving, low consumption, fast dynamic response, high efficiency and good welding performance. It is gradually becoming the mainstream of arc welding power. It is precisely on the platform of the inverter welding power source, with the help of computer technology, using modern scientific means to continuously solve the higher technical requirements of gas shielded welding.
At present, domestic welding technology research institutions such as Beijing University of Technology and Chengdu Welding Institute and manufacturers from all over the world are actively exploring "how to apply new methods to improve welding quality and achieve 'less splash and no splash', 'less pores and no pores'", “How to apply new methods to reduce welding costs and achieve the fastest welding speed with minimal energy inputâ€. Therefore, actively promote the research and development of digital inverter gas shielded welding machine, and replace the analog control with digital control is the scientific road for the development of gas shielded welder.
3.2 New AC short circuit transition welding method
To meet the low heat input and low spatter CO2/MAG welding requirements, Japan's OTC and Matsushita introduced the AC CBT method and the low-splash all-digital CO2/MAG welder using BB technology. The GLC353CP welder from Germany Cruises and the DL350 digital inverter MIG/MAG welder from OTC Japan adopt a new AC short-circuit transition welding method, which is the welding power source in the positive (EP) and negative (EN) A method of switching between output polarities for soldering. According to reports, compared with the traditional inverter gas welding method, the amount of splash adhesion is significantly reduced. According to OTC, the use of φ1.2 welding wire 250A CO2 gas shielded welding, the traditional inverter CO2 gas shielded welding spatter generation is 2.4g / min, and the AC CBT method of CO2 gas shielded welding spatter generation is only 1.2g /min, the amount of splash is doubled.
4. Short-circuit transition technology under precise control
Miller's RMD welding is a short-circuit transition technology under precise control. It can control the welding current and welding voltage in time to detect the short-circuit current. It can control the molten pool accurately. It is a dynamic control technology. The root weld seam using RMD technology is not only fused, but also can be filled in both size and clearance. In addition, the optimization of welding spatter, heat-affected zone and smooth transition is obviously stronger than traditional cellulose electrode root welding, excellent welding performance, and can realize all the processes of pipeline welding, which is very suitable for construction work in the field environment.
5. Multi-wire welding technology can be seen everywhere
In recent years, double-filament, three-wire and four-wire, five-wire and other multi-filament submerged arc welding have appeared frequently and are used in many industries.
At the exhibition, LINCOLN exhibited multi-wire submerged arc welding technology, using 1000A class AC/DC inverter arc welding power supply and digital cooperative control technology. The first wire is powered by two 1000A-class AC/DC inverter arc welding power supplies in parallel. The remaining wires are powered by 1000A AC/DC power supply, which is mainly used for high-speed welding of thick-walled pipes. According to reports, double wire welding improves welding speed by 30% and increases input heat by 23%. Four wire welding improves welding speed and production by 35% compared with triple wire welding, and increases welding speed from 1.7m/min to 2.3m/min.
ESAB's four-wire and six-wire submerged arc welding technology uses 1200A class thyristor DC arc welding power source, and both use one head (one torch/mouth) double wire, two ends four wires and three heads and six wires. For multi-wire submerged arc welding, each double wire is powered by a 1200A class power supply, which is more efficient. According to reports, the amount of deposited metal is increased from 12kg/h to 38kg/h compared with the monofilament (1*¢4) welding of four wires (2*2*¢2.5).
One to two to one drag four, quickly replace the welding method to improve productivity.
Another technology to increase productivity is the use of a versatile arc welding power supply with 2-4 wire feed systems and their control drive units. According to the different requirements of welding materials and welding methods, one of the corresponding wire feeding systems and control units is selected, and the required welding state is quickly entered, and the auxiliary time is greatly reduced.
The double wire gas shielded welding system of the German company Cruz is also very popular in China.
6. The welding process performance of the welding machine has become the new technical competition focus of the welding machine industry.
It can be seen from the exhibition that the high-end products of the inverter welding machine are still dominated by foreign products. Any important new technology, new methods (such as STT, CMT, Cold Arc, etc.) are all related to the welding process. This shows that the technical competition focus of inverter welding products has begun to shift from power technology and control technology to welding process performance.
For the domestic welding machine industry, whether this transfer can be achieved is a new and more severe challenge, because achieving technological breakthroughs in the welding process will never be easier than breaking through the bottleneck of the inverter welding machine power supply technology. This is a new challenge we have to face. Perhaps it will determine the success or failure of a company in a new round of competition.
7. The use of automated welding systems has been greatly improved
Welding automation is to achieve high efficiency, high quality and low cost batch scale of the workpiece to be welded through the advanced integration of welding technology, materials, equipment, automatic control system and welding tire fixture, card positioning and motion system. Production to ensure stable, consistent batch production of high quality products. Welding automation mainly includes welding automation planes and welding robots.
Nearly half of the exhibits at the show are special planes, most of which are equipped with robots. It is seen from the exhibition that in the field of welding, the most automated is the industrial robot. The use of industrial robots in countries such as Europe and the United States has been very extensive. The large-scale application of industrial robots to meet the automation, flexibility and multi-function of complete sets of equipment is the future development trend.
Most of the welding special machines displayed in China belong to the combination of welding auxiliary machines and welding power supplies and wire feeders.
The most prominent exhibitions in welding automation technology and equipment are: laser and its composite welding robot; arc welding robot; servo welding torch for spot welding robot; various seam tracking technology necessary for automatic welding and intelligent welding.
7.1 Laser welding robot ensures welding flexibility
Compared with the traditional welding method, laser welding has the advantages of energy concentration, small welding deformation, high welding speed and good accessibility. It can be said that the combination of robot and laser welding is a perfect combination of high efficiency and high flexibility.
7.2 The application prospect of electric servo spot welding tongs is good
At present, most of the welding guns used in the spot welding industry are pneumatic welding torches. The technical characteristics of the pneumatic welding torch and the technical requirements of the resistance spot welding determine that the electrode force is fixed, not adjustable, and has a long response time during the welding process. Therefore, it is difficult for the pneumatic welding torch to control the quality of the solder joint by changing the electrode force in a short time. However, the electric servo spot welding gun applies the welding pressure by the AC servo motor to drive the electrode, and each parameter can be accurately controlled. At the same time, after the servo welding gun is applied to the spot welding industry, the response time of the instantaneous forging pressure in the resistance spot welding can be satisfied due to the change of the electrode pressure and the short response time. Therefore, the demand for galvanized steel sheets, aluminum alloys and ultra-high-strength steels for the current automotive industry is increasing. The electrode force controllability of servo welding tongs is used, and other technical characteristics are combined to optimize the welding parameters. The welding and quality control of hard-to-weld materials has opened up a good application prospect.
At the exhibition, the number of spot welding robots increased significantly. Robot manufacturers such as NIMAK in Germany exhibited robots equipped with electric servo spot welding tongs.
7.3 Welding automation special machine to standardization and modular development
Special automatic welding equipment is a welding equipment specially designed for users. The difficulty in manufacturing is due to the individualized design, manufacture, commissioning and service for the user, resulting in long product delivery cycle, high risk and high technical service cost. However, in recent years, with the rapid development of China's modern manufacturing industry and the continuous improvement of the technical level, the long delivery period and the urgent needs of users have become the prominent contradiction in the development of automated welding equipment. Through the exhibition, many welding automation manufacturers, such as welding and research technology, gradually realized the importance of modular design, and actively carried out modular design and production management of automated welding equipment, and made great progress. This shows that modularity is the development direction of automated special welding machines.
From the exhibitions over the years, the proportion of welding automation equipment exhibits has increased year by year, and the level of manufacturing technology and the level of electronic control systems have increased significantly.
8. Research on automatic welding of trolleys, wire feeders, welding torches, etc.
For a long time, CO2 / MIG wire feeders and automatic welding trolleys have been recognized by welding personnel as auxiliary equipment for electric welding machines, and have not received much attention from the welding industry. In fact, these products are indispensable components of welding power supply, representing the application depth and automation level of CO2 / MIG welding, submerged arc welding machine. A good welding power supply provides the welding energy and the driver, and the weld quality, welding effect and welding efficiency pursued by the welding machine are all synthesized by the wire feeder or the automatic trolley connected to the welding torch, and the welding power source is composed. A complete welding system can be realized. Therefore, the quality difference and reliability of these auxiliary tools directly restrict the performance of the main power welding performance. With the popularization and improvement of welding automation, as well as the attention and pursuit of welding efficiency, the position and role of wire feeders and automatic welding trolleys have become more and more prominent, and more and more attention has been paid to the industry.
9. Reasonable industrial structure and technological innovation are gradually forming
From the exhibition point of view, many mature foreign technologies have just started in China. There is a big gap between domestic and foreign welding technology. The development history of advanced technology can fully play a reference role in the development direction of domestic welding technology.
However, the collective appearance of Chinese brand welding machines at the Essen exhibition undoubtedly shows the world that China's welding machines are ready to march into the European market. Industry is not in size, the key lies in vitality, realizing new development, and enhancing the strength of enterprise technology research and development. Shanghai Hugong, Nantong Sanjiu, Shenzhen Ruiling, Jiashi Technology and many other general-purpose product manufacturers have fully utilized the technology and brand advantages of the old enterprises, and have played a world in the international market; Kunshan Huaheng actively promoted the development of robots Tangshan Kaiyuan Robot System Co., Ltd. has developed strongly from Tangshan Kaiyuan Automatic Welding Equipment Co., Ltd.; Shanda Aotai, Nantong Zhenkang, Chengdu Xionggu, Beijing Times, etc. focus on R&D of general-purpose products; Beijing Zhongdian Huaqiang, Welding Research Wei Da, Welding Research Technology, Guangzhou Songxing, Wuxi Weihua, etc. have invested more in the development of special and complete sets of equipment, and the products are constantly innovating; the scale and fine management of Shanghai GM, Shanghai Dongsheng, Chengdu Huayuan and Shanghai Warwick The large-scale development of Yangtong Group and Hualian Group; Hangzhou Kelda not only pays attention to technology investment, but also vigorously develops the CNC cutting machine business, etc., each with distinctive characteristics, outlines the welding equipment industry to adjust the product structure, The development of new products and new technologies will give enterprises a new level of development.
10. Planning, concept, awareness
Without exception, the world's famous welding equipment manufacturers have both long-term professional planning and a strong focus on implementation. For example, ESAB has been working on submerged arc welding for decades. KEMPPI has been producing power since 1946. Still focusing on inverter power research, it has created many world firsts.
Through extensive contacts with domestic and foreign welding machine manufacturers, the impression is very profound: foreign well-known companies have their own core technology and its proprietary technical terms (such as STT, CMT, Power Wave, etc.), there are many new Or technical terms that we have not paid attention to before (such as Force Arc, etc.), and have the R logo. This shows that foreign companies have a strong awareness of core technologies and their intellectual property protection.
In short, in the above-mentioned three major exhibitions, the image of companies from all over the world is vivid, and the new products, new technologies and new techniques that are colorful and colorful have opened the eyes of visitors and also reflected the future development trend of the industry. Especially in the developed countries such as Europe and the United States, the research on welding technology is very deep and very systematic. From complete equipment to welding single machine, from welding materials to welding auxiliary tools... not only the appearance of the product is beautiful, the color is coordinated, the performance is stable, and the reliability is good. And the technical characteristics are very clear, these are worth learning and learning from Chinese companies.
It can be said that the above exhibitions provide a stage for the exhibition of welding equipment and technology at home and abroad, and also push the progress of welding equipment and technology at home and abroad to a brand-new stage, and point out the direction of the development of welding equipment and technology in China. We believe that China's welding technology will follow the objective laws, seek truth from facts and steadily move forward, and will soon be integrated into the world's leading ranks in the near future.
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Development trend of welding technology at home and abroad
With the rapid development of the world's manufacturing industry, welding technology is becoming more and more widely used, and the level of welding technology is getting higher and higher. New welding methods continue to emerge, and professional welding equipment is changing with each passing day. At the same time, domestic and foreign welding equipment manufacturers have also demonstrated their strength through various means, especially through the exhibition to display a wide variety of products and advanced technology.