The Design Of Pulse TIG Welding Filler Wire Control System

Pulse TIG welding is advanced welding process which based on TIG. Filler wirecontrol system is fully automated key research direction of pulse TIG welding. It’sperformance directly affect the pulse TIG welding quality and production efficiency. PulseTIG welding filler wire control system based on high-performance control chip as the corecontrol unit. On the basis the pulse welding process parameters and feed of full analysis,filler wire system control by software, efficient, economical, high quality, energy savingprominent advantages, Greatly improving the efficiency of ordinary TIG production.Based on the analysis of the pulse tungsten arc welding filler wire welding processcontrol mode, PI control algorithm based on three closed-loop feedback control of thearmature current, wire feed motor speed, pulse TIG welding process parameters.Designedas the core controller PIC16F877A pulse tungsten inert gas welding filler wire controlsystem.The control system to ensure the pulse current in the range50A to200A, the basevalue of the current range can be preset in the case of5A to10A adjustable pulse TIGwelding current frequency of1Hz, guarantee solder center spacing in the range1mm~5mm, wire feed control system of up to26mm/s.Control the process controllerthrough the Hall current sensor detection pulse Tungsten Arc Welding current state of thepulse current wire feed, wire feed, stop when the base current pulse current of the gastungsten arc welding and filler wire control system the same frequency ripple control withthe same pulse width.According to the pulse TIG welding filler wire control system to achieve the functionand design of the drive mechanism complies with the requirements of the filler wirecontrol system, the hardware architecture and software programs.The design part of the drive mechanism, the design focuses on the pulse current frequency of1Hz filler wire control the MHMD022GIU DC servo motor as filler wiredrive motor, the maximum response frequency up to2kHz.The selection of a controlsystem of this motor pulsation fill yarn properties to meet the frequency responserequirements of the pulse current.In the hardware structure of the section, The design of the core controller usingPIC16F877A, including the completion of each functional module of the motor drivecircuit, pulse current sampling circuit, DC power supply design.The design part of the software program, the design uses a modular design, andsimulation and debugging through MPLAB and PROTUES on each module.