巴西专利BR112013007672B1 WELDING MACHINE AND WELDING METHOD

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公开号:BR112013007672B1
申请号:R112013007672-0
申请日:2010-09-29
公开日:2018-04-03
发明作者:Berg Michael
申请人:Esab Ab；
IPC主号:

专利说明:

(54) Title: WELDING EQUIPMENT AND WELDING METHOD (73) Holder: ESAB AB. Address: P.O. Box 8004, S-402 77 Gõeteborg, SWITZERLAND (CH) (72) Inventor: MICHAEL BERG
Validity Term: 20 (twenty) years from 9/29/2010, subject to legal conditions
Issued on: 03/04/2018
Digitally signed by:
Júlio César Castelo Branco Reis Moreira
Patent Director
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Descriptive Report of the Invention Patent for WELDING EQUIPMENT AND WELDING METHOD.
TECHNICAL FIELD [001] The present invention relates to a welding apparatus according to the preamble of claim 1 and to a welding method according to the preamble of claim 19. In particular, the invention relates to a welding apparatus for conducting double wire welding, where at least two consumable electrodes are connected to a single power source. The at least two consumable electrodes are connected to an outlet providing the same potential for said at least two consumable electrodes. The invention further relates to a method of double wire welding for a double wire welding apparatus.
BACKGROUND OF THE INVENTION [002] Welding methods and welding apparatus are continually being developed to achieve higher deposition rates with maintained or improved weld quality. One way to increase deposition rates is to use a plurality of electrodes that operate in a single welding process from a single weld pool. The use of a plurality of welding electrodes from a single weld pool requires that the electrodes are located in close proximity to each other. The arrangement around the electrode will, however, lead to an interaction between magnetic fields generated by each electrode. This can result in distorted welding results.
[003] Two different approaches to using a plurality of welding electrodes in a single welding process are known, tandem and double welding.
[004] In tandem welding, each electrode is powered through a separate power supply. Tandem welding can be
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2/28 advantageous in many applications since the control of the energy supply to each of the electrodes is facilitated. In tandem welding, the magnetic interference between the electrodes can be reduced by supplying displaced phase welding currents to the electrodes. This can be achieved by conventional Scott coupled energy sources or by using complex energy sources, such as high frequency converters, for example.
[005] Since tandem welding requires the presence of two separate power supplies, tandem welding devices tend to be expensive and bulky. Thus, for some applications, such as welding in confined spaces, double welding may be a preferred solution or only possible.
[006] In contrast, in double welding, a single source of energy is used to supply a welding current to the electrodes.
[007] An advantage of double welding methods is that the deposition rate can be increased for a given amount of energy input. In double welding methods, the use of more than one electrode allows the reduction of the electrode diameter, which in turn increases the current density of each electrode. The increase in current density allows the high preheat increase of the electrode, consequently, a higher deposition rate can be maintained with less heat transfer to the weld puddle.
[008] In the initial double machines as, for example, disclosed in DE2107617, double welding processes were activated with the rectification of the supply current to be applied in such a way that one arc is supplied with positive and the other by the half current. negative wave. Such arrangements led to severe interaction between the electrodes. In order to reduce the interaction problem, the electrodes
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3/28 had to be positioned at a relatively large distance from each other, making it difficult to allow both electrodes to operate in the same weld pool. If the separation of the welding processes for each electrode occurs, the welding process will be deteriorated.
[009] In order to allow positioning closer to the electrodes to ensure that both electrodes can operate in the same weld pool, it has been suggested to provide double wires through a common electrically conductive contact element which ensures that both wires assume the same potential. An example of this type of double wire welding arrangement is presented in US 5,155,330.
[0010] Although double welding methods in which consumable electrodes are fed through a common electrically conductive contact element to ensure that both wires assume the same potential have been shown to be beneficial for both metal arc welding methods. gas and submerged arc welding methods, further improvements are desirable in order to improve weld quality as well as increase the deposition rate in the welding process.
BRIEF DESCRIPTION OF THE INVENTION [0011] An objective of the present invention is, therefore, to provide a double wire welding apparatus, where the at least two consumable electrodes are connected to a single outlet providing the same potential, whose double wire welding apparatus it allows the improvement of the weld quality and increases the deposition rate. This objective is achieved by a double wire welding apparatus according to claim 1.
[0012] Another objective of the present invention is to provide a double wire welding method, where at least two electroPetition 870170099343, from 12/19/2017, p. 6/40
4/28 of the consumables are connected to a single outlet providing the same potential, whose double wire welding method improves the weld quality and increases the deposition rate. This objective is achieved through a double wire welding method according to claim 19.
[0013] The double wire welding apparatus of the invention includes a first contact tube to guide a first consumable electrode into the weld puddle and transfer welding current to the first consumable electrode, a second contact tube to guide a second electrode consumable to said weld puddle and transfer welding current to the second consumable electrode. The double wire welding apparatus may include more than two contact tubes to allow double welding with more than two consumable electrodes. The first and second contact tubes can be formed on a single contact tip as two parallel main passages on the contact tip, where the consumable electrodes are forced to allow contact between the power source and the consumable electrode. An arrangement of contact tubes, preferably parallel, can be arranged on a single contact tip or, alternatively, be arranged on separate contact tips. The arrangement with more than one contact tube on a single contact tip facilitates the parallel arrangement of consumable electrodes at a close distance, while the use of separate contact tips to house the contact tubes facilitates the arrangement of the contact tubes at an angle to each other.
[0014] With separate contact tips it is intended that the contact tips are not formed as a monolithic conductive structure containing all contact tubes. Instead, a plurality of separate contact tips are provided each housing a single contact tube. In case of contact points sePetição 870170099343, of 12/19/2017, p. 7/40
5/28 stops are used, they will be electrically connected to allow all consumable electrodes to assume the same potential when connected to a single power source. The electrical connection can be provided at the contact tips, the power supply or anywhere between the contact tip and the power source.
[0015] The single energy source is connected to said first and second contact tubes. This can be achieved by a suitable conductor, such as a cable, connecting the power supply with the contact tube. Hence, the welding current will be distributed from the energy source to the respective consumable electrode through the contact tubes.
[0016] According to the invention, the double wire welding apparatus also includes a feeding arrangement for feeding a cold wire to a weld pool formed by arcs created by the first and second consumable electrodes.
[0017] The introduction of a cold wire in the weld puddle will allow the weld puddle to cool in order to keep the weld puddle at a desired temperature. The reduction in the temperature of the weld pool can cause alloying additives to be vaporized to a lesser extent in an area directly affected by the arcs of the consumable electrodes. This can lead to better control of the composition of the weld alloy, which can lead to improved welds. For the purpose of reducing peak temperatures in the weld pool, as well as maintaining a relatively high deposition rate from the cold wire, it is preferable to introduce the cold wire in the vicinity of the arc, preferably in the arc of at least one of the wires consumables. In addition, feeding a cold wire into the weld pool can lead to an increase in deposition rate of more than 20%, with a view to an increase in productivity of around 50% with optimized welding parameters. The invention allows for a higher deposit rate 870170099343, of 12/19/2017, p. 8/40
6/28 tion, without increasing the welding speed. Advantageously, the invention allows reworking of existing welding systems, in particular for welding large workpieces, such as tube mills.
[0018] According to the invention, the feeding arrangement for said cold wire is arranged to feed said cold wire, essentially orthogonally in said weld pool. It has been found that the oblique introduction of the cold electrode, that is, when the cold wire is fed into the weld puddle at an angle to a normal one at the weld puddle surface, can lead to variations in the welding process with a result of deteriorated weld. Variations in the height of the workpiece are believed to have an influence on where the cold wire will enter the weld pool in relation to an extension of the consumable electrode. Such variation will have an effect on the melting rate of the cold wire and also on the peak temperature in the weld puddle. By placing the cold wire so that it is introduced essentially orthogonal to the weld pool, a more stable welding process is achieved. By orthogonal to the weld puddle we mean normal to an upper surface of the weld puddle in a quiescent state without disturbances. It is understood that the weld pool will be exposed to oscillations during welding. However, the top surface of the weld pool in a quiescent state without disturbances would essentially form a plane at the point of introduction of the cold wire into the weld pool, whose plane has a vector from the tip of a consumable electrode to the point closest to the weld pool. solder as a normal one.
[0019] In arc welding, an arc is present between the tip of the electrode and the work piece. The arc contact point on the workpiece will be moving in a random manner. However, it is normally assumed that the arc is present within a
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7/28 cone of the consumable electrode tip for the workpiece. The cone opening angle can vary from case of welding to case of welding. However, a normal opening angle can be about 30 °. For this reason, it is preferable to place the cold wire in such a way that it enters the weld pool in a direction essentially orthogonal to it at an axial distance less than L * cos15 ° from the consumable electrode measured at the end of the consumable electrode. [0020] It may be preferable to arrange the cold wire between two consumable wires. Consumable wires can preferably be mounted at an axial distance less than an arc cone diameter measured at the surface of the weld pool. With this arrangement, the cold wire will be introduced into the outer parts of the arc area defined by the cones of both consumable electrodes, which proved to be beneficial for the welding result.
[0021] In preferred embodiments, the feed arrangement is arranged to feed said cold wire into said weld pool at an angle preferably less than 5 °, preferably still less than 2 °, relative to a normal one at surface. This corresponds to a cone having an opening angle, preferably less than 10 °, preferably even less than 4 °.
[0022] In a preferred embodiment, the consumable electrodes, as well as the cold wire, are arranged in parallel and are arranged to be fed into the weld pool in a direction essentially orthogonal to a weld pool surface.
[0023] The double wire welding arrangement can advantageously include an electric arc welding head comprising a contact device and a supply portion, the contact device comprising an electrode assembly, the electrode assembly comprising at least minus two consumable wire electrodes continuously fed arranged in a conPetition tip 870170099343, of 12/19/2017, pg. 10/40
8/28 touch. An electrically insulated duct is provided for electrical insulation of a cold wire, so that it is electrically insulated from the consumable electrodes in the electrode assembly on the contact device.
[0024] The electrically insulating duct comprises isolated portions in the wire feeder and wire straightening units, as well as guide tubes outside the feeder and straightening units. The duct may consist of a plurality of electrically insulating sections along the cold wire from a wire reservoir, such as a wire coil, for the contact device near the workpiece to be welded. Preferably, the electric arc welding head is used for submerged arc welding. Submerged arc welding can be operated as a fully mechanized or automatic process or, optionally, it can be semi-automatic. Typical welding parameters are current, arc voltage and travel speed, all of which can affect the bead shape, depth of penetration and chemical composition of the weld metal deposited from the consumable electrodes and cold wire.
[0025] The welding head can also be used for gas metal arc welding. In this case, a gas cup and gas ducts, to feed the gas into the cup, will be included in the welding head.
[0026] Favorably, the welding head is compact and allows independent handling of at least one cold wire compared to the consumable electrodes in the welding head electrode assembly. The electrodes, as well as the cold wire, can be supplied by coils of wire mounted on the back of a so-called column and lance arrangement. A column and boom is a rail motion manipulator that loads the weld head Petition 870170099343, of 19/12/2017, pg. 11/40
9/28 gem. The column and the lance are used to position the welding head for the welding groove. The column and lance can also be designed to carry welding equipment, such as energy sources, flow handling equipment and coils as known in the arc welding system art. Preferably, the cold wire can be fed through a spring loaded contact device inside a ceramic tube. The two or more consumable electrodes and the cold wire electrode can have separate wire feeders, making this a non-synergistic arrangement, offering a much wider weld parameter window compared to a synergistic configuration.
[0027] According to a favorable embodiment of the invention, the electrically insulated duct may comprise an electrically insulated wire conduit in the contact device. The insulated wire conduit may be a ceramic tube arranged in the contact device. The ceramic tube can be inserted into the contact device or a part of the contact device can be treated, for example, oxidized, to form an oxide of sufficient thickness for electrical insulation.
[0028] According to a favorable embodiment of the invention, the electrically insulated tube may comprise an electrically insulated portion in a wire straightening unit to straighten one or more of the consumable electrodes and the cold wire. Consumable electrodes and cold wire can be handled in the same wire straightening device.
[0029] According to a favorable embodiment of the invention, an individual wire straightening unit can be provided for the cold wire separate from the wire straightening units of the consumable electrodes of the electrode assembly. Advantageously, the cold wire can be manipulated independently of the electrodes
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10/28 consumables.
[0030] According to a favorable embodiment of the invention, the electrically insulated duct may comprise an electrically insulated portion of a wire feeder unit for feeding consumable electrodes and the cold wire towards a workpiece. Consumable electrodes and cold wire can be handled in the same wire feed device.
[0031] According to a favorable embodiment of the invention, an individual wire feed unit can be provided for cold wire separate from the wire feed units of the consumable electrodes of the electrode assembly. Advantageously, the cold wire can be handled independently of the consumable electrodes.
[0032] According to a favorable embodiment of the invention, an individual speed control unit can be provided for the cold wire separate from the speed control unit of the consumable electrodes of the electrode assembly. Advantageously, the cold wire can be handled independently of the consumable electrodes.
[0033] Favorably, the cold wire can be fed independently from the consumable electrodes in the contact device. This allows for comfortable control of the welding process. The cold wire electrode can be fed with a different speed, in particular, with a variable speed and / or with a different diameter, independent of the consumable electrodes in the contact device.
[0034] According to a favorable embodiment of the invention, the cold wire in the electrically insulated duct can be arranged in sequential order between a main and a later consumable electrode in relation to a welding direction in a workpiece. ORPetition 870170099343, of 12/19/2017, p. 13/40
11/28 dem of cold wire can be used to adjust the weld deposition rate. A symmetrical arrangement can yield very high deposition rates. The sequential order of the cold wire can be chosen depending on the welding requirements.
[0035] According to a favorable embodiment of the invention, the cold wire in the electrically insulated duct can be arranged upstream of the consumable electrodes of the electrode set with respect to a welding direction in a workpiece. Depending on the welding requirements, the sequential order of the cold wire can be chosen. The outermost consumable electrodes can be tilted at a desired angle in relation to the other electrodes. An asymmetric arrangement particularly allows to adjust such an angle in a simple way.
[0036] According to a favorable embodiment of the invention, the cold wire in the electrically insulated duct can be arranged downstream of the other electrodes of the electrode assembly in relation to a welding direction in a workpiece. The sequential order of the cold wire can be chosen depending on the welding requirements.
[0037] According to a favorable embodiment of the invention, a feed unit and / or a straightening unit for the consumable electrodes can provide a through feed to guide the cold wire through the feed unit. Favorably, the cold wire can pass through the feed through the wire straightening unit or the wire feed unit, without interacting with these units or consumable electrodes. The cold wire can be manipulated independently of the consumable electrodes in the same contact device of the same welding head.
[0038] According to another aspect of the invention, a set of
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12/28 welding head is proposed comprising at least two arc welding welding heads, at least one of which comprises a contact device and a supply portion, the contact device comprising an electrode assembly, in which the The electrode assembly comprises at least two wire electrodes continuously fed consumables arranged in a contact device. An electrically insulated duct is provided for electrical insulation of at least one cold wire, so that the cold wire is electrically isolated from the consumable electrodes of the electrode assembly. Favorably, such a weld head assembly is a powerful tool for very high deposition rates, with reduced heat impact on workpieces. The quality of the welding can thus be improved.
[0039] According to a favorable embodiment of the invention, a first welding head can be arranged in sequential order before a second welding head, so that the electrode assemblies of each welding head are aligned along one direction during the welding operation in sequential order. The welding head according to the invention allows a great degree of freedom when designing such a welding head assembly.
[0040] According to a favorable embodiment of the invention, an order of the cold wire in each set of electrodes can be the same for each of the welding heads in relation to the consumable electrodes in each set of electrodes. The welding head according to the invention allows a great degree of freedom when designing such a welding head assembly.
[0041] According to a favorable embodiment of the invention, an order of cold wire in one set of electrodes can be reversed in relation to an order of cold wire in another set of elePetição 870170099343, of 12/19/2017, p. 15/40
13/28 trode of the welding head device. The welding head according to the invention allows a great degree of freedom when designing such a welding head assembly.
[0042] According to a favorable embodiment of the invention, each cold wire can be supplied with a wire straightening unit and / or a wire feed unit separate from the wire straightening units and / or the electrode feed units consumable electrode sets. Cold wires can be handled independently of the consumable electrodes and independently on each welding head, thus giving a great degree of freedom in adapting the welding parameters to particular welding requirements imposed by the material and / or geometry and / or environmental conditions of the parts to be welded.
[0043] According to another aspect of the invention, an electric arc welding contact device for an electric arc welding head and / or a welding head assembly is proposed comprising a device body and an electrically insulated portion for guide the cold wire in an electrically insulated path through the contact device and at least two ducts for at least two consumable electrodes that are in electrical contact with the device body. Favorably, a contact device is provided where one or more cold wires can be used in conjunction with two or more consumable electrodes. The two or more consumable electrodes can be provided to be consumed in arcs during welding, whereas cold wires are not consumed by arcs, but are intended to melt in the weld pool during welding. The cold wire can be used with various diameters chosen regardless of the consumable electrodes in the contact device.
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According to a favorable embodiment of the invention, the electrically insulated portion may comprise an electrically insulating tube. An electrically insulating tube can be easily inserted into the device body. Advantageously, the tube can be made of ceramic which provides superior electrical insulation as well as good heat resistance.
[0045] According to a favorable embodiment of the invention, the device body can be composed of a main part and a removable part that can be fixed to the main part. An arrangement of the consumable electrodes and cold wire in a desired sequential order can be easily achieved or changed.
[0046] According to a favorable embodiment of the invention, a tip can be provided at one end of the device body that has recesses for receiving the electrically insulated portion for cold wire and ducts for other electrodes. Favorably, the recesses for consumable electrodes and the electrically insulated portion can be arranged in the grooves of the tip in a defined manner and maintained securely during operation.
[0047] According to a favorable embodiment of the invention, the electrically insulating portion can be arranged in a symmetrical position between ducts for the consumable electrodes. Favorably, the electrically insulated portion to guide the cold wire can be arranged between two consumable electrode ducts. Such a symmetrical arrangement provides a high deposition rate during welding.
[0048] According to a favorable embodiment of the invention, the electrically insulating part can be arranged in an eccentric position in relation to the ducts for the consumable electrodes in the device body.
[0049] According to another aspect of the invention, an electric arc welding system is provided to generate a weld puddle
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15/28 in a workpiece, comprising at least one welding head or at least one welding head assembly according to any of the characteristics described above. A highly versatile system can be provided that allows easy adjustment of parameters and welding conditions.
[0050] It is evident that more than two consumable electrodes and / or more than one cold wire can be used in a welding apparatus according to the invention. The more than two consumable electrodes and / or the more than 1 cold wires can be arranged on the same welding head.
[0051] With cold wire we mean an elongated metal structure that is fed into the weld pool. The cold wire can have any cross section, such as oval, circular, elliptical, rectangular, quadratic, triangular or any other suitable shape. The consumable electrode can likewise have any cross section, such as oval, circular, elliptical, rectangular, quadratic, triangular or any other suitable shape.
[0052] The invention also relates to a double wire welding method comprising:
- guide a first consumable electrode through a first contact tube towards a welding area,
- guide a second consumable electrode through a second contact tube to the welding area,
- transfer a welding current to the first and second consumable electrodes from a single energy source connected to a first and second consumable electrodes via said first and second contact tubes, to maintain a first and a second arc, respectively, for the generation of a weld pool, in which the said single energy source provides the same potential in said first and second contact tubes. According to the
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16/28 invention, a cold wire is fed essentially orthogonal to said weld pool.
[0053] In one embodiment of the invention, the method includes directing a flow of shielding gas to the common welding area for said first and second consumable electrodes in which a weld pool is held by said first and second arcs, respectively, under the flow of shielding gas.
[0054] The method can also be applied in submerged arc welding.
BRIEF DESCRIPTION OF THE DRAWINGS [0055] The present invention, together with the above mentioned objectives and others and the advantages, can be better understood from the following detailed description of the modalities, but not restricted to the modalities, in which it is shown schematically:
Figure 1 shows a double wire welding apparatus according to the invention.
Figure 1a, a weld puddle with a coordinate system indicating a direction for feeding a cold wire to the weld puddle.
Figure 2 shows a first view of an example embodiment of an arc welding welding head according to the invention for submerged arc welding.
Figure 3 shows the arc welding welding head of Figure 1 rotated counterclockwise by 90 °.
Figure 4 is a perspective view of the arc welding head of Figure 1.
Figures 5a-5e, several views of a contact device for two consumable electrodes and a cold wire with open sectional views (Figures 5a, 5e) and side views (Figures 5b, 5d) and a front view (Figure 5c).
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Figure 6, a side view of an example embodiment of an arc welding welding head.
Figures 7a-7c, an arrangement of a cold wire and a consumable electrode in a first electrode set comprising two electrodes (Figure 7a), a second electrode set comprising two consumable electrodes with the cold wire being the central electrode (Figure 7b) , and a third electrode assembly comprising two consumable electrodes with the cold wire being outside the electrode assembly (Figure 7c); and
Figures 8a-8c, an arrangement of two arc welding welding heads, each comprising cold wire and a consumable electrode in a first electrode assembly comprising two electrodes in each welding head (Figure 8a), a second electrode assembly comprising two consumable electrodes and a cold wire on each welding head, with the cold wire being the central electrode (Figure 8b), and a third electrode set comprising two consumable electrodes and a cold wire on each welding head, with the wire cold being outside the electrode assembly (Figure 8c.).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION [0056] In the drawings, the same or similar elements are referred to by equal reference numerals. The drawings are only schematic representations, not intended to represent specific parameters of the present invention. In addition, the drawings are intended to represent only typical embodiments of the invention and, therefore, should not be considered as limiting the scope of the invention. [0057] Figure 1 shows a schematic drawing of a double wire welding apparatus 1 according to the invention. The double wire welding apparatus includes a first contact tube 2
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18/28 to guide a first consumable electrode 4 towards a weld puddle 6. The first contact tube 2 is arranged on a contact tip 8 in a conventional manner. In the contact tube 2, the welding current is transferred to the first consumable electrode 4. In addition, a second contact tube 10 is arranged in the double wire welding apparatus 1 to guide a second consumable electrode 12 into the weld puddle 6. The second contact tube 10 is arranged on a contact tip 14 in a conventional manner. The first and second contact points can be arranged in a single body, which can be joined by parts, or in separate bodies. In the second contact tube 10, the welding current is transferred to the second consumable electrode 12.
[0058] A single power source 16 is connected to a contact device 18 including contact tips 8, 14 and housing the first and second contact tubes 2, 10. Contact device 18 can include separate contact devices 18a, 18b or a common contact device for both contact tips. The single power source 16 provides the same potential for the first and second consumable electrodes 4, 12. The power source can be of any conventional type operable for the welding of double wire, such as a welding converter, a transformer of welding, a rectifier, a thyristor-controlled rectifier or an inverter. [0059] The double wire welding apparatus 1 further includes a feed arrangement 20 for feeding a cold wire 22 to the weld puddle 6. The feeding arrangement includes a tube 22, which is electrically insulated from the first and second ends contact. The cold wire is fed through tube 22. When welding, an arc will be present in the first and second consumable electrodes 4, 12, but not in cold wire 22. The cold wire is melted by introducing the cold wire into the weld puddle 6 Properly, cold wire
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19/28 is not connected to any source of electrical energy and therefore, in general, assumes an earth potential. However, it may be possible to connect the cold wire to a power source to preheat the cold wire. However, the cold wire will not be connected to an energy source for the purpose of generating an arc between the cold wire and the workpiece. Tube 22 may be a metal tube, which is insulated from the first and second contact points, or a ceramic tube, as in the form of a welding head, as described below, which is suitable for a double welding apparatus of according to the invention.
[0060] The feeding arrangement 20 for said cold wire is arranged to feed said cold wire 22, essentially orthogonally to said weld pool. Figure 1A shows a schematic drawing of a weld puddle 6, including a reference coordinate system 26. The reference coordinate system 26 indicates a welding direction x, which is the direction in which the welding head is moved with respect to a workpiece 28, in which a weld seam is generated. The reference coordinate system 26 also includes a transverse y direction. The welding direction and the transverse direction form an xy plane that is coplanar with an upper surface 30 of the weld pool. It is known that the weld pool can be somewhat agitated during welding. The upper surface at an introduction point 32 of the cold wire is considered to be an upper surface 30 of the weld pool at the introduction point 32 in the quiescent state without disturbance.
[0061] This top surface 30 of the weld puddle in the undisturbed quiescent state would form an xy plane at the point of introduction 32 of the cold wire in the weld puddle, whose xy plane is normal for a vector 38 of the tip 34 of a consumable electrode for the closest point 36 to the weld pool. The reference coordinate system
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20/28 includes a third z direction, which is orthogonal to the xy plane. A vector c is shown here which represents the direction of introduction of the cold wire into the weld pool. The vector c must be essentially orthogonal to the xy plane. A perfect alignment with the z direction is preferable, however, some deviation from the introduction direction of the z direction may be acceptable. The deviation from perfect alignment is indicated by an angle a. In embodiments of the invention, the feed arrangement is arranged to feed said cold wire to said weld pool at an angle of less than 15 °, preferably less than 5 °, still preferably less than 2 ° with respect to a normal to the surface. This corresponds to a cone having an opening angle of less than 30 °, preferably less than 10 °, preferably even less than 4 °.
[0062] In arc welding an arc is present between the tip of the electrode and the work piece. An arc 40 is shown in figure 1. The arc contact on the workpiece will be moving in a random manner. However, it is normally assumed that the arc is present within a cone 42 from the tip of the consumable electrode 34 to the weld puddle. The opening angle β of cone 42 can vary from case of welding to case of welding. However, a normal opening angle β is about 30 °. For this reason, it is preferable to place the cold wire 22 so that it enters the weld pool in a direction essentially orthogonal to it at an axial distance D being less than L * cotan (β / 2) from the consumable electrode measured at tip 34 of the consumable electrode. Here L is the arc length, which is the distance from the electrode tip to the nearest point 36 of the weld pool.
[0063] It may be preferable to arrange cold wire 22 between two consumable wires. Consumable wires can preferably be mounted at an axial distance A being less than a cone diameter d measured on the surface 30 of the weld puddle 6. With this provision 870170099343, of 12/19/2017, pg. 23/40
21/28 position, the cold wire will be introduced in the outer parts of the arc area defined by the cones 42 of both consumable electrodes, which has been shown to be beneficial for the welding result.
[0064] The welding apparatus can include a contact tube spacing mechanism to adjust a spacing between a respective tip of said first and second contact tubes. The welding apparatus may further include a contact tube tilting mechanism for adjusting an inclination between a respective length axis of said first and second contact tubes.
[0065] Figures 2 to 4 represent different views of an exemplary embodiment of an arc welding welding head 100 according to the invention for submerged arc welding, the views of which are described in combination.
[0066] Along its longitudinal extension the arc welding welding head 100 comprises a contact device 160 at its lower end which during welding is in close proximity to the workpiece to be welded. Contact device 160 holds electrodes 172, 176 and a cold wire 174 (Figures 3, 4) from electrode assembly 170 of welding head 100. Electrodes 172, 176 and 174 and cold wire come out of contact device 160 through an outlet 162 at the lower end of the contact device 160 which faces the workpiece during the welding operation. Electrodes 172, 176 and cold wire 174 can be fed from respective reservoirs, such as coils (not shown) towards the arc welding head 100.
[0067] The set of electrodes 170 comprises, as an example, two consumable wire electrodes continuously fed, fused 172, 176 and a cold wire 174 arranged in the
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Contact 160. Contact device 160 comprises an electrically insulating portion 166 for cold wire 174. Only cold wire 174 is shown along the length of the welding head. Consumable electrodes 172, 176 are shown only on contact device 160. Consumable electrodes 172, 176 are arranged as so-called double wires preferably being fed in parallel as a double wire electrode arrangement. The electrically insulating portion 166 is preferably an extra insulated wire conduit, for example, made of a heat resistant material, such as ceramic.
[0068] Above the contact device 160, a feeder device 150 is arranged that feeds the electrodes and the cold wire towards the contact device 160. Typically, the feed unit 150 comprises grooved wheels that move the wire electrodes 172, 176 (not shown in this portion for the sake of clarity) towards contact device 160. The feed unit 150 comprises an electrically insulating portion 156 for direct feeding of cold wire 174. The electrically insulating portion 156 may consist of feed wheels with an extra insulated groove for the electrically insulated cold wire 174. The electrically insulated cold wire 174 can pass through the wire feed unit 150 freely. The feed wheels are driven by a drive unit 152, for example, an electric motor.
[0069] In addition to the wire feed unit 150, a flow hopper 114 is arranged which feeds granular flow to contact device 160 through a nozzle (not shown) for submerged arc welding. In addition to the drive unit 152, the wire feed unit 150 comprises a gear with a drive shaft. On the gear drive shaft a feed wheel 154 (Figure 6) is arranged that can
Petition 870170099343, of 12/19/2017, p. 25/40
23/28 be pressurized by another wheel (not shown). The feed wheel 154 drives the electrode forward towards the contact device 160.
[0070] Above the wire feed unit 150, the wire straightening unit 140 is arranged to straighten consumable electrodes 172, 176. Two rollers (not referred to with reference numbers) shown in a position further ahead of the feed unit wire straightening 140 are used to exert pressure on the three fixed wheels arranged vertically on top of each other at the rear of the wire straightening device. The pressure that the rollers are exerting on the wheels is adjustable by means of buttons on the outside of the wire straightening unit 140. The pressure of the rollers on the three wheels is straightening the wire. The wire straightening unit 140 comprises an electrically insulating portion 146 through which the cold wire 174 can pass freely through the wire straightening unit 140.
[0071] Above the wire straightening unit 140, a separate wire feed unit 130 is arranged to feed the cold wire 174 towards the contact device 160. In the wire feed unit 130, a drive unit 132, for example, an electric motor, is arranged that drives the feed wheels of the wire feed unit 130. In addition to the drive unit 132, the wire feed unit 130 comprises a gear with a drive shaft. On the gear drive shaft, a feed wheel 134 (Figure 6) is arranged which can be pressurized by another wheel (not shown). The feed wheel 134 drives the cold wire forward towards the contact device 160.
[0072] Above the wire feed unit 130, the separate wire straightening unit 120 is arranged to straighten the
Petition 870170099343, of 12/19/2017, p. 26/40
24/28 cold wire 174. Thus, along the longitudinal extension of the welding head 100 an electrically insulating duct 180 is provided to guide the cold wire 174 from a wire reservoir, such as a wire coil (not shown) for the contact nozzle. Between the feed units 150 and 130 and above the wire straightening unit 120 an electrically insulated wire conduit can be arranged which receives the cold wire 174.
[0073] In particular, the electrically insulating duct 180 consists of the electrically insulating portion 146 of the wire straightening unit 140, the electrically insulating portion 156 of the wire feed unit 150 for the consumable electrodes 172, 176, and the insulated portion 166 electrically from contact device 160, as well as electrically insulated wire ducts between them and units 130, 140, 150, 160 and above wire straightening unit 120 for cold wire 174.
[0074] Figure 5a and Figure 5e illustrate several views of a contact device 160 which are described in combination. Contact device 160 comprises a device body 161 comprising ducts for receiving consumable electrodes and cold wire (not shown), in which an electrically insulated portion 166 is one of the ducts.
[0075] As an example, the device body 161 is made of two parts 161a, 161b separated in the longitudinal direction, where a removable part 161b is attached to the main part 161a. The main part 161a has a cylindrical upper portion and a lower portion that is slightly set back from the cut through the middle (Figure 5a, 5e). Removable part 161b is secured to the recessed portion of main part 161a by screws.
[0076] Alternatively, device body 161 may be a monolithic metal body with one or more holes drilled for
Petition 870170099343, of 12/19/2017, p. 27/40
25/28 passage of consumable electrodes and cold wire, instead of several parts.
[0077] Between the removable part 161b and the main part 161b remains a small free distance, when the parts 161a and 161 b are attached to each other. The distance allows several wire diameters to be used for the consumable electrodes in contact device 160. As the cold wire is guided separately in the electrically insulated portion 166 the diameter of the cold wire can be chosen independently of the diameters of the other electrodes in the device body 161.
[0078] Parts 161a, 161 b of device body 161 surround a tip 163 which is composed of two parts 163a, 163b where part 163a is attached to main part 161a and part 163b is attached to removable part 161b of body of device 161. The parts 163a, 163b of the tip 163 can be fixed to the main part 161a and the removable part 161b, respectively, by screws inserted in respective holes 164a, 164b provided in the main part 161a and in the removable part 161b.
[0079] The tip 163 may be smaller in diameter than the rest of the device body 161 which may be predominantly cylindrical in shape. The electrically insulating portion 166 extends the entire longitudinal length of the contact device 166 and provides an outlet 169 for the cold wire (not shown) at an outlet 162 of the tip 163 of the contact device 160.
[0080] As can be seen in the open sectional views presented in Figures 5a and 5e, the device body 161 has an interior section 167 with the electrically insulating portion 166 disposed in a central position, providing an electrically insulating portion of a cold wire ( not shown). The electrically insulating portion 166 is preferably an insulating tube, such as a ceramic tube. In
Petition 870170099343, of 12/19/2017, p. 28/40
26/28 both sides of the electrically insulating central portion 166, a duct 168a, 168b is provided for consumable electrodes (not shown) which are intended to be consumed by arcs during welding. The ducts 168a, 168b comprise corresponding groove portions in the tip parts 163a, 163b. The groove portions form an enclosure for the consumable electrodes when the removable part 161 b is attached to the main part 161a of the device body 161.
[0081] On the outside of the device body 161 a screw 165 is arranged which holds the parts 161a, 161b of the device body together by means of spring elements, such as disc springs, for example, providing a pressure of contact of parts 161a, 161b virtually independent of the actual diameter of the consumable electrodes.
[0082] An electrical contact can be attached to the contact device 160 in the contact portion 164c disposed in the main part 161a of the device body 161. A wire connected to a power source can be connected to the contact portion 164c to transfer electrical voltage and current to the contact device 160 so that arcs can develop in the consumable electrodes that are in close electrical contact with the device body 161.
[0083] In the electrically insulating portion 166 the cold wire can pass through the contact device 160, without coming into contact with the other electrodes (not shown).
[0084] Figure 6 is a side view of an example embodiment of an arc welding welding head 100 of virtually the same arrangement as shown in Figures 2 to 4. In order to avoid unnecessary repetition we refer to these drawings for a detailed description of similar elements. Above the wire straightening unit 140, two guide tubes 142, 144
Petition 870170099343, of 12/19/2017, p. 29/40
27/28 are provided for double electrodes. The guide tubes 142, 144 are arranged transversely to the longitudinal extension of the welding head 100. Between the wire feed unit 130 for the cold wire electrode (not shown) and the wire straightening unit 140 of the consumable electrodes ( not shown), a guide tube 182 for the cold wire (not shown) is arranged. The drive units 132, 152 can be equipped with pulse sensors for electrode speed control. Next to the contact device 160, a nozzle 116 for a flow hopper 114 (Figures 2-4) is arranged, the nozzle 116 is attached to a rod 116 disposed parallel to the longitudinal axis of the contact device 160.
[0085] Figures 7a to 7c show electrode arrangements in electrode sets 170 with respect to a welding direction 20. [0086] Figure 7a shows a first variant of an electrode set 170 with an electrically insulated cold wire 174 and a non-insulated consumable electrode. This welding head must be combined with an additional welding head to include at least two consumable electrodes as suggested by the invention. A second variant of an electrode array 170 is shown in Figure 7b comprising two consumable electrodes 172, 176 and a cold wire, with cold wire 174 being centrally located. A third variant of an electrode assembly 170 comprising two consumable electrodes 172, 176 and a cold wire, with cold wire 174 being outside the electrode assembly is shown in Figure 7c.
[0087] The Figures. 8a to 8c show arrangements of a welding head assembly 200 comprising two arc welding welding heads 100a, 100b. Each welding head 100a, 100b comprises an electrode assembly 170a, 170b with cold wire 174a, 174b and one or more consumable electrodes 172a, 172b. In a
Petition 870170099343, of 12/19/2017, p. 30/40
28/28 first variant of a welding head assembly 200 shown in Figure 8a, each welding head 100a, 100b comprises two electrodes 172a, 172b, and two cold wires 174a, 174b, on each welding head 100a, 100b. Cold wires 174a, 174b are the outermost electrodes in the welding head assembly 200. [0088] A second variant is shown in Figure 8b, in which each welding head 100a, 100b comprises an electrode assembly 170a, 170b, with three electrodes 172a, 176a, 172b, 176b, and two cold wires 174a, 174b, in which cold wire 174a, 174b is disposed in the middle between the two consumable electrodes 172a, 176a, 172b, 176b as central electrodes for each welding head 100a, 100b.
[0089] Figure 8c shows a third variant, with two consumable electrodes 172a, 176a, 172b, 176b, and two cold wires 174a, 174b, on each welding head 100a, 100b, with cold wire 174a, 174b being on the side from the welding head assembly 200.
Petition 870170099343, of 12/19/2017, p. 31/40
1/5

权利要求:
Claims (20)
[1]
1. Double wire welding apparatus (1) including a first contact tube (2) to guide a first consumable electrode (4) towards a weld puddle (6) and transfer welding current to the first consumable electrode ( 4), a second contact tube (10) to guide a second consumable electrode (12) towards said weld pool (6) and transfer welding current to the second consumable electrode (12), and a single source of energy (16) connected to said first and second contact tubes (2.10) to provide the same potential for said two consumable electrodes (4.12), characterized by the fact that said double wire welding apparatus (1) it further includes a feeding arrangement (20) for feeding a cold wire (22) to said weld pool which is arranged to feed said cold wire (22) orthogonally to said weld pool (6).
[2]
2. Welding apparatus (1) according to claim 1, characterized by the fact that said feeding arrangement (20) is arranged to feed said cold wire (22) to said weld pool (6) a an angle of less than 5 ° from a normal to the surface.
[3]
3. Welding apparatus (1), according to claim 1, characterized by the fact that said first and second contact tubes (2.10) are formed in separate contact tips (8.14).
[4]
Welding apparatus (1) according to any one of claims 1 to 3, characterized in that the first and second contact tubes (2.10) are connected to said simple power supply (16) by means of first and second contact devices (18a, 18b) which are separated for the first and second contact tubes (2,10).
Petition 870170099343, of 12/19/2017, p. 32/40
2/5
[5]
5. Welding apparatus (1) according to any one of the preceding claims, characterized by the fact that said welding apparatus (1) further includes a contact tube spacing mechanism for adjusting a spacing between a respective tip of the first and second contact tubes (2.10).
[6]
Welding apparatus (1) according to any one of the preceding claims, characterized in that said welding apparatus further includes a contact tube tilting mechanism for adjusting an inclination between an axis of respective length of said first and second contact tubes (2, 10).
[7]
Welding apparatus according to any one of the preceding claims, characterized by the fact that an electrically insulated duct (180) is provided for electrical insulation of said cold wire (174) to be electrically insulated from said first and second contact (168a, 168b) in an electrode assembly housing said first and second contact tubes and said electrically insulated duct.
[8]
8. Welding apparatus according to claim 7, characterized in that the insulated wire duct (180) is a ceramic tube.
[9]
Welding apparatus according to claim 7 or 8, characterized in that the electrically insulated duct (180) comprises an electrically insulated portion (146) in a wire straightening unit (120, 140) to straighten a or more of consumable electrodes and cold wire (172, 174, 176).
[10]
Welding apparatus according to any one of claims 7 to 9, characterized in that an individual wire straightening unit (120) is provided for the wire
Petition 870170099343, of 12/19/2017, p. 33/40
3/5 cold (174) separated from the wire straightening units (140) of the first and second consumable electrodes (172, 176) of the electrode assembly (170).
[11]
Welding apparatus according to any one of claims 7 to 10, characterized in that the electrically insulated duct (180) comprises an electrically insulated portion (156) in a wire feeder unit (130, 150) to feed one or more electrodes (172, 176) and cold wires (174) towards a workpiece (10).
[12]
Welding apparatus according to any one of claims 7 to 11, characterized in that an individual wire feed unit (130) is provided for the cold wire (174) separate from the wire feed unit (150) the first and second consumable electrodes (172, 176).
[13]
13. Welding apparatus according to any one of the preceding claims, characterized by the fact that an individual speed control unit (132) is provided for the cold wire (174) separate from the speed control unit (152) of the first and second consumable electrodes (172, 176).
[14]
14. Welding apparatus according to any one of the preceding claims, characterized by the fact that the cold wire (174) in the electrically insulated duct (180) is in sequential order disposed between the first and the second consumable electrodes with respect to a welding direction (20) on a workpiece (10).
[15]
Welding apparatus according to any one of claims 1 to 11, characterized in that the cold wire (174) is arranged upstream of the first and second consumable electrodes with respect to a welding direction (20) in a workpiece (10).
Petition 870170099343, of 12/19/2017, p. 34/40
4/5
[16]
16. Welding apparatus according to any one of claims 1 to 11, characterized by the fact that the cold wire (174) is disposed downstream of the consumable electrodes (172, 176) of the electrode assembly (170) in relation to a welding direction (20) on a workpiece (10).
[17]
17. Welding apparatus according to any one of the preceding claims, characterized by the fact that a feeder unit (150) and / or a straightening unit (140) for the first and second consumable electrodes (172, 176) provide a through feed to guide the cold wire (174) through the feeder unit (150).
[18]
18. Welding apparatus (100) according to any one of the preceding claims, characterized in that said welding apparatus is a gas metal arc welding apparatus including a gas cup for directing a gas flow of protection towards the welding area common to the referred first and second electrodes (172, 176).
[19]
19. Method for welding double wire, comprising:
- guide a first consumable electrode (4) through a first contact tube (2) towards a welding area,
- guide a second consumable electrode (12) through a second contact tube (10) towards the welding area,
- transfer a welding current to the first and second consumable electrodes (4.12) from a single energy source (16) connected to a first and second consumable electrodes via said first and second contact tubes (2.10) to maintain a first and a second arcs, respectively, for the generation of a weld pool (6), in which the said single energy source provides the same potential in said first and second contact tubes,
Petition 870170099343, of 12/19/2017, p. 35/40
5/5 characterized by the fact that a cold wire (22) is fed orthogonally to the said weld pool (6).
[20]
20. Welding method according to claim 19, characterized by the fact that it additionally comprises:
- direct a flow of shielding gas towards the common welding area for said first and second electrodes (4,12), in which the weld pool (6) is maintained by said first and second arcs, respectively, under the shielding gas flow.
Petition 870170099343, of 12/19/2017, p. 36/40
1/9
2/9

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法律状态:
2017-10-24| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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优先权:

申请号 | 申请日 | 专利标题

PCT/EP2010/064499|WO2012041375A1|2010-09-29|2010-09-29|A welding apparatus and a method for welding|

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